2004 SUZUKI GRAND VITARA steering

YH4
GRAND
VITARA
AIR BAG STEERING WHEEL AND COLUMN 3C1-17
1. Capsule
2. Steering column bracket
3. Plate
1. Steering column assembly
1. Steering column lower seal ªaº
CHECKING STEERING COLUMN FOR
ACCIDENT DAMAGE
NOTE:
Vehicles involved in accidents resulting in body damage,
where steering column has been impacted or air bag
deployed, may have a damaged or misaligned steering col-
umn.
CHECKING PROCEDURE
1) Check that two capsules are attached to steering column brack-
et securely. Check clearance between capsules and steering
column bracket. Clearance should be 0 mm (0 in.) on both sides.
If found loose or clearance, replace steering column assembly.
2) Check two plates for any damages such as crack or breakage.
If anything is found faulty, replace as steering column assembly.
3) Take measurement ªaº as shown. If it is shorter than specified
length, replace column assembly with new one.
Length ªaº: 895
0.8 mm (35.24
0.03 in.)
4) Check steering column lower seal for breakage or deformation.
If found defective, replace.
5) Check steering shaft joints and shaft for any damages such as
crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as steering shaft lower assem-
bly or steering column assembly.
6) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
7) Check steering shaft and column for bend, cracks or deforma-
tion.
If found defective, replace as column assembly.

YH4
GRAND
VITARA
1. Lower position
2. Upper position
3C1-18 AIR BAG STEERING WHEEL AND COLUMN
09944-36011
Steering wheel remover
ADJUSTABLE STEERING COLUMN RELEASE
LEVER
INSPECTION
Check to make sure that the following:

Steering column moves smoothly when adjustable steering col-
umn release lever is at lower position (i.e., steering column is not
locked).

Steering column is fixed securely when adjustable steering col-
umn release lever is at upper position (i.e., steering column is
locked).
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Driver air bag (inflator) module bolt90.96.5
Steering shaft nut333.323.5
Steering column mounting bolt232.317.0
Steering shaft joint bolt252.518.0
Steering lower shaft assembly lower joint bolt252.518.0
Shift (key) interlock cable screw2.20.221.6
SPECIAL TOOL

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
1. Paint
3F-4 WHEELS AND TIRES
Higher than Recommended Pressure Can Cause:
1. Hard ride
2. Tire bruising or carcass damage
3. Rapid tread wear at center of tire
Unequal Pressure on Same Axle Can Cause:
1. Uneven braking
2. Steering lead
3. Reduced handling
4. Swerve on acceleration
Valve caps should be kept on valves to keep dust and
water out.Lower than Recommended Pressure Can Cause:
1. Tire squeal on turns
2. Hard steering
3. Rapid and uneven wear on the edges of the tread
4. Tire rim bruises and rupture
5. Tire cord breakage
6. High tire temperatures
7. Reduced handling
8. High fuel consumption
MAINTENANCE AND MINOR ADJUSTMENTS
WHEEL AND TIRE
Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced.
STUDS
If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure.
MATCHED TIRES AND WHEELS
(For vehicle equipped with steel wheels)
Tires and wheels are matchmounted at the assembly plant.
This means that the radially stiffest part of the tire, or ªhigh spotº, is
matched to the smallest radius or ªlow spotº of the wheel.
This is done to provide the smoothest possible ride.
The ªhigh spotº of the tire is originally marked by paint dot on the
outboard sidewall. This paint dot will eventually wash off the tire.
The ªlow spotº of the wheel is originally marked by paint dot on the
wheel rim-flange. Properly assembled, the wheel rims' paint dot
should be aligned with the tires' paint dot as shown in left figure.
Whenever a tire is dismounted from its wheel, it should be re-
mounted so that the tire and wheel are matched. If the tire's paint
dot cannot be located, a line should be scribed on the tire and wheel
before dismounting to assure that it is remounted in the same posi-
tion.
INFLATION OF TIRES
The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread
wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should
be checked monthly or before any extended trip. Set to the specifications on the tire placard located on the side
of instrument panel.
It is normal for tire pressure increase when the tires become hot during driving. Do not bleed or reduce tire pressure
after driving. Bleeding reduces the ªCold Inflation Pressureº.

YH4
GRAND
VITARA
BRAKES 5-5
ConditionPossible CauseCorrection
Excessive pedal
travel (Pedal
stroke too large)
Partial brake system failure.

Insufficient fluid in master cylinder
reservoirs.

Air in system. (pedal soft / spongy)

Rear brake system not adjusted.
(malfunctioning auto adjusting mechanism)

Bent brake shoes.

Worn rear brake shoes.Check brake systems and repair as
necessary.
Fill reservoirs with approved brake
fluid.
Check for leaks and air in brake
systems.
Check warning light. Bleed system if
required.
Bleed system.
Repair auto adjusting mechanism.
Adjust rear brakes.
Replace brake shoes.
Replace brake shoes.
Dragging brakes
(A very light drag
is present in all
disc brakes
immediately
after pedal is
released)
Master cylinder pistons not returning
correctly.

Restricted brake pipes or hoses.

Incorrect parking brake adjustment on rear
brakes.

Weakened or broken return springs in the
brake.

Sluggish parking-brake cables or linkage.

Wheel cylinder or caliper piston sticking.

Malfunctioning ABS, if equipped with ABS.Replace master cylinder.
Check for soft hoses or damaged
pipes and replace with new hoses
and / or new brake pipes.
Check and adjust to correct specifi-
cations.
Replace.
Repair or replace.
Repair as necessary.
Check system and replace as
necessary.
Pedal pulsation
(Pedal pulsates
when depressed
for braking)
Damaged or loose wheel bearings.

Distorted steering knuckle or rear axle
shafts.

Excessive disc lateral runout.

Parallelism not within specifications.

Rear drums out of round.Replace wheel hub component.
Replace knuckle or rear axle shaft.
Check per instructions. If not within
specifications, replace or machine
the disc.
Check per instructions. If not within
specifications, replace or machine
the disc.
Check runout.
Repair or replace drum as
necessary.
Braking noise
Glazed shoe linings, or foreign matters
stuck to linings.

Worn or distorted shoe linings.

Loose front wheel bearings.

Distorted backing plates or loose mounting
bolts.Repair or replace shoe lining.
Replace shoe lining (or pad).
Replace wheel hub component.
Replace or retighten securing bolts.

YH4
GRAND
VITARA
5A-4 BRAKES PIPE / HOSE / MASTER CYLINDER
DIAGNOSIS
Refer to Section 5 (BRAKES)
CHECK AND ADJUSTMENT
Refer to Section 5 (BRAKES)
ON-VEHICLE SERVICE
FRONT BRAKE HOSE / PIPE
REMOVAL
1) Raise and suitably support vehicle. Remove tire and wheel.
This operation is not necessary when removing pipes connecting master cylinder and flexible hose.
2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.
INSTALLATION
1) Reverse removal procedure for brake hose and pipe installation procedure.
For installation, make sure that steering wheel is in straightforward position and hose has no twist or kink. Check
to make sure that hose doesn't contact any part of suspension, both in extreme right and extreme left turn condi-
tions. If it does at any point, remove and correct. Fill and maintain brake fluid level in reservoir. Bleed brake sys-
tem.
2) Perform brake test and check installed part for fluid leakage.

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-5
[A]: Vehicle with ABS for right hand steering vehicle
[B]: Vehicle with ABS for left hand steering vehicle
1. E-ring
2. Flexible hose
3. Hose washer
4. Hose bolt
5. Brake caliper
6. 2 way joint
NOTE:
Insert E-ring till its end surface is flush
with or lower than bracket end surface.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
(c): 10 N.m (1.0 kg-m, 7.5 lb-ft)
(b): 21 N.m (2.1 kg-m, 15.5 lb-ft)
A: View A
B: View B
C: View Ca: Clamp a
b: Clamp b
c: Clamp c
d: Clamp d
C
t: Top side
f: Front side
[A]
[B]

YH4
GRAND
VITARA
5A-6 BRAKES PIPE / HOSE / MASTER CYLINDER
NOTE:
Insert E-ring till its end surface is flush
with or lower than bracket end surface.
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)
[C]: Vehicle without ABS for right hand steering vehicle
[D]: Vehicle without ABS for left hand steering vehicle
1. E-ring
2. Flexible hose
3. Hose washer
4. Hose bolt
5. Brake caliper
6. 4way joint
[C]
[D]
D: View D a: Clamp a
b: Clamp b
c: Clamp c
d: Clamp dt: Top side
f: Front side