2003 SUZUKI GRAND VITARA Cover

YH4
GRAND
VITARA
1
1. Steering column hole cover 1. Steering column cover screw
2. Steering column upper cover
3. Steering column lower cover: Standard screw
: Tapping screw
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* *
AIR BAG STEERING WHEEL AND COLUMN 3C1-9
3) Connect all connectors that have been removed in removal.
4) Install steering column upper and lower cover, and then tighten
steering column cover screws.
CAUTION:
When installing lower cover and upper cover, be careful
so that contact coil and combination switch lead wire is
not caught between covers.
5) Install steering column hole cover.
6) Install steering wheel to steering column. Refer to ªSTEERING
WHEELº in this section.
STEERING COLUMN
CAUTION:
Once the steering column is removed from the vehicle, the
column is extremely susceptible to damage.
Dropping the column assembly on its end could collapse
the steering shaft or loosen the plastic shear pins which
maintain column length leaning on the column assembly
could cause it to bend or deform.
Any of the above damage could impair the column's col-
lapsible design.
When loosening steering column mounting bolts, make
sure that steering column assembly and steering shaft low-
er assembly have been separated. Loosening them with
steering column assembly and steering shaft lower assem-
bly assembled could cause damage to bearing in steering
shaft lower assembly.
NOTE:
When servicing steering column or any column-mounted
component, remove steering wheel. But when removing steer-
ing column simply to gain access to instrument panel compo-
nents, leave steering wheel installed on steering column.

YH4
GRAND
VITARA
1. Steering column assembly
2. Steering shaft joint
3. Marks
1. Steering column assembly
2. Steering shaft joint
3. Steering lower shaft assembly
4. Bolt (column side)
5. Bolt (lower shaft assembly side)1. Steering column hole cover
1
3C1-10 AIR BAG STEERING WHEEL AND COLUMN
REMOVAL
WARNING:
Never rest a steering column assembly on the steering
wheel with air bag (inflator) module face down and column
vertical. Otherwise personal injury may result.
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to ªDISABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
3) Remove steering wheel and contact coil and combination switch
assembly, if necessary. Refer to ªSTEERING WHEELº and
ªCONTACT COIL AND COMBINATION SWITCH ASSEMBLYº
in this section.
Perform the following procedure if not removing steering wheel
and/or combination switch.
ii) Turn steering wheel so that vehicle's front tires are at straight-
ahead position.
ii) Turn ignition switch to ªLOCKº position and remove key.
4) Remove steering column hole cover.
5) Disconnect all connectors for the following parts.

Contact coil and combination switch

Ignition switch
6) Make alignment marks on shaft joint and shaft (column side) for
a guide during reinstallation.
7) After removing bolt on column side of shaft joint and loosening
bolt on its lower shaft assembly side, move shaft joint to lower
shaft assembly side (in arrow direction in the figure).

YH4
GRAND
VITARA
1. Steering shaft joint
2. Steering shaft (column side)
3. Marks
1. Steering shaft joint
2. Bolt (column side)
3. Bolt (lower shaft assembly side)
1. Steering column hole cover
1
AIR BAG STEERING WHEEL AND COLUMN 3C1-13
4) Install steering shaft joint to steering shaft by matching it to
marks made before removal.
5) Install shaft joint bolt (column side) to steering shaft joint. Tighten
shaft joint bolt (column side) to specified torque first and then
shaft joint bolt (lower shaft assembly side) to specified torque.
Tightening Torque
(c): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
6) If contact coil and combination switch assembly is removed,
install it, referring to ªCONTACT COIL AND COMBINATION
SWITCH ASSEMBLYº in this section.
7) Connect all connectors that have been removed in removal.
8) Install steering column hole cover.
9) If steering wheel is removed, install it by referring to ªSTEER-
ING WHEELº in this section.
10) Connect negative battery cable.
11) After installing steering column assembly, be sure to enable air
bag system by referring to ªENABLING AIR BAG SYSTEMº un-
der ªSERVICE PRECAUTIONSº in Section 10B.

YH4
GRAND
VITARA
3D-4 FRONT SUSPENSION
SUSPENSION CONTROL ARM JOINT CHECK
1) Check for smoothness of rotation.
2) Inspect ball stud for damage.
3) Inspect dust cover for damage.
Replace any parts found defective in steps 1) ± 3).
SUSPENSION CONTROL ARM BUSHING
CHECK
Inspect for damage, wear or deterioration.
WHEEL DISC, NUT & BEARING CHECK
1) Inspect each wheel disc for dents, distortion and cracks.
Disc in badly damaged condition must be replaced.
2) Check wheel nuts for tightness and retighten them to specifica-
tion as necessary.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
3) Check wheel bearing for wear. After retightening lock nut to spe-
cified torque, apply dial gauge to wheel hub center and measure
thrust play.
Thrust play limit: 0.05 mm (0.002 in.)
When measurement exceeds limit, replace bearing.
4) By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If defective, replace bearing.

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
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
5-10 BRAKES
BRAKE PEDAL PLAY CHECK
Pedal play should be within specification. If out of specification,
check brake light switch for proper installation position and adjust
if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Pedal play ªdº: 1 ± 8 mm (0.04 ± 0.32 in.)
BRAKE FLUID LEVEL CHECK
Be sure to use particular brake fluid either as indicated on reservoir
cap of that vehicle or recommended in owner's manual which
comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked on reser-
voir.
When warning light lights sometimes during driving, replenish fluid
to MAX line.
When fluid decreases quickly, inspect brake system for leakage.
Correct leaky points and then refill to specified level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has been
used for mineral oil or a container which is wet from water.
Mineral oil will cause swelling and distortion of rubber parts
in hydraulic brake system and water mixed into brake fluid
will lower fluid boiling point. Keep all fluid containers
capped to prevent contamination.
BRAKE HOSE AND PIPE CHECK
The brake hose assembly should be checked for road hazard dam-
age, for cracks and chafing of the outer cover, for leaks and blisters.
A light and mirror may be needed for an adequate inspection. If any
of the above conditions are observed on the brake hose, it is neces-
sary to replace it.
Inspect the pipe for damage, cracks, dents and corrosion. If any de-
fect is found, replace it.
MASTER CYLINDER CHECK
Check for a cracked master cylinder casting or brake fluid around
the master cylinder. Leaks are indicated only if there is at least a
drop of fluid. A damp condition is not abnormal.

YH4
GRAND
VITARA
1. Parking brake lever cover
2. Brake cable locking nut
1. Brake drum
2. 8 mm bolts
PARKING AND REAR BRAKE 5C-7
BRAKE DRUM
REMOVAL
1) Hoist vehicle and pull up parking brake lever.
2) Remove wheel.
3) Release parking brake lever.
4) Remove rear center console box screws and with rear part of
rear center console box lifted a little, loosen parking brake cable
locking nut.
5) Remove brake drum by using 8 mm bolts (2 pcs.).
INSPECTION
Brake Drum
Inspect drum for cleanliness. Check wear of its braking surface by
measuring its inside diameter.
Inside diameter ªaº
Standard: 220 mm (8.66 in.)
Service Limit: 222 mm (8.74 in.)
Whenever brake drums are removed, they should be thoroughly
cleaned and inspected for cracks, scores, deep grooves.