front axle SUZUKI GRAND VITARA 2003 2.G Service Workshop Manual

YH4
GRAND
VITARA
1. Front differential housing
2. Rear axle
housing
When using floor jack:
Front
Rear
1. Safety stands
0A-20 GENERAL INFORMATION
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of the front suspension
frame or rear axle housing.
WARNING:

Never apply jack against suspension parts (i.e., stabilizer,
etc.) or vehicle floor, or it may get deformed.

If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands under chassis frame so that body is
securely supported. And then check to ensure that chassis frame
does not slide on safety stands and the vehicle is held stable for
safety's sake.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-19
11) Check coil spring, upper rod, lower rod and lateral rod for de-
formation and damage.
12) Check upper rod, lower rod and lateral rod bushings and bump
stopper for wear, damage and deterioration.
13) Check other suspension parts for damage, loose or missing
parts; also for parts showing signs of wear or lack of lubrication.
Replace any parts found defective in steps 1) to 13).
ITEM 6-9
Propeller Shafts and Drive Shafts Inspection
1) Check universal joint and spline of propeller shaft for rattle. If
rattle is found, replace defective part with a new one.
2) Check propeller shaft (front & rear) flange yoke bolts for tight-
ness, and retighten them as necessary.
Refer to Section 4B for tightening torque.
3) Check drive axle boots (wheel side and differential side) for
leaks, detachment, tear or other damage.
Replace boot as necessary.

YH4
GRAND
VITARA
3
STEERING, SUSPENSION, WHEELS AND TIRES 3-1
GENERAL DIAGNOSIS3-1 . . . . . . . . . . . . . . . . .
Diagnosis Table 3-1. . . . . . . . . . . . . . . . . . . . . .
TIRE DIAGNOSIS3-6 . . . . . . . . . . . . . . . . . . . . . .
Irregular and / or Premature Wear 3-6. . . . . . .
Wear Indicator 3-6. . . . . . . . . . . . . . . . . . . . . . . Radial Tire Waddle 3-6. . . . . . . . . . . . . . . . . . .
Radial Tire Lead 3-8. . . . . . . . . . . . . . . . . . . . . .
VIBRATION DIAGNOSIS3-8 . . . . . . . . . . . . . . .
SECTION 3
STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT END ALIGNMENT3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING SYSTEM3B1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG STEERING WHEEL AND COLUMN3C1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION3D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION3E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEELS AND TIRES3F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS
GENERAL DIAGNOSIS
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered
when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged parts.
3) Spin front wheel. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and / or rough wheel bear-
ings.
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Vehicle Pulls (Leads)
Mismatched or uneven tires.

Tires not adequately inflated.

Broken or sagging springs.

Radial tire lateral force.

Disturbed front end alignment.

Disturbed rear axle alignment.

Brake dragging in one road wheel.

Loose, bent or broken front or rear
suspension parts.Replace tire.
Adjust tire pressure.
Replace spring.
Replace tire.
Check front end alignment.
Check rear axle alignment.
Repair front brake.
Tighten or replace suspension part.

YH4
GRAND
VITARA
1. Body
2. Strut assembly
3. Steering knuckle
4. Suspension control arm
(Lower arm)
5. Ball stud
6. Wheel bearing
7. Axle shaft drive flange
8. Wheel
2WD
4WD
3D-2 FRONT SUSPENSION
GENERAL DESCRIPTION
The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the body
by a strut support. The strut and strut support are isolated by a rubber mount.
The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is attached
to the stud of a ball joint which is incorporated in a unit with a suspension control arm. And this steering knuckle
is connected to the tie rod end.
Thus, movement of the steering wheel is transmitted to the tie rod end and then to the knuckle, eventually causing
the wheel-and-tire to move.

YH4
GRAND
VITARA
3D-8 FRONT SUSPENSION
1. Circlip
2. Washer
1. Wire
1. Front wheel
speed sensor
2. Harness clamp bolt
COIL SPRING
REMOVAL
1) Hoist vehicle, allowing front suspension to hang free.
2) Remove wheels.
3) Remove axle shaft drive flange (For 4WD vehicle).
4) Remove front drive shaft circlip and washer (For 4WD vehicle).
5) Remove caliper bolts and suspend caliper with a wire hook.
CAUTION:
Hang removed caliper with a wire hook so as to prevent
brake hose from bending and twisting excessively or be-
ing pulled.
Don't operate brake pedal with pads removed.
6) If equipped with ABS, remove harness clamp bolt and remove
front wheel speed sensor from knuckle.
CAUTION:

Do not pull wire harness when removing front wheel
speed sensor.

Do not cause damage to surface of front wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.
7) Remove brake disc.
NOTE:
If brake disc can not be removed by hand, use 8 mm bolts
as shown.

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
3D-12 FRONT SUSPENSION
1. Lock washer
2. Screws 1. Axle shaft drive flange
WHEEL HUB (INCLUDED WHEEL BEARING)
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange (4WD vehicle) or hub cap (2WD
vehicle).
3) If equipped with ABS, remove wheel speed sensor from knuckle
and harness clamp from strut.
4) Remove caliper bolt and suspend caliper.
CAUTION:
Hang removed caliper with a wire hook or the like so as to
prevent brake hose from bending and twisting excessively
or being pulled.
Don't operate brake pedal with pads removed.
5) Remove brake disc.
NOTE:
If brake disc can not be removed by hand, use 8 mm bolts as
shown.
6) Remove front wheel bearing lock washer by loosening 4 screws.
7) Remove front wheel bearing lock nut by using special tool.
Special Tool
(A): 09951-16050
8) Remove front wheel bearing washer.
9) Remove wheel hub component by hand.

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
(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
3D-24 FRONT SUSPENSION
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSENO.
Lithium greaseSUZUKI SUPER GREASE (A)
(99000-25010)
Bearing inner oil seal / drive shaft oil seal
Recess of wheel spindles
Spindle outer washer
Spindle part of drive shaft
Spindle bush (inside and flange part)
Spindle inner washera
b
c
d
e
f
SealantSUZUKI BOND NO. 1215
(99000-31110)Mating surfaces of wheel spindle
and knuckle1
Sealing compound
SUZUKI SEALING COM-
POUND 366E
(99000-31090)
Front axle cap
Mating surfaces of wheel hub and drive
flange
Knuckle cap
Hub capA
B
C
D