2004 SUZUKI GRAND VITARA front suspension

YH4
GRAND
VITARA
1. Clamp
2. Upper rod
1. Upper rod front bolt
2. Nut
3. Upper rod
4. Wheel speed sensor
harness bracket
(Toward outside of body)1. Upper rod
2. Bolt
5. Upper rod rear bolt
6. Washer
7. Body center
8. Front side
REAR SUSPENSION 3E-9
UPPER ROD
REMOVAL
1) Hoist vehicle and remove rear wheel.
2) If equipped with ABS, disconnect wheel speed sensor harness
clamp from left upper rod.
3) Remove upper rod.
INSTALLATION
1) Install upper rod to chassis frame and axle housing, referring to
figure for installing direction of bolts.
Nuts should not be tightened.
2) See figure for distinction of installing direction of left side upper
rod for vehicle equipped with ABS.
3) Connect wheel speed sensor harness clamp to upper rod (if
equipped with ABS).
4) Lower hoist and with vehicle in non-loaded condition, tighten
front bolt and rear nut of upper rod to specified torque.
Tightening Torque
(a): 90 N
.m (9.0 kg-m, 65 lb-ft)

YH4
GRAND
VITARA
1. Flexible hose
2. E-ring
3. Brake pipe
4. Cross member1. LSPV stay
1. Hose
2. Axle housing
1. Propeller shaft
2. Differential carrier
REAR SUSPENSION 3E-17
7) Using special tools (B) & (C) indicated below, draw out axle
shafts. For vehicle equipped with ABS, remove wheel speed
sensor from axle housing before drawing out axle shaft.
NOTE:
Use care not to pull brake back plate along with shaft.
Special Tool
(C): 09943-35512
(B): 09942-15510
8) For vehicle without ABS, remove LSPV stay from axle housing.
9) Remove brake back plate from rear axle housing.
10) Disconnect brake pipe from flexible hose and remove E-ring
(front side).
11) Remove brake pipe clamps and pipes from axle housing and
disconnect breather hose from axle housing.
12) Disconnect propeller shaft and remove propeller shaft from
transmission.

YH4
GRAND
VITARA
5-4 BRAKES
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Not enough brak-
ing force
Brake oil leakage from brake lines.

Brake disc or pads stained with oil.

Overheated brakes.

Poor contact of shoes on brake drum.

Brake shoes linings stained with oil or wet
with water.

Badly worn brake shoe linings.

Defective wheel cylinders.

Malfunctioning caliper assembly.

Air in system.

Maladjusted sensor spring length of LSPV.

Broken sensor spring of LSPV.

Defective collar of LSPV.

Malfunctioning ABS (Antilock brake system),
if equipped.Locate leaking point and repair.
Clean or replace.
Determine cause and repair.
Repair for proper contact.
Replace.
Replace.
Repair or replace.
Repair or replace.
Bleed system.
Check or adjust.
Replace.
Replace.
Check system and replace as
necessary.
Brake pull
(Brakes not work-
ing in unison)
Pad or shoe linings are wet with water or
stained with oil in some brakes.

Drum-to-shoe clearance out of adjustment in
some brakes.
(Malfunctioning auto adjusting mechanism)

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Malfunctioning wheel cylinders.

Disturbed front end alignment.

Unmatched tires on same axle.

Restricted brake pipes or hoses.

Malfunctioning caliper assembly.

Loose suspension parts.

Loose calipers.Replace.
Check for inoperative auto adjusting
mechanism.
Replace.
Inflate equally.
Repair or replace.
Adjust as prescribed.
Tires with approximately the same
amount of tread should be used on the
same axle.
Check for soft hoses and damaged
lines.
Replace with new hoses and new
brake pipes.
Check for stuck or sluggish pistons
and proper lubrication of caliper slide
bush.
Caliper should slide.
Check all suspension mountings.
Check and torque bolts to specifica-
tions.
Noise (High pitched
squeak without
brake applied)
Front lining worn out.Replace linings.
Rear brake locked
prematurely
Maladjusted sensor spring length of LSPV.

Malfunction LSPV assembly.Check or adjust.
Replace assembly.
Brake locked
(For vehicles
equipped with
ABS)
Malfunctioning ABS, if equipped.Check system and replace as
necessary.

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
BODY SERVICE 9-25
a. Front bumper
b. 1st mounting
c. Suspension frame
d. Front strut
e. Suspension arm
f. 2nd mounting
g. ù20 zig hole
h. Zig hole
i. 3rd mounting
j. Lower rod
k. Upper rod
l. Lateral rod
m. Rear shock absorber
n. 4th mounting
o. Fuel tank
p. Fuel tank
q. Lower roda ± g : 1315 mm (51.77 in.)
a ± g' : 1534 mm (60.39 in.)
b ± g : 1243 mm (48.94 in.)
b ± g' : 1518 mm (59.76 in.)
c ± g : 1377 mm (54.21 in.)
c ± g' : 1105 mm (43.50 in.)
d ± g' : 1319 mm (51.93 in.)
d ± f : 874 mm (34.41 in.)
e ± g : 525 mm (20.67 in.)
e ± g' : 857 mm (33.74 in.)
f ± g' : 927 mm (36.50 in.)
h ± i : 178 mm (7.01 in.)
h ± j : 133 mm (5.24 in.)
h ± k : 325 mm (12.80 in.)
h ± l : 674 mm (26.54 in.)h ± m : 803 mm (31.61 in.)
h ± n : 1161 mm (45.71 in.)
h ± o : 1184 mm (46.61 in.)
h ± p : 1190 mm (46.85 in.)
i ± q : 999 mm (39.33 in.)
j ± q : 997 mm (39.25 in.)
k ± q : 824 mm (32.44 in.)
l ± q : 1130 mm (44.49 in.)
m ± q : 1258 mm (49.53 in.)
n ± q : 1483 mm (58.39 in.)
o ± q : 1349 mm (53.11 in.)
p ± q : 1334 mm (52.52 in.)
For 4 door model
g' ± q : 1275 mm (50.20 in.)
g ± q : 1534 mm (60.39 in.)
For 2 door model
g' ± q : 995 mm (39.17 in.)
g ± q : 1310 mm (51.57 in.)
UNDER BODY DIMENSIONS