wheel torque SUZUKI GRAND VITARA 2004 2.G Service Service Manual

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
1. Axle housing
2. Floor jack
1. Lower rod
2. Rear mount nut1. Lower rod
2. Front mount bolt
1. Lower rod
2. Front bolt
3. Rear bolt
4. Vehicle body
5. Axle housing
6. Body center
7. Body out side
[A]: Body side
[B]: Axle side
3E-8 REAR SUSPENSION
LOWER ROD
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) Support rear axle housing by using floor jack.
3) Remove lower rod front mount bolt.
4) Remove lower rod rear mount bolt.
INSTALLATION
1) Install lower rod to chassis frame and axle housing, referring to
figure for proper installing direction of bolts.
Nuts should not be tightened.
2) Remove floor jack from rear axle housing.
3) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque for wheel nuts
100 N
.m (10.0 kg-m, 72.5 lb-ft)
4) Lower hoist and with vehicle in non loaded condition, tighten
front bolt and rear nut of lower rod to specified torque.
Tightening Torque
(a): 90 N
.m (9.0 kg-m, 65.0 lb-ft)

YH4
GRAND
VITARA
1. Clamp
2. Upper rod
1. Upper rod front bolt
2. Nut
3. Upper rod
4. Wheel speed sensor
harness bracket
(Toward outside of body)1. Upper rod
2. Bolt
5. Upper rod rear bolt
6. Washer
7. Body center
8. Front side
REAR SUSPENSION 3E-9
UPPER ROD
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) If equipped with ABS, disconnect wheel speed sensor harness
clamp from left upper rod.
3) Remove upper rod.
INSTALLATION
1) Install upper rod to chassis frame and axle housing, referring to
figure for installing direction of bolts.
Nuts should not be tightened.
2) See figure for distinction of installing direction of left side upper
rod for vehicle equipped with ABS.
3) Connect wheel speed sensor harness clamp to upper rod (if
equipped with ABS).
4) Lower hoist and with vehicle in non-loaded condition, tighten
front bolt and rear nut of upper rod to specified torque.
Tightening Torque
(a): 90 N
.m (9.0 kg-m, 65 lb-ft)

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
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
3. Container 1. Plug cap
2. Vinyl tube
1. Bearing retainer
(e)
(f)
(g)
REAR SUSPENSION 3E-21
16) 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
17) 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
(e): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
18) For vehicle with ABS, tighten wheel speed sensor bolt to speci-
fied torque.
Tightening Torque
(f): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
19) Connect brake pipes to wheel cylinders (right & left) and tighten
brake pipe flare nuts to specified torque.
Tightening Torque
(g): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
20) Install brake drum (right & left). For details, refer to SECTION
5C ªBRAKE DRUM INSTALLATIONº.
21) Refill differential gear housing with new specified gear oil. Re-
fer to ªON-VEHICLE SERVICEº in SECTION 7F for refill.
22) Fill reservoir with brake fluid and bleed brake system.(For
bleeding operation, see SECTION 5.)

YH4
GRAND
VITARA
3E-22 REAR SUSPENSION
23) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(h): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
24) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load three to ten times so as to obtain proper drum-
to-shoe clearance.
Adjust parking brake cable (for adjustment, see SECTION 5C
of this manual.)
25) Tighten parking brake lever cover screws.
26) Lower hoist.
27) Tighten right and left lower / upper rod nuts lateral rod mount
bolt and shock absorber nuts to specified torque.
NOTE:
When tightening these nuts, be sure that vehicle is off
hoist and in non loaded condition.
Tightening Torque
(i): 90 N
.m (9.0 kg-m, 65.0 lb-ft)
(j): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
28) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
29) Perform brake test (foot brake and parking brake).
30) Check each installed part for oil leakage.

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.