parts SUZUKI GRAND VITARA 2004 2.G Service Service Manual

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. Axle shaft
2. Wheel bearing
3. Press
1. Stud bolt
2. Hydraulic press
1. Rear wheel bearing
retainer ring
2. Grind with a grinder
3. Rear axle
3E-12 REAR SUSPENSION
9) Break with a chisel the thin ground sensor rotor, and it can be
removed (if equipped with ABS).
10) In order to remove the retainer ring from the shaft, grind with
a grinder two parts of the bearing retainer ring as illustrated till
it becomes thin.
CAUTION:
Be careful not to grind too far not to damage the shaft.
11) Break with a chisel the thin ground retainer ring, and it can be
removed.
12) Remove bearing from shaft by using hydraulic press.
13) Remove bearing retainer.
14) Remove stud bolt(s) by using hydraulic press.

YH4
GRAND
VITARA
[B]
1
2
[A]
1. Bearing retainer
2. Oil seal
3. Wheel side
4. Differential side
1. Stud bolt
2. Nut
3. Washer
4. Flange of axle shaft
1. Axle shaft
2. Bearing retainer
[A]: Vehicle without ABS
[B]: Vehicle with ABS
1. Bearing
2. Retainer ring
REAR SUSPENSION 3E-13
INSTALLATION
Install removed parts in reverse order of removal procedure, noting
the following.
1) Apply grease to oil seal lip as shown and install it to axle shaft.
NOTE:
Amount of grease applied to hollow in oil seal should be
more than 60% of its vacant space.
ªAº: Grease 99000-25010
2) Aligning serrations between new stud bolt(s) and flange, install
new stud bolt(s) by tightening nut as shown.
3) Install bearing retainer to shaft.
4) Press-fit wheel bearing and retainer ring as shown.
NOTE:

Use care not to cause any damage to outside of retainer
ring.

Refer to figure so that wheel bearing is installed in proper
direction.

YH4
GRAND
VITARA
1. Brake pipe flare nut
2. Brake pipe
3. Brake back plate
1. Bearing retainer
2. Parking brake shoe
lever
3. Clearance1. Nut 1. Wheel speed sensor
2. Wheel speed sensor coupler
3. Wheel speed sensor harness clamp
4. Wheel speed sensor harness
3E-16 REAR SUSPENSION
REAR AXLE HOUSING
REMOVAL
1) Drain differential gear oil.
Carry out steps 2) to 7) and 15) to 18) on both right and left
wheels.
Note that left wheel and its related parts are used in illustrations
in this section.
2) Remove rear brake drum. (Refer to steps 1) to 5) of BRAKE
DRUM REMOVAL.)
3) Disconnect brake pipe from wheel cylinder. With right side wheel
cylinder, disconnect 2 brake pipes.
4) For vehicle with ABS, disconnect wheel speed sensor coupler
and remove wheel speed sensor with its harness.
5) Remove rear wheel bearing retainer nuts from rear axle hous-
ing.
6) Check to ensure that there is clearance between rear wheel
bearing retainer and parking brake shoe lever. If no clearance
is found, loosen cable locking nut further to obtain clearance.

YH4
GRAND
VITARA
1. Lower rod
2. Body center
1. Rear axle housing
2. Spring seat
3. Coil spring
4. Stepped part
1. Axle housing ªAº 1. Body center
1
2
1
REAR SUSPENSION 3E-19
INSTALLATION
Install removed parts in reverse order of removal, noting the follow-
ing.
1) Place rear axle housing on floor jack. Then install upper / lower
rod rear mounting bolts (right & left) in proper direction as shown
(refer to UPPER ROD INSTALLATION for upper rod bolts). At
this time, mount nuts but don't tighten them.
2) Install coil spring (right & left) on spring seat of axle housing and
raise axle housing.
NOTE:
When seating coil spring, mate spring end with stepped
part of rear axle spring seat as shown.
3) Install lateral rod to rear axle housing.
4) Install lower part of shock absorber to right and left sides of axle
housing and install bolts in proper direction as shown in figure.
At this time, mount nuts but don't tighten them.
5) Clean mating surfaces of axle housing and differential carrier
and apply sealant to housing side.
ªAº: Sealant 99000-31110
6) Install differential carrier assembly to axle housing and tighten
carrier nuts to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)

YH4
GRAND
VITARA
REAR SUSPENSION 3E-23
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mKg-mlb-ft
Shock absorber lock nut292.921.0
Shock absorber nut292.921.0
Shock absorber lower nut858.561.5
Lower rod bolt and nut
Upper rod bolt and nut909.065.0
Lateral rod bolt
Differential carrier nut555.540.0
Propeller shaft nut505.036.5
Brake pipe flare nut161.611.5
Bearing retainer nut232.317.0
Differentiation gear oilFiller plug505.036.5g
filler & drain plugDrain plug272.716.0
Wheel nut10010.072.5
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
Brake fluidDOT 3Brake reservoir tank
Sealant
SUZUKI BOND NO. 1215
(99000-31110)
Joint seam of axle and brake back
plate

Joint seam of bearing retainer and
brake back plate

Joint seam of differential carrier and
axle housing

Drain plug

Mating surface of oil seal and axle
housing
Gear oilFor gear oil information, refer to
SECTION 7F of this manualDifferential gear
(Refer axle housing.)

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
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.

YH4
GRAND
VITARA
1. Boot
2. Snap ring
1. Circlip
2 Snap ring plier
3. Cage
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-5
DISASSEMBLY
1) Remove boot band of differential side joint.
2) Slide boot toward the center of shaft and remove snap ring from
outer race, then take shaft out of outer race.
3) Remove circlip and then cage.
4) Remove inside and outside boots from shaft.
CAUTION:

Do not disassemble wheel side joint (outboard joint). If
any malcondition is found in joint, replace it as assem-
bly.

Do not disassemble ball joint of differential side joint.
If any malcondition is found in ball joint, replace differ-
ential side joint assembly.
INSPECTION

Check boots for breakage or deterioration. Replace them as nec-
essary.

Check circlip, snap ring and boot bands for breakage or deforma-
tion. Replace as necessary.
CLEANING

Wash disassembled parts (except boots) in degreaser. After
washing, dry parts completely by blowing air.

Clean boots with cloth. DO NOT wash boots in degreaser, such
as gasoline or kerosene, etc.
Washing in degreaser causes deterioration of boot.