wheel torque SUZUKI GRAND VITARA 2003 2.G Service Owner's Guide

YH4
GRAND
VITARA
3D-10 FRONT SUSPENSION
ªaº < ªbº
1. Circlip
2. Large diameter
1. Axle shaft drive flange
2. Bolt 1. Spring seat
Bottom
INSTALLATION
Reverse removal procedure to install coil spring.
NOTE:
Upper and lower diameters of coil spring are different.
Bring larger diameter end at bottom and set its open end in
place on spring seat.

Be sure to use specified torque for tightening each fastener.

Refer to torque specification chart at the end of this section.

As for ball stud nut, be sure to insert split pin and bend it after tight-
ening it.

Tighten tie-rod end nut with pushing ball stud to upper side so as
not ball stud to be rotated.

For 4WD vehicle
Apply lithium grease to front drive shaft washer and front wheel
spindle outer.
ªAº: Grease 99000-25010

For 4WD vehicle
When installing circlip to drive shaft, utilize screw hole in drive
shaft to pull it out and bring large diameter of circlip at right as
shown.

For 4WD vehicle
When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange and tighten flange bolt
to specified torque.
ªAº: Sealant 99000-31090
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-11
1. Front wheel speed sensor
2. Bolt
1. Spring rubber
seat
2. Bump stopper2, (b)
1

Check that no foreign material is attached to sensor and rotor.
Install wheel speed sensor and its harness clamp.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
CAUTION:

Do not pull wire harness or twist more than necessary
when installing front wheel speed sensor.

Fit harness grommet to inner fender securely.

Check that there is no clearance between sensor and knuckle.
BUMP STOPPER / SPRING RUBBER SEAT
REMOVAL
1) Remove coil spring. Refer to steps 1) to 15) of item ªCOIL
SPRING REMOVALº in this section.
2) Remove spring rubber seat.
3) Remove bump stopper, using special tool.
Special Tool
(A): 09941-66010
INSTALLATION
1) Tighten bump stopper to specified torque, using special tool.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
2) Install spring rubber seat.
3) Install coil spring. Refer to item ªCOIL SPRING INSTALLATIONº
in this section.

YH4
GRAND
VITARA
1. Wheel hub
2. Wheel spindle
3. Bearing inner race
1. Lock washer 1. Sensor rotor
2. Wheel hub
3. Hydraulic press
OK NG
3D-14 FRONT SUSPENSION
2) Install new sensor rotor by using special tool (if equipped with
ABS).
NOTE:
Use care not to insert wheel hub diagonally.
Special Tool
(A): 09952-86510
(B): 09924-74510
Wheel speed sensor rotor installing position
Reference Dimension ªaº : 4.9
0.1 mm (0.19
0.004 in.)
3) Install wheel hub component to spindle supporting wheel bear-
ing inner race by finger as shown.
CAUTION:
Don't tap wheel hub component by hammer or the like.
Otherwise, it will be broken.
NOTE:
When it is impossible to install wheel hub component by
hand, which means the inner race is out of alignment, re-
move wheel hub component once and reinstall it.
4) Install wheel bearing washer, and the install wheel bearing lock
nut.
5) Tighten wheel bearing lock nut to specified torque while turning
wheel hub by hand.
Special Tool
(A): 09951-16050
Tightening Torque
(a): 216 N
.m (21.6 kg-m, 157 lb-ft)
6) Using lock washer, lock bearing lock nut. If lock screw hole is not
aligned with screw hole in lock nut, turn lock nut in tightening
direction till they align.
Tightening Torque
(b): 1.5 N
.m (0.15 kg-m, 1.1 lb-ft)

YH4
GRAND
VITARA
2, (b)
1
1. Circlip
2. Large diameter
1. Front wheel speed sensor
2. Bolt
FRONT SUSPENSION 3D-15
7) For 4WD vehicle, apply lithium grease to front drive shaft wash-
er and front wheel spindle outer.
ªAº: Grease 99000-25010
8) For 4WD vehicle, when installing circlip to drive shaft, utilize
screw hole in drive shaft to pull it out and bring large diameter
of circlip at right as shown.
9) For vehicle with ABS, check that no foreign material is attached
to sensor and rotor. Install wheel speed sensor and its harness
clamp.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
CAUTION:

Do not pull wire harness or twist more than necessary
when installing front wheel speed sensor.

Fit harness grommet to inner fender securely.
Check that there is no clearance between sensor and knuckle.
10) Install brake disc and caliper assembly.
Tightening Torque
(e): 85 N
.m (8.5 kg-m, 61.5 lb-ft)

YH4
GRAND
VITARA
1. Axle shaft drive
flange
2. Bolt
3. Hub cap
4. Wheel hub
For 4WD vehicle
For 2WD vehicle
3D-16 FRONT SUSPENSION
11) Apply sealant and install axle shaft drive flange or hub cap.

For 4WD vehicle
Apply sealant mating surface of axle shaft drive flange, then
install axle shaft drive flange and tighten flange bolt to speci-
fied torque.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
ªAº: Sealant 99000-31090

For 2WD vehicle
Remove grease, old sealant and dusts from mating surfaces
of hub cap and hub to clean, apply water tight sealant ªAº to
cap mating surface evenly, and install cap to hub.
ªAº: Sealant 99000-31090
12) Install wheel.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
13) For vehicle equipped with ABS, perform driving test referring
to ªDRIVING TESTº of ªABS DIAGNOSTIC FLOW TABLEº in
Section 5E or 5E1.

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-19
1. Knuckle
2. Knuckle cap
3. Wheel spindle 1. Oil seal
2. Drive shaft
3. Drive shaft
thrust washer
Type A Type B

Tighten wheel spindle nut to specified torque.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

For 4WD vehicle
Press-fitting inner oil seal.
Drive in inner oil seal until its end contacts stepped surface of
knuckle by using special tools.
Special Tool
(B): 09944-66010
(C): 09924-74510

For 4WD vehicle

Apply lithium grease to oil seal lip and into its hollow to fill more
than 60% of its vacant space.

Apply lithium grease ªAº to drive shaft.
ªAº: Grease 99000-25010

Press-fit front drive shaft thrust washer to drive shaft, if it is re-
moved (for Type B drive shaft thrust washer). Apply lithium
grease ªAº to drive shaft thrust washer.
ªAº: Grease 99000-25010

Apply lithium grease ªAº and install front drive shaft thrust wash-
er with its chamfered side facing to center side (for Type A drive
shaft thrust washer).
ªAº: Grease 99000-25010

For 2WD vehicle
Remove grease, old sealant and dusts from mating surfaces of
knuckle cap and knuckle to clean, apply water tight sealant to cap
mating surface evenly, and install cap to knuckle.
ªBº: Sealant 99000-31090

YH4
GRAND
VITARA
(a)
1. Axle shaft drive flange
2. Bolt1. Hub cap
2. Wheel hub
3D-20 FRONT SUSPENSION

Tighten control arm ball stud nut
When tightening ball stud nut, use new nut and tighten it to speci-
fied torque.
Tightening Torque
(a): 60 N
.m (6.0 kg-m, 43.5 lb-ft)

For 2WD vehicle
Apply water tight sealant to mating surface of wheel hub and
install hub cap to wheel hub.
ªAº: Sealant 99000-31090

For 4WD vehicle
When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange.
ªAº: Sealant 99000-31090
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

For installation procedures of wheel hub component, refer to
ªWHEEL HUB (INCLUDED WHEEL BEARING)º in this section.

Connect tie-rod end to knuckle and tighten new tie-rod end nut.
Tightening Torque
(a): 43 N
.m (4.3 kg-m, 31.5 lb-ft)

For any tightening torque other than those specified in text, refer
to ªTIGHTENING TORQUE SPECIFICATIONº in this section.

YH4
GRAND
VITARA
3E
REAR SUSPENSION 3E-1
GENERAL DESCRIPTION3E- 2 . . . . . . . . . . . . . .
DIAGNOSIS3E- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3E- 3. . . . . . . . . . . . . . . . . . . . . .
Shock Absorber Check 3E- 3. . . . . . . . . . . . . . . .
Lower / Upper / Lateral Rod Check 3E- 3. . . . . . . .
Axle Housing and Coil Spring Check 3E- 3. . . .
Bearing Retainer & Axle Shaft Inner Oil
Seal Check 3E- 4. . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Disc, Nut & Bearing Check 3E- 4. . . . . .
ON-VEHICLE SERVICE3E- 5 . . . . . . . . . . . . . . . .
Shock Absorber 3E- 5. . . . . . . . . . . . . . . . . . . . . . Coil Spring 3E- 6. . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Rod 3E- 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Rod 3E- 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Lateral Rod 3E-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Shaft and Wheel Bearing 3E-10. . . . .
Rear Axle Shaft Inner Oil Seal 3E-15. . . . . . . . . .
Rear Axle Housing 3E-16. . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3E-23 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS3E-23 . . . . . .
SPECIAL TOOLS3E-24 . . . . . . . . . . . . . . . . . . . . . .
SECTION 3E
REAR SUSPENSION
NOTE:

All suspension fasteners are an important attaching part in that it 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 replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of this part.

Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or damage
to the part may result.
CONTENTS

YH4
GRAND
VITARA
3E-4 REAR SUSPENSION
REAR SUSPENSION FASTENERS
Check each bolt and nut fastening suspension parts for tightness.
Tighten loose one, if any, to specified torque, referring to ªTIGHT-
ENING TORQUE SPECIFICATIONSº of this section.
BEARING RETAINER AND AXLE SHAFT
INNER OIL SEAL CHECK

When brake drum has been removed, check inside of brake drum
for gear oil leakage.

Also, check backside of brake back plate for oil leakage.
If oil leakage is found, replace defective oil seal.

Whenever it is possible to check oil seal during disassembly,
check its lip for wear.
If oil leakage or worn lip is found, replace defective oil seal.
WHEEL DISC, NUT & BEARING CHECK

Inspect each wheel disc for dents, distortion and cracks. A disc
in badly damaged condition must be replaced.

Check wheel hub nuts for tightness and retighten to specification
as necessary.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)

Check wheel bearings for wear. When measuring thrust play, ap-
ply a dial gauge to axle shaft center after removing wheel center
cap from wheel.
Thrust play limit
Rear0.8 mm (0.03 in.)
When measurement exceeds limit, replace bearing.

By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If it is defective, replace bearing.

YH4
GRAND
VITARA
1. Rear axle housing
2. Floor jack
1. Lock nut (if equipped)
2. Absorber nut
3. Upper support
4. Rubber bush
5. Lower support
6. Shock absorber
7. Bolt
Upper side
Lower side
1. Lock nut (if equipped)
2. Absorber nut
3. Body outside
REAR SUSPENSION 3E-5
ON-VEHICLE SERVICE
SHOCK ABSORBER
The shock absorber is non-adjustable, non-refillable, and cannot
be disassembled. The only service the shock absorber requires is
replacement when it has lost its resistance, is damaged, or leaking
fluid.
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack to prevent it from
lowering.
3) Remove lock nut (if equipped) and absorber nut.
4) Remove lower mounting bolt.
5) Remove shock absorber.
INSTALLATION
1) Install shock absorber. Refer to figure for proper installing direc-
tion of lower mounting bolt.
2) Remove floor jack.
3) Lower hoist.
4) Tighten nuts to specified torque.
NOTE:

Tighten lower nut with vehicle off hoist and in non-loaded
condition.
Tightening Torque
(a): 29 N
.m (2.9 kg-m, 21.0 lb-ft)
(b): 85 N
.m (8.5 kg-m. 61.5 lb-ft)