2004 SUZUKI GRAND VITARA wheel

YH4
GRAND
VITARA
3D
FRONT SUSPENSION 3D-1
GENERAL DESCRIPTION3D- 2 . . . . . . . . . . . . . .
DIAGNOSIS3D- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3D- 3. . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar and Bushing Check 3D- 3. . . . . .
Strut Damper and / or Coil Spring Check 3D- 3. .
Suspension Arm / Knuckle Check 3D- 3. . . . . . . .
Suspension Control Arm Joint Check 3D- 4. . . .
Suspension Control Arm Bushing Check 3D- 4.
Wheel Disc, Nut & Bearing Check 3D- 4. . . . . .
ON-VEHICLE SERVICE3D- 5 . . . . . . . . . . . . . . . . Stabilizer Bar / Bushings 3D- 5. . . . . . . . . . . . . . .
Strut Damper 3D- 6. . . . . . . . . . . . . . . . . . . . . . . .
Coil Spring 3D- 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Bump Stopper / Spring Rubber Seat 3D-11. . . . .
Wheel Hub (Included Wheel Bearing) 3D-12. . .
Knuckle / Wheel Spindle 3D-17. . . . . . . . . . . . . . . .
Suspension Control Arm / Bushings 3D-21. . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3D-23 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS3D-24 . . . . . .
SPECIAL TOOLS3D-25 . . . . . . . . . . . . . . . . . . . . . .
SECTION 3D
FRONT SUSPENSION
CAUTION:

All front suspension fasteners are an important attaching part in that it 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 assure proper retention of this part.

Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or
damage to the part may result.
CONTENTS

YH4
GRAND
VITARA
1. Body
2. Strut assembly
3. Steering knuckle
4. Suspension control arm
(Lower arm)
5. Ball stud
6. Wheel bearing
7. Axle shaft drive flange
8. Wheel
2WD
4WD
3D-2 FRONT SUSPENSION
GENERAL DESCRIPTION
The front suspension is the strut type independent suspension. The upper end of a strut is anchored to the body
by a strut support. The strut and strut support are isolated by a rubber mount.
The lower end of the strut is connected to the upper end of a steering knuckle and lower end of knuckle is attached
to the stud of a ball joint which is incorporated in a unit with a suspension control arm. And this steering knuckle
is connected to the tie rod end.
Thus, movement of the steering wheel is transmitted to the tie rod end and then to the knuckle, eventually causing
the wheel-and-tire to move.

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
3D-6 FRONT SUSPENSION
1. Strut tower bar
1. E-ring
1. Front wheel speed sensor harness clamp bolt
1. Strut bracket bolts
2. Lower arm
3. Jack
1. Strut support nuts
STRUT DAMPER
REMOVAL
1) Remove strut tower bar (if equipped).
2) Hoist vehicle, allowing front suspension to hang free.
3) Remove wheel.
4) Remove E-ring securing brake hose and take brake hose off
strut bracket as shown.
5) If equipped with ABS, remove front wheel speed sensor harness
clamp bolt.
6) Remove strut bracket bolts, then support lower arm with jack.
7) Remove strut support nuts.
Hold strut by hand so that it will not fall off.
8) Remove strut.

YH4
GRAND
VITARA
3D-8 FRONT SUSPENSION
1. Circlip
2. Washer
1. Wire
1. Front wheel
speed sensor
2. Harness clamp bolt
COIL SPRING
REMOVAL
1) Hoist vehicle, allowing front suspension to hang free.
2) Remove wheels.
3) Remove axle shaft drive flange (For 4WD vehicle).
4) Remove front drive shaft circlip and washer (For 4WD vehicle).
5) Remove caliper bolts and suspend caliper with a wire hook.
CAUTION:
Hang removed caliper with a wire hook so as to prevent
brake hose from bending and twisting excessively or be-
ing pulled.
Don't operate brake pedal with pads removed.
6) If equipped with ABS, remove harness clamp bolt and remove
front wheel speed sensor from knuckle.
CAUTION:

Do not pull wire harness when removing front wheel
speed sensor.

Do not cause damage to surface of front wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.
7) Remove brake disc.
NOTE:
If brake disc can not be removed by hand, use 8 mm bolts
as shown.

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-9
1. Coil spring
8) Remove stabilizer bar, refer to steps 2) to 5) of item STABILIZ-
ER BAR / BUSHINGS REMOVAL in this section.
9) Disconnect tie rod end from knuckle by using puller.
10) Support lower arm, using jack as shown.
11) Remove strut bracket bolts.
12) Remove ball stud castle nut.
13) Using puller, disconnect knuckle from ball stud.
14) Remove knuckle and wheel hub comp, while lowering jack.
15) Remove coil spring.

YH4
GRAND
VITARA
3D-10 FRONT SUSPENSION
ªaº < ªbº
1. Circlip
2. Large diameter
1. Axle shaft drive flange
2. Bolt 1. Spring seat
Bottom
INSTALLATION
Reverse removal procedure to install coil spring.
NOTE:
Upper and lower diameters of coil spring are different.
Bring larger diameter end at bottom and set its open end in
place on spring seat.

Be sure to use specified torque for tightening each fastener.

Refer to torque specification chart at the end of this section.

As for ball stud nut, be sure to insert split pin and bend it after tight-
ening it.

Tighten tie-rod end nut with pushing ball stud to upper side so as
not ball stud to be rotated.

For 4WD vehicle
Apply lithium grease to front drive shaft washer and front wheel
spindle outer.
ªAº: Grease 99000-25010

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.

For 4WD vehicle
When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange and tighten flange bolt
to specified torque.
ªAº: Sealant 99000-31090
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-11
1. Front wheel speed sensor
2. Bolt
1. Spring rubber
seat
2. Bump stopper2, (b)
1

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.
BUMP STOPPER / SPRING RUBBER SEAT
REMOVAL
1) Remove coil spring. Refer to steps 1) to 15) of item ªCOIL
SPRING REMOVALº in this section.
2) Remove spring rubber seat.
3) Remove bump stopper, using special tool.
Special Tool
(A): 09941-66010
INSTALLATION
1) Tighten bump stopper to specified torque, using special tool.
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
2) Install spring rubber seat.
3) Install coil spring. Refer to item ªCOIL SPRING INSTALLATIONº
in this section.