Pin SUZUKI GRAND VITARA 2004 2.G Service Service Manual

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. Drive shaft
circlip
2. Spindle thrust
washer
3. Drive shaft
4. Wheel spindle
1. Tie-rod end
2. Knuckle
1. Strut
2. Knuckle
1. Dust cover
2. Wheel spindle
3. Knuckle
4. Inner oil seal /
knuckle cap
FRONT SUSPENSION 3D-17
KNUCKLE / WHEEL SPINDLE
REMOVAL
1) Remove wheel hub. Refer to ªWHEEL HUB (INCLUDED
WHEEL BEARING)º in this section.
2) Remove front drive shaft circlip and front spindle thrust washer
(for 4WD vehicle) or front hub cap (for 2WD vehicle).
3) Disconnect tie-rod end from knuckle.
4) Remove stabilizer bar. Refer to ªSTABILIZER BAR / BUSH-
INGSº in this section.
5) Remove ball stud nut.
6) Support lower arm with jack.
7) Remove strut bracket bolts from strut bracket.
8) By using puller, disconnect knuckle from ball stud.
9) While lowering jack, remove knuckle / wheel spindle comp.
10) Remove inner oil seal (for 4WD vehicle), knuckle cap (for 2WD
vehicle), dust cover and wheel spindle.

YH4
GRAND
VITARA
ªAº
ªBº
1. Wheel spindle
2. Drive shaft bearing
1. Wheel spindle
2. Drive shaft
bearing
3. Front drive shaft
thrust washer
4. Inner oil seal
5. Knuckle cap
6. Drive shaft oil sealType A Type B
1. Drive shaft bearing
2. Wheel spindle
3D-18 FRONT SUSPENSION
11) For 4WD vehicle
Remove drive shaft bearing by using special tool.
Special Tool
(A): 09923-74510
(B): 09930-30102
INSTALLATION
Reverse removal sequence to install knuckle, wheel spindle oil seal
and drive shaft bearing,noting following points.

For 4WD vehicle
Install drive shaft bearing by using special tool.
Special Tool
(A): 09913-76010 Type A drive shaft thrust washer. . . . . . . .
(A): 09913-80112 Type B drive shaft thrust washer. . . . . . . .
Dimension ªaº: 0 ± 1 mm (0 ± 0.04 in.)
Dimension ªaº: Type A drive shaft thrust washer . . . . . . . . .
Dimension ªaº: 1.75 ± 2.50 mm (0.069 ± 0.098 in.)
Dimension ªaº: Type B drive shaft thrust washer . . . . . . . . .

When installing wheel spindle to knuckle, coat their mating sur-
faces with sealant.
ªAº: Sealant 99000-31110

For 4WD vehicle
Also, fill recess in wheel spindle with about 10 g lithium grease.
ªBº: Grease 99000-25010

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
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

YH4
GRAND
VITARA
1. Axle housingªAº
(c)
1. Axle housing
3E-20 REAR SUSPENSION
7) For vehicle with ABS, connect wheel speed sensor coupler and
install harness.
8) Install propeller shaft and torque nuts to specification.
Tightening Torque
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
9) Remove floor jack from axle housing and connect breather
hose onto axle housing and clamp it securely.
10) Connect brake pipes onto axle housing and clamp them se-
curely.
For clamping positions, refer to SECTION 5A of this manual.
11) Connect brake flexible hose to bracket on axle housing and se-
cure it with E-ring.
12) Install LSPV stay to axle housing, tighten LSPV stay bolt to
specified torque.
And adjust LSPV referring to ªLSPV ASSEMBLY INSPEC-
TION AND ADJUSTMENTº in SECTION 5A.
Tightening Torque
(c): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
13) Connect brake pipe to brake flexible hose and tighten brake
pipe flare nut to specified torque.
Tightening Torque
(d): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
14) Clean mating surface of axle housing (right & left) and brake
back plate, then apply sealant as shown.
ªAº: Sealant 99000-31110
15) Apply grease to axle shaft inner oil seal lip as shown.
ªAº: Grease 99000-25010

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
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
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Drive shaft flange
bolts and nuts
1. Oil seal
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-3
ON-VEHICLE SERVICE
DRIVE SHAFT
REMOVAL (LEFT SIDE)
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange.
3) Remove drive shaft circlip and front spindle thrust washer.
4) Remove drive shaft flange bolts and nuts.
5) Remove drive shaft assembly to differential side as shown in left
figure.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
6) Remove drive shaft thrust washer (vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.

YH4
GRAND
VITARA
1. Oil filler / level plug
2. Front drain plug
1. Circlip
2. Washer
1. Differential side joint
2. Tire lever
3. Front differential assembly
1. Oil seal 2
1
4A2-4 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
REMOVAL (RIGHT SIDE)
1) Hoist vehicle and remove wheel.
2) Drain differential gear oil.
3) Remove axle shaft drive flange.
4) Remove circlip and front spindle thrust washer.
5) Remove knuckle and wheel hub comp, refer to steps 5) to 7) and
9) to 14) of item COIL SPRING REMOVAL in Section 3D.
6) Remove drive shaft assembly.
To detach snap ring fitted on the spline of differential side joint
(inboard joint) from differential side gear, pull inboard joint by us-
ing a tire lever.
CAUTION:
To prevent breakage of boots (wheel side and differential
side), be careful not to bring them into contact with other
parts when removing drive shaft assembly.
7) Remove drive shaft thrust washer (to vehicle with G16 or J20 en-
gine) from drive shaft and remove drive shaft oil seal as shown
in figure.
CAUTION:
Be careful not to cause damage to drive shaft joint.