suspension SUZUKI GRAND VITARA 2004 2.G Service Workshop Manual

YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram 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.

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VITARA
MAINTENANCE AND LUBRICATION 0B-3
Interval:
This interval should be
judged by
This table includes services as scheduled up to 90,000 km
(54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry
out the same services at the same intervals respectively.
This interval should be judged by
odometer reading or months,Km (x 1,000)153045607590g
whichever comes first.Miles (x 1,000)91827364554
Months122436486072
CHASSIS AND BODY
6-1. Clutch (pedal and fluid level)±I±I±I
6-2.Brake discs and pads (thickness, wear, damage)IIIIII
Brake drums and shoes (wear, damage) ±I±I±I
6-3. Brake hoses and pipes (leakage, damage, clamp)±I±I±I
6-4. Brake fluid±R±R±R
6-5. Brake lever and cable (damage, stroke, operation)Inspect at first 15,000 km (9,000 miles)
only
6-6. Tires (wear, damage, rotation)IIIIII
6-7. Wheel discs (damage)IIIIII
6-8. Suspension system (tighteness, damage, rattle, breakage)±I±I±I
6-9. Propeller shafts and drive shafts±±I±±I
6-10. Manual transmission oil (leakage, level)
(I: 1st 15,000 km only)I±R±±R
6-11. Automatic transmissionFluid level±I±I±I
Fluid changeReplace every 165,000 km
(99,000 miles)
Fluid hose±±±R±±
6-12. Transfer oil (leakage, level)I±I±I±
6-13. Differential oil (leakage, level) (R: 1st 15,000 km only)R or I±I±I±
6-14. Steering system (tighteness, damage, breakage, rattle)±I±I±I
6-15. Power steering (if equipped)IIIIII
6-16. All latches, hinges and locks±I±I±I
6-17. Air conditioning filter (if equipped)±IR±IR
NOTES:
ªRº : Replace or change
ªIº : Inspect and correct, replace or lubricate if necessary

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VITARA
0B-4 MAINTENANCE AND LUBRICATION
MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as given in the chart
below.
Severe condition code
A ± Repeated short trips E ± Repeated short trips in extremely
B ± Driving on rough and / or muddy roads cold weather
C ± Driving on dusty roads F ± Leaded fuel use
D ± Driving in extremely cold weather G ± ± ± ± ± ± ± ± ±
and / or salted roads H ± Trailer towing (if admitted)
Severe
Condition Code
MaintenanceMaintenance
OperationMaintenance Interval
BCDITEM 1-1IEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± ±Drive belt (V-rib belt)REvery 45,000 km
(27,000 miles) or 36 months
A ± C D E F ± HITEM 1-4
Engine oil and oil filterREvery 5,000 km
(3,000 miles) or 4 months
± B ± ± ± ± ± ±ITEM 1-6
Exhaust pipe mountingsIEvery 15,000 km
(9,000 miles) or 12 months
CITEM 3-1IEvery 2,500 km
(1,500 miles)
± ± C ± ± ± ± ±Air cleaner filter*1REvery 30,000 km
(18,000 miles) or 24 months
ABC EF HITEM 2-1Nickel plugREvery 10,000 km
(6,000 miles) or 8 months
A B C ± E F ± HSpark plugsIridium plugREvery 30,000 km
(18,000 miles) or 24 months
± B ± D E ± ± HITEM 6-9
Propeller shafts and drive shaftsIEvery 15,000 km
(9,000 miles) or 12 months
± B ± ± E ± ± H
ITEM 6-10, 6-12, 6-13
Manual transmission,
transfer and differential oil
REvery 30,000 km
(18,000 miles) or 24 months
± B ± ± E ± ± HITEM 6-11
Automatic transmission fluidREvery 30,000 km
(18,000 miles) or 24 months
± B ± ± ± ± ± ±ITEM 6-8
Suspension bolts and nutsTEvery 15,000 km
(9,000 miles) or 12 months
± B C D ± ± ± HITEM 6-7
Wheel bearingIEvery 15,000 km
(9,000 miles) or 12 months
CD
ITEM 6-17
Air conditioning filter*2
IEvery 15,000 km
(9,000 miles) or 12 months
± ± C D ± ± ± ±Air conditioning filter 2
(if equipped)REvery 45,000 km
(27,000 miles) or 36 months
NOTES:
ªIº : Inspect and correct, replace or lubricate if necessary
ªRº : Replace or change
ªTº : Tighten to the specified torque
*1 : Inspect or replace more frequently if necessary.
*2 : Clean or replace more frequently if the air from the air conditioning decreases.

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VITARA
0B-18 MAINTENANCE AND LUBRICATION
ITEM 6-8
Suspension System Inspection
Check suspension bolts and nuts for tightness and retighten them
as necessary.
Repair or replace defective parts, if any.
NOTE:
For details of check points, refer to tables of Tightening Torque
Specification in Section 3D and 3E.
Front
1) Check stabilizer bar for damage or deformation.
2) Check bushing for damage, wear or deterioration.
3) Inspect strut for damage, deformation, oil leakage and opera-
tion. If strut is found faulty, replace it as an assembly unit, be-
cause it can not be disassembled.
Refer to strut check Section 3D for operation check.
4) Inspect strut boot for damage or crack.
5) Inspect for cracks or deformation in spring seat.
6) Inspect for deterioration of bump stopper.
7) Inspect strut mount for wear, cracks or deformation.
8) Check ball joint stud dust seal (boot) for leaks, detachment,
tear or other damage. Check suspension arm bushing for dam-
age, wear or deterioration.
Rear
9) Check shock absorber for damage, deformation, oil leakage
and operation.
10) Check bushings for wear and damage.

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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.

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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
3-2 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Abnormal or
Excessive Tire Wear
Sagging or broken springs.

Tire out of balance.

Disturbed front end alignment.

Faulty shock absorber.

Hard driving.

Overloaded vehicle.

Tires not rotating.

Worn or loose road wheel bearings.

Wobbly wheel or tires.

Tires not adequately inflated.Replace spring.
Adjust balance or replace tire.
Check front end alignment.
Replace shock absorber.
Replace tire.
Replace tire.
Replace or rotate tire.
Replace wheel bearing.
Replace wheel or tire.
Adjust the pressure.
Wheel Tramp
Blister or bump on tire.

Improper shock absorber action.Replace tire.
Replace shock absorber.
Shimmy, Shake or
Vibration
Tire or wheel out of balance.

Loose wheel bearings.

Worn tie rod ends.

Worn lower ball joints.

Excessive wheel runout.

Blister or bump on tire.

Excessively loaded radial runout of
tire / wheel assembly.

Disturbed front end alignment.

Loose or worn tie-rod end.

Loose steering gear case bolts.Balance wheels or replace tire and /
or wheel.
Replace wheel bearing.
Replace tie rod end.
Replace front suspension control
arm.
Repair or replace wheel and / or tire.
Replace tire.
Replace tire or wheel.
Check front end alignment.
Tighten or replace tie-rod end.
Tighten case bolts.
Hard Steering
Bind in tie rod end ball studs or
lower ball joints.

Disturbed front end alignment.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)

Tire not adequately inflated.

Bind in steering column.

Low fluid level, loose drive belt or
malfunction of power steering system.
(if equipped with P / S)Replace tie rod end or front
suspension control arm.
Check front end alignment.
Check and adjust steering gear box.
Inflate tires to proper pressure.
Repair or replace.
Check and correct.

YH4
GRAND
VITARA
STEERING, SUSPENSION, WHEELS AND TIRES 3-3
ConditionPossible CauseCorrection
Too Much Play in
Steering
Wheel bearings worn.

Loose steering gear case bolts.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)

Worn steering shaft joints.

Worn tie rod ends or tie rod
inside ball joints.

Worn lower ball joints.Replace wheel bearing.
Tighten.
Check and adjust rack and pinion
torque.
Replace joint.
Replace tie rod end or steering
gear case.
Replace front suspension control
arm.
Poor Returnability
Bind in tie rod end ball studs.

Bind in ball joints.

Bind in steering column.

Poorly lubricated rack and pinion.
(if equipped with manual steering gear
case)

Disturbed front end alignment.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)

Tires not adequately inflated.Replace tie rod end.
Replace ball joint.
Repair or replace.
Check, repair or lubricate rack and
pinion.
Check and adjust front end
alignment.
Check and adjust rack and pinion
torque.
Adjust pressure.
Steering Noise
(Rattle or Chuckle)
Loose bolts and nuts.

Broken or otherwise damaged wheel
bearings.

Worn or sticky tie rod ends.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)Retighten.
Replace.
Replace.
Check and adjust rack and pinion
torque.
Abnormal Noise,
Front End
Worn, sticky or loose tie rod
ends, lower ball joints, tie rod
inside ball joints or drive shaft
joints.

Damaged shock absorbers, struts
or mountings.

Worn control arm bushings.

Loose stabilizer bar.

Loose wheel nuts.

Loose suspension bolts or nuts.

Broken or otherwise damaged
wheel bearings.

Broken suspension springs.

Poorly lubricated or worn strut
bearings.Replace tie rod end, control arm,
steering gear case or drive shaft
joint.
Replace or repair.
Replace.
Tighten bolts or replace bushes.
Tighten wheel nuts.
Tighten suspension bolts or nuts.
Replace wheel bearing.
Replace spring.
Lubricate or replace strut bearing.

YH4
GRAND
VITARA
3-4 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Wander or Poor
Steering Stability
Mismatched or uneven tires.

Loose ball joints and tie rod
ends.

Faulty shock absorbers / struts or
mounting.

Loose stabilizer bar.

Broken or sagging springs.

Rack and pinion not properly adjusted.
(if equipped with manual steering
gear case)

Disturbed front end alignment.Replace tire or inflate tires to
proper pressure.
Replace suspension control arm or
tie rod end.
Replace absorber / strut or repair
mounting.
Tighten or replace stabilizer bar or
bushes.
Replace spring.
Check or adjust rack and pinion
torque.
Check and adjust front end alignment.
Erratic Steering when
Braking
Worn wheel bearings.

Broken or sagging springs.

Leaking wheel cylinder or caliper.

Warped discs.

Badly worn brake linings.

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Defective wheel cylinders.

Disturbed front end alignment.Replace wheel bearing.
Replace spring.
Repair or replace wheel cylinder or
caliper.
Replace brake disc.
Replace brake shoe lining.
Replace brake drum.
Inflate tires to proper pressure.
Replace or repair wheel cylinder.
Check front end alignment.
Low or Uneven Trim
Height
Right-to-left trim height
(H) difference should be
within 15 mm (0.6 in.)
with curb weight.
*Same with rear side.
Broken or sagging springs.

Overloaded.

Incorrect springs.Replace spring.
Check loading.
Replace spring.
Ride Too Soft
Faulty shock absorber or struts.Replace shock absorber or strut.
Suspension Bottoms
Overloaded.

Faulty shocks or struts.

Incorrect broken or sagging springs.Check loading.
Replace shock absorber or strut.
Replace spring.