2004 SUZUKI GRAND VITARA Pin

YH4
GRAND
VITARA
(A)
1
1. Make alignment marks
1. Steering wheel
Turn slowly till coil stops
Turn contact coil back about 2 and
a half turns
1. Align marks
3C1-6 AIR BAG STEERING WHEEL AND COLUMN
STEERING WHEEL
CAUTION:
Removal of the steering wheel allows the contact coil to turn
freely but do not turn the contact coil (on the combination
switch) more than allowable number of turns (about two and
a half turns from the center position clockwise or counter-
clockwise respectively), or coil will break.
REMOVAL
1) Remove driver air bag (inflator) module from steering wheel re-
ferring to ªDRIVER AIR BAG (INFLATOR) MODULEº earlier in
this section.
2) Remove steering shaft nut.
3) Make alignment marks on steering wheel and shaft for a guide
during reinstallation.
4) Remove steering wheel with special tool.
Special Tool
(A): 09944-36011
CAUTION:
Do not hammer the end of the shaft. Hammering it will
loosen the plastic shear pins which maintain the column
length and impair the collapsible design of the column.
CENTERING CONTACT COIL
1) Check that vehicle's wheels (front tires) are set at straight-ahead
position.
2) Check that ignition switch is at ªLOCKº position.
3) Turn contact coil counterclockwise slowly with a light force till
contact coil will not turn any further.
NOTE:
Contact coil can turn about 5 turns at maximum, that is, if
it is at the center position, can turn about two and a half
turns both clockwise and counterclockwise.
4) From the position where contact coil became unable to turn any
further (it stopped), turn it back clockwise about two and a half
rotations and align center mark with alignment mark.

YH4
GRAND
VITARA
1
1. Contact coil and combination switch assembly
2. Screw
1. Contact coil and combination switch assembly
1. Seal (if equipped, remove lock pin after installing
contact coil and combination switch assembly.)
2. Lock pin (if equipped, remove lock pin after installing
contact coil and combination switch assembly.)
3C1-8 AIR BAG STEERING WHEEL AND COLUMN
6) Remove contact coil and combination switch assembly from
steering column.
INSPECTION
Check contact coil and combination switch wire harness for any
signs of scorching, melting or other damage. If it is damaged, re-
place.
INSTALLATION
1) Check to make sure that vehicle's front tires are set at straight-
ahead position and then ignition switch is at ªLOCKº position.
2) Install contact coil and combination switch assembly to steering
column.
NOTE:
New contact coil and combination switch assembly is sup-
plied with contact coil set and held at its center position
with a lock pin and seal. Remove this lock pin after installing
contact coil and combination switch assembly to steering
column.

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
*
* *
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
2
1
1. Steering shaft joint
2. Bolt (Steering column assembly side)
3. Bolt (Steering lower shaft assembly side)1. Steering shaft joint
2. Steering lower shaft assembly
1. Steering lower shaft
assembly
2. Steering lower shaft
assembly lower joint
3. Steering lower shaft
assembly lower joint bolt
4. Steering shaft joint
5. Mark
6. Slit
1. Steering column assembly
2. Steering shaft joint
3C1-16 AIR BAG STEERING WHEEL AND COLUMN
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight
ahead position.
2) Align flat part ªAº of lower shaft assembly with bolt hole ªBº of
shaft joint as shown. Then insert shaft joint into lower shaft as-
sembly.
3) Install shaft joint bolt (lower shaft assembly side) to shaft joint.
Then tighten it by hand.
4) Insert pinion shaft into lower shaft assembly lower joint with slit
of lower joint, marks on pinion shaft and gear case aligned.
And then install lower shaft assembly lower joint bolt to lower
shaft assembly lower joint. Tighten it to specified torque.
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
5) Install steering shaft joint to steering shaft.
NOTE:
Be sue that front wheels and steering wheel are in straight-
ahead position.
6) Install shaft joint bolt (column side) to shaft joint. Tighten shaft
joint bolt (column side) to specified torque first and then shaft
joint bolt (shaft lower assembly side) to specified torque.
Tightening Torque
(b): 25 N
.m (2.5 kg-m, 18.0 lb-ft)

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
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
1. Sensor rotor
2. Wheel hub
3. Vise
4. Flat end rod
1. Bearing lock washer
2. Screw
3. Bearing lock nut
4. Wheel bearing washer
5. Wheel hub component
6. Bolt
1. Oil hydraulic press
2. Hub bolt
FRONT SUSPENSION 3D-13
NOTE:
If wheel hub can not be removed by hand, use special tools
as shown.
Special Tool
(B): 09943-35512
(C): 09942-15510
CAUTION:
If wheel bearing inner race remains on wheel spindle
when removing wheel hub, which means break of wheel
bearing, replace wheel hub component (included wheel
bearing).
10) Remove sensor rotor from wheel hub as shown (if equipped
with ABS).
CAUTION:

Pull out sensor rotor from wheel hub gradually and
evenly.

Do not reuse sensor rotor once removed.
Be sure to new sensor rotor when installing.
11) Remove hub bolts from hub.
INSTALLATION
1) Insert new stud in hub hole. Rotate stud slowly to assure serra-
tions are aligned with those made by original bolt.

YH4
GRAND
VITARA
1. Wheel hub
2. Wheel spindle
3. Bearing inner race
1. Lock washer 1. Sensor rotor
2. Wheel hub
3. Hydraulic press
OK NG
3D-14 FRONT SUSPENSION
2) Install new sensor rotor by using special tool (if equipped with
ABS).
NOTE:
Use care not to insert wheel hub diagonally.
Special Tool
(A): 09952-86510
(B): 09924-74510
Wheel speed sensor rotor installing position
Reference Dimension ªaº : 4.9
0.1 mm (0.19
0.004 in.)
3) Install wheel hub component to spindle supporting wheel bear-
ing inner race by finger as shown.
CAUTION:
Don't tap wheel hub component by hammer or the like.
Otherwise, it will be broken.
NOTE:
When it is impossible to install wheel hub component by
hand, which means the inner race is out of alignment, re-
move wheel hub component once and reinstall it.
4) Install wheel bearing washer, and the install wheel bearing lock
nut.
5) Tighten wheel bearing lock nut to specified torque while turning
wheel hub by hand.
Special Tool
(A): 09951-16050
Tightening Torque
(a): 216 N
.m (21.6 kg-m, 157 lb-ft)
6) Using lock washer, lock bearing lock nut. If lock screw hole is not
aligned with screw hole in lock nut, turn lock nut in tightening
direction till they align.
Tightening Torque
(b): 1.5 N
.m (0.15 kg-m, 1.1 lb-ft)