SUZUKI GRAND VITARA 2003 2.G Service Workshop Manual

YH4
GRAND
VITARA
3E-24 REAR SUSPENSION
09924-74510
Bush remover handle09926-88310
Oil seal installer09942-15510
Sliding hammer09943-35512
Brake drum remover
09913-75510
Oil seal installer
SPECIAL TOOLS

YH4
GRAND
VITARA
3F
WHEELS AND TIRES 3F-1
GENERAL DESCRIPTION3F- 1 . . . . . . . . . . . . . .
Tires 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels 3F- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Tires 3F- 1. . . . . . . . . . . . . . . . . . .
Wheels Replacement 3F- 2. . . . . . . . . . . . . . . . .
Metric Lug Nuts and Wheel Studs 3F- 2. . . . . .
DIAGNOSIS3F- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3F- 3. . . . . . . . . . . . . . . . . . . . . .
Balancing Wheels 3F- 3. . . . . . . . . . . . . . . . . . . . MAINTENANCE AND MINOR
ADJUSTMENTS3F- 4 . . . . . . . . . . . . . . . . . . . . . .
Wheel and Tire 3F- 4. . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3F- 6 . . . . . . . . . . . . . . . .
Wheel 3F- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire 3F- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3F- 8 . . . . . . . . . . . . . . . . . . . .
SECTION 3F
WHEELS AND TIRES
NOTE:
All wheel fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and / or could result in major repair expense. They must be replaced with one of the same
part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used as specified during reassembly to as-
sure proper retention of all parts.
There is to be no welding as it may result in extensive damage and weakening of the metal.
CONTENTS
GENERAL DESCRIPTION
TIRES
This vehicle is equipped with following tire. P215 / 65 R16, 215 / 65 R16 or 235 / 60 R16
The tires are of tubeless type. The tires are designed to operate satisfactorily with loads up to the full rated load
capacity when inflated to the recommended inflation pressure.
Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid
acceleration, and unnecessary sharp braking increase tire wear.
WHEELS
Standard equipment wheels are following steel wheel. 16
6 1 / 2 J or 16
7JJ
REPLACEMENT TIRES
When replacement is necessary, the original equipment type tire should be used. Refer to the Tire Placard. Re-
placement tires should be of the same size, load range and construction as those originally on the vehicle. Use
of any other size or type tire may affect ride, handling, speedometer / odometer calibration, vehicle ground clear-
ance and tire or snow chain clearance to the body and chassis.
NOTE:
Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except in
emergencies, because vehicle handling may be seriously affected and may result in loss of control.
It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to equalize braking traction.

YH4
GRAND
VITARA
3F-2 WHEELS AND TIRES
The metric term for tire inflation pressure is the kilopascal (kPa).
Tire pressures will usually be printed in both kPa and psi on the Tire
Placard. Metric tire gauges are available from tool suppliers. The
chart, left table, converts commonly used inflation pressures from
kPa to psi.kPakgf / cm2psi
160
180
200
220
240
260
280
300
320
3401.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.423
26
29
32
35
38
41
44
47
50
Conversion:1 psi = 6.895 kPa
1 kgf / cm
2 = 98.066 kPa
WHEELS REPLACEMENT
Wheels must be replaced if they are bent, dented, have excessive
lateral or radial runout, leak air through welds, have elongated bolt
holes, if lug nuts won't stay tight, or if they are heavily rusted.
Wheels with greater runout than shown in left figure may cause ob-
jectional vibrations.
Wheels for replacement must be equivalent to the originally
equipped wheels in load capacity, diameter, rim width, off-set and
mounting configuration. A wheel of improper size or type may affect
wheel and bearing life, brake cooling, speedometer / odometer cal-
ibration, ground clearance to the body and chassis.
To measure the wheel runout, it is necessary to use accurate dial
indicator. The tire may be on or off the wheel. The wheel should be
installed to the wheel balancer of the like for proper measurement.
Take measurements of both lateral runout and radial runout at both
inside and outside of the rim flange. With dial indicator set in place
securely, turn the wheel one full revolution slowly and record every
reading of the indicator.
When the measured runout exceeds the specification and correc-
tion by the balancer adjustment is impossible, replace the wheel.
If the reading is affected by welding, paint or scratch, it should be
ignored.
Lateral runout limit ªaº: 1.20 mm (0.047 in.)
Radial runout limit ªbº: 1.20 mm (0.047 in.)
METRIC LUG NUTS AND WHEEL STUDS
All models use metric lug nuts and wheel studs (size M12 x 1.25).

YH4
GRAND
VITARA
[A]: Before correction
[B]: Corrective weights
1. Heavy spot wheel tramp
2. Balance weights addition point
3. C / L of spindle
[C]: Before correction
[D]: Corrective weights
1. Heavy spot wheel shimmy
2. Balance weights addition point
3. C / L of spindle
WHEELS AND TIRES 3F-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to SECTION 3.
BALANCING WHEELS
There are two types of wheel and tire balance: static and dynamic.
Static balance, as shown in left figure, is equal distribution of weight
around wheel. Wheels that are statically unbalanced cause bounc-
ing action called tramp. This condition will eventually cause uneven
tire wear.
Dynamic balance, as shown in left figure, is equal distribution of
weight on each side of wheel centerline so that when the tire spins
there is no tendency for the assembly to move from side to side.
Wheels that are dynamically unbalanced may cause shimmy.
GENERAL BALANCE PROCEDURE
Deposits of mud, etc. must be cleaned from inside of rim.
WARNING:
Stones should be removed from tread in order to avoid operator injury during spin balancing and to
obtain good balance.
Tire should be inspected for any damage, then balanced according to equipment manufacturer's recommendation.
OFF-VEHICLE BALANCING
Most electronic off-vehicle balancers are more accurate than on-vehicle spin balancers. They are easy to use and
give a dynamic (two plane) balance. Although they do not correct for drum or disc unbalance as does on-vehicle
spin balancing, this is overcome by their accuracy, usually to within 1 / 8 ounce.
ON-VEHICLE BALANCING
ON-vehicle balancing methods vary with equipment and tool manufacturers. Be sure to follow each manufacturer's
instructions during balancing operation.

YH4
GRAND
VITARA
1. Paint
3F-4 WHEELS AND TIRES
Higher than Recommended Pressure Can Cause:
1. Hard ride
2. Tire bruising or carcass damage
3. Rapid tread wear at center of tire
Unequal Pressure on Same Axle Can Cause:
1. Uneven braking
2. Steering lead
3. Reduced handling
4. Swerve on acceleration
Valve caps should be kept on valves to keep dust and
water out.Lower than Recommended Pressure Can Cause:
1. Tire squeal on turns
2. Hard steering
3. Rapid and uneven wear on the edges of the tread
4. Tire rim bruises and rupture
5. Tire cord breakage
6. High tire temperatures
7. Reduced handling
8. High fuel consumption
MAINTENANCE AND MINOR ADJUSTMENTS
WHEEL AND TIRE
Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced.
STUDS
If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure.
MATCHED TIRES AND WHEELS
(For vehicle equipped with steel wheels)
Tires and wheels are matchmounted at the assembly plant.
This means that the radially stiffest part of the tire, or ªhigh spotº, is
matched to the smallest radius or ªlow spotº of the wheel.
This is done to provide the smoothest possible ride.
The ªhigh spotº of the tire is originally marked by paint dot on the
outboard sidewall. This paint dot will eventually wash off the tire.
The ªlow spotº of the wheel is originally marked by paint dot on the
wheel rim-flange. Properly assembled, the wheel rims' paint dot
should be aligned with the tires' paint dot as shown in left figure.
Whenever a tire is dismounted from its wheel, it should be re-
mounted so that the tire and wheel are matched. If the tire's paint
dot cannot be located, a line should be scribed on the tire and wheel
before dismounting to assure that it is remounted in the same posi-
tion.
INFLATION OF TIRES
The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread
wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should
be checked monthly or before any extended trip. Set to the specifications on the tire placard located on the side
of instrument panel.
It is normal for tire pressure increase when the tires become hot during driving. Do not bleed or reduce tire pressure
after driving. Bleeding reduces the ªCold Inflation Pressureº.

YH4
GRAND
VITARA
1. Front
WHEELS AND TIRES 3F-5
TIRE PLACARD
The tire placard is located on the driver's side door lock pillar and
should be referred to for tire information. The placard lists the maxi-
mum load, tire size and cold tire pressure where applicable.
TIRE ROTATION
To equalize wear, rotate tires periodically as shown in figure.

YH4
GRAND
VITARA
3F-6 WHEELS AND TIRES
ON-VEHICLE SERVICE
WHEEL
REMOVAL
1) Loosen wheel nuts by approximately 180
(half a rotation).
2) Hoist vehicle.
3) Remove wheel.
NOTE:
Never use heat to loosen tight wheel because application of
heat to wheel can shorten life of wheel and damage wheel
bearings.
INSTALLATION
Wheel nuts must be tightened in sequence and to proper torque to
avoid bending wheel or brake drum or disc as in figure.
NOTE:
Before installing wheels, remove any build-up of corrosion on
wheel mounting surface and brake drum or disc mounting sur-
face by scraping and wire brushing. Installing wheels without
good metal-to-metal contact at mounting surfaces can cause
wheel nuts to loosen, which can later allow wheel to come off
while vehicle is moving.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)

YH4
GRAND
VITARA
WHEELS AND TIRES 3F-7
TIRE
MOUNTING AND DEMOUNTING
Use tire changing machine to mount or demount tires. Follow equip-
ment manufacturer's instructions. Do not use hand tools or tire
irons alone to change tires as they may damage tire beads or wheel
rim.
Rim bead seats should be cleaned with wire brush or coarse steel
wool to remove lubricants, old rubber and light rust. Before mount-
ing or demounting tire, bead area should be well lubricated with ap-
proved tire lubricant.
After mounting, inflate to 240 kPa (35psi) so that beads are com-
pletely seated. Then adjust pressure to specified shown an tire
placard.
WARNING:
Do not stand over tire when inflating. Bead may break when
bead snaps over rim's safety hump and cause serious per-
sonal injury.
Do not exceed 240 kPa (35 psi) pressure when inflating. If
240 kPa (35 psi) pressure will not seat beads, deflate, re-lu-
bricate and reinflate. Over inflation may cause bead to break
and cause serious personal injury.
Install valve core and inflate to proper pressure.
TIRE REPAIR
There are many different materials and techniques on the market
to repair tires. As not all of these work on all types of tires, tire
manufacturers have published detailed instructions on how and
when to repair tires. These instructions can be obtained from the
tire manufacturer.

YH4
GRAND
VITARA
3F-8 WHEELS AND TIRES
TIGHTENING TORQUE
SPECIFICATIONS
Tightening Torque for wheel nut
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)

YH4
GRAND
VITARA
4A2
1. Drive shaft oil seal
2. Double off set joint (DOJ)
3. Joint circlip
4. DOJ boot
5. Ball joint boot
6. Ball joint assembly (RH side)
7. Drive shaft assembly (LH side)
8. Left drive shaft
9. Drive shaft bearing circlip
10. Drive shaft bearing
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-1
SECTION 4A2
FRONT DRIVE SHAFT/SHAFT BEARING,
OIL SEAL
CONTENTS
GENERAL DESCRIPTION4A2- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS4A2- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table4A2- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Boot And Joint Check 4A2- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE4A2- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft4A2- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft Bearing / Oil Seal4A2- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS4A2-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION
The drive shaft joint is a constant velocity joint (C.V. joint) which slides in the axial direction. The joint is composed
of an outer race, cage, inner race and balls. In the turning direction, the joint rotates in the same way as a ball bear-
ing. The balls lock rotation completely and transmit drive. In addition this vehicle is also characterized by a function
that the shaft can slide through the balls in the grooves of the outer race in the extension / contraction direction of
the drive shaft.