sec 8 SUZUKI GRAND VITARA 2004 2.G Service Workshop Manual

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
FRONT SUSPENSION 3D-21
(1)
(2)
(A)
1. Hydraulic press
1. Hydraulic press Cut off flange
Bush outer diameter
SUSPENSION CONTROL ARM / BUSHINGS
REMOVAL
1) Remove coil spring. Refer to COIL SPRING in this section.
2) Remove control arm bolts and nuts. Then remove control arm.
3) Cut flange part of control arm bush (rubber and steel) with using
care not to damage control arm end surface.
Dimension ªAº: Approx. 6 mm (0.236 in.)
4) Place control arm and special tool on hydraulic press. Set con-
trol arm cutting flange to welded part (1) of the special tool and
control arm joint side to the stepped part (2) of special tool.
CAUTION:
Use special care in driving out control arm bush to press
it vertically.
Or it may cause personally injury.
Special tool
(A): 09951-46020
5) Remove front bushing by using hydraulic press and special
tools, pull out bushing.
Special Tool
(A): 09951-46020
(B): 09924-74510
(C): 09951-16060
6) Remove rear bushing by using hydraulic press and special
tools, pull out bushing.
Special Tool
(A): 09951-46020
(D): 09913-80112
(E): 09925-58210

YH4
GRAND
VITARA
3D-22 FRONT SUSPENSION
1. Hydraulic press
2. Front bushing
A: Bushing flange
contacts housing edge
1. Hydraulic press
2. Rear bushing
A: Bushing flange
contacts housing edge
INSTALLATION
1) Front bushing
Press-fit front bushing until its flange contacts housing edge of
control arm, use special tools as shown.
Special Tool
(C): 09951-16060
(F): 09913-85210
NOTE:
When press-fitting bushing, compounding oil or soap water
applied to inside of control arm housing will facilitate work.
2) Rear bushing
Press-fit rear bushing until its flange contacts housing edge of
control arm, use special tools as shown.
Special Tool
(E): 09925-58210
(F): 09913-85210
NOTE:
When press-fitting bushing, compounding oil or soap water
applied to inside of control arm housing will facilitate work.
3) Install control arm to chassis.
Tighten suspension arm nut to specified torque after lowering
hoist and vehicle in non-loaded condition.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
(b): 127 N.m (12.7 kg-m, 92.0 lb-ft)
4) As installation procedure hereafter is the same as that for coil
spring. Refer to ªCOIL SPRINGº in this section.
NOTE:
For any tightening torque other than those specified in text,
refer to ªTORQUE SPECIFICATION TABLEº at the end of
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
ªAº: Drill hole with approximately
3 mm (0.12 in.) diameter.
REAR SUSPENSION 3E-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to SECTION 3.
SHOCK ABSORBER CHECK

Inspect for deformation or damage.

Inspect bushings for wear or damage.

Inspect for evidence of oil leakage.
Replace any defective part.
WARNING:
When handling rear shock absorber in which high-pressure
gas is sealed, make sure to observe the following precau-
tions.
1) Don't disassemble it.
2) Don't put it into the fire.
3) Don't store it where it gets hot.
4) Before disposing it, be sure to drill a hole in it where
shown by an arrow in the figure and let gas and oil out.
Lay it down sideways for this work.
5) The gas itself is harmless but it may issue out of the hole
together with chips generated by the drill. Therefore, be
sure to wear goggle.
LOWER ROD, UPPER ROD, LATERAL ROD
CHECK
Inspect for cracks, deformation or damage.
Replace any defective part.
Inspect each bush for wear and breakage. If found defective, re-
place.
AXLE HOUSING AND COIL SPRING CHECK
Inspect for cracks, deformation or damage.
Inspect for evidence of oil leakage at axle housing.
If any, replace defective part.

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. Spring seat
3. Coil spring
4. Stepped part
1. Body center
2. Body outside
1. Body center
2. Body outside 1. Parking brake
cable hanger
2. Cross member
3. Clamp
4. Chassis frame
REAR SUSPENSION 3E-7
INSTALLATION
1) Install coil spring on spring seat of axle housing and then raise
axle housing.
NOTE:
When seating coil spring, mate spring end with stepped
part of rear axle spring seat as shown.
2) Install shock absorber lower bolt. For its proper installing direc-
tion, refer to figure.
Nut should not be tightened.
3) Install wheel speed sensor clamp (if equipped) and E-ring, and
connect breather hose to axle housing.
4) Connect cable hanger to chassis frame and clamp to cross
member. Remove floor jack from axle housing.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
6) Lower hoist and tighten absorber lower nut to specified torque.
Tightening Torque
(b): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
NOTE:
For tightening of lower nut, refer to NOTE given under
SHOCK ABSORBER INSTALLATION in this section.

YH4
GRAND
VITARA
(a)
(a)
1. Bolt
2. Washer
3. Lateral rod
1. Nut
1
3E-10 REAR SUSPENSION
LATERAL ROD
REMOVAL
1) Hoist vehicle.
2) Remove lateral rod mounting bolts.
3) Remove lateral rod.
INSTALLATION
1) Install lateral rod to rear axle, and vehicle body.
2) Lower hoist.
3) Tighten lateral rod mounting bolts to specified torque.
Tightening Torque
(a): 90 N
.m (9.0 kg-m, 65.0 lb-ft)
REAR AXLE SHAFT AND WHEEL BEARING
REMOVAL
1) Remove rear brake drum. For details, refer to REAR BRAKE
DRUM REMOVAL in SECTION 5C.
2) Drain gear oil from rear axle housing by loosening drain plug.
3) Remove rear wheel bearing retainer nuts from axle housing.

YH4
GRAND
VITARA
1. Sensor rotor
1. Axle housing
1. Bearing retainer
(b)
3E-14 REAR SUSPENSION
5) For vehicle with ABS, press-fit new sensor rotor as shown.
NOTE:
Use care not to cause any damage to outside of retainer
ring.
6) Apply grease to axle shaft inner oil seal lip as shown.
ªAº: Grease 99000-25010
7) Apply sealant to mating surface of bearing retainer with brake
back plate.
NOTE:
Make sure to remove old sealant before applying it anew.
ªBº: Sealant 99000-31110
8) Install rear axle shaft to rear axle housing and tighten bearing
retainer nuts to specified torque.
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
9) Tighten wheel speed sensor bolt to specified torque (if
equipped with ABS).
Tightening Torque
(b): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
10) Refill rear axle (differential) housing with new specified gear oil.
Refer to SECTION 7F for refill.
11) Install brake drum. (For details, refer to BRAKE DRUM
INSTALLATION in SECTION 5.)

YH4
GRAND
VITARA
REAR SUSPENSION 3E-15
1. Inner oil seal
2. Axle housing
1. Hammer
2. Screwdriver
3. Oil seal protector
4. Oil seal
5. Body center
REAR AXLE SHAFT INNER OIL SEAL
REMOVAL
1) Remove rear axle shaft. For details, refer to steps 1) to 7) of
REAR AXLE SHAFT REMOVAL in this section.
2) Fix brake back plate by inserting screwdriver to the hole for bear-
ing retainer mounting.
3) Remove rear axle shaft inner oil seal.
NOTE:
Take care not to bend the brake pipe.
INSTALLATION
1) Using special tool drive in oil seal until it contacts oil seal protec-
tor in axle housing.
NOTE:

Make sure that oil seal is free from inclination as it is
installed.

Refer to figure so that oil seal is installed in proper direc-
tion.
Special Tool
(A): 09913-75510
ªAº: Grease 99000-25010
ªBº: Sealant 99000-31110
2) For procedure hereafter, refer to steps 6) to 11) of REAR AXLE
SHAFT INSTALLATION in this section.