2004 SUZUKI GRAND VITARA front suspension

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 3.
STABILIZER BAR AND BUSHING CHECK
BAR
Inspect for damage or deformation. If defective, replace.
BUSHING
Inspect for damage, wear or deterioration. If defective, replace.
STRUT DAMPER AND / OR COIL SPRING
CHECK
1) Inspect strut for oil leakage. If strut is found faulty, replace it as
an assembly unit, because it can not be disassembled.
2) Strut function check
Check and adjust tire pressures as specified.
Bounce body three or four times continuously by pushing front
end on the side with strut to be checked. Apply the same amount
of force at each push and note strut resistance both when
pushed and rebounding.
Also, note how many times vehicle body rebounds before com-
ing to stop after hands are off. Do the same for strut on the other
side.
Compare strut resistance and number of rebound on the right
with those on the left.
And they must be equal in both. With proper strut, body should
come to stop the moment hands are off or after only one or two
small rebounds. If struts are suspected, compare them with
known good vehicle or strut.
3) Inspect for damage or deformation.
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.
Replace any parts found defective in steps 2) ± 7).
SUSPENSION ARM / KNUCKLE CHECK
Inspect for cracks, deformation or damage.

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
FRONT SUSPENSION 3D-5
1. Suspension control arm
2. Stabilizer bar
3. Stabilizer ball joint
4. Ball joint bushings
5. Ball joint washers
6. Ball joint nuts
7. Bracket bolts
1. Painted
2. Mount bush bracket
3. Mount bush
ON-VEHICLE SERVICE
STABILIZER BAR / BUSHINGS
REMOVAL
1) Hoist vehicle.
2) Remove stabilizer bar mount bush bracket bolts.
3) Remove stabilizer ball joint nuts, washers and bushings.
4) Remove stabilizer bar with its ball joints.
5) Disconnect stabilizer ball joints from stabilizer bar.
INSTALLATION
NOTE:
For correct installation of stabilizer bar, side-to-side, be sure
that color paint on stabilizer bar aligns with mount bush, both
right and left, as shown.
1) Connect stabilizer ball joints and stabilizer bar.
2) Install stabilizer ball joints to control arms.
NOTE:
Do not tighten stabilizer ball joint nuts completely.
3) Install stabilizer bar mount bush brackets.
4) When installing stabilizer, loosely assemble all components
while insuring that stabilizer is centered, side-to-side.
Check that ball joint is set at neutral position seeing from body
upper side.
5) Tighten stabilizer bracket bolts and stabilizer ball joint nuts to
specified torque.
Tightening Torque
(a): 29 N
.m (2.9 kg-m, 21.0 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(c): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

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
FRONT SUSPENSION 3D-7
1. E-ring
2. Bracket end surface
INSTALLATION
1) Install strut by reversing removal steps 1) ± 8). Insert bolts in
such a direction as shown.
2) Torque all fasteners to specifications.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)
(b): 95 N
.m (9.5 kg-m, 69.0 lb-ft)
(c): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
NOTE:
Brake hose installation.
Don't twist hose when installing it. Install E-ring as far as
bracket end surface as shown.

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)