Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual — part 25

2B-20 Front Suspension:

12) Connect steering lower shaft from pinion shaft

Steering referring to “P/S Gear Case Assembly
Removal and Installation in Section 6C in related
manual”.

13) Connect front height sensor connector (1) (if

equipped with head light auto leveling system) and
then detach clip (2).

14) Connect front fender lining clip (1) (if equipped with

head light auto leveling system).

15) Install stabilizer joints (1), and tighten nuts to

specified torque. When tightening, hold stud with
hexagon wrench.

Tightening torque
Stabilizer joint nut (a): 60 N·m (6.0 kgf-m, 43.5
lb-ft)

16) Install right side and left side front drive shaft

assembly referring to “Front Drive Shaft Assembly
Removal and Installation: Front in Section 3A in
related manual”.

17) Install suspension control arm referring to

“Suspension Control Arm Removal and Installation”.

18) Install engine under cover.
19) Install wheels (right & left) and lower hoist.
20) After installation, be sure to fill specified power

steering fluid and bleed air referring to “P/S System
Air Bleeding Procedure in Section 6C in related
manual”.

21) Adjust headlight auto leveling system, refer to

“Initialization of Auto Leveling Headlight System in
Section 9B in related manual”.

Front Suspension Frame Check

S5JB0E2206017

Inspect for cracks, deformation or damage.
If defective, replace.

1

2

I5JB0A220043-01

1

I5JB0A220042-01

(a)

1

1

(a)

I5JB0A220055-01

I5JB0A220056-01

Front Suspension: 2B-21

Front Stabilizer Bar, Bushing and/or Joint
Check

S5JB0E2206018

Stabilizer Bar
Inspect for damage or deformation.
If defective, replace.

Stabilizer Bushing
Inspect for damage, wear or deterioration.
If defective, replace.

Stabilizer Joint

1) Check for smooth rotation.
2) Check damages of ball stud.
3) Check damages of dust cover.

NOTE
Stabilizer joint (1) cannot be disassembled.

If there is any damage to either parts, stabilizer joint
assembly must be replaced as a complete unit.

Front Suspension Fasteners Check

S5JB0E2206019

Check each bolt and nut fastening suspension parts for
tightness. Tighten loose one, if any, to specified torque,
referring to “Front Suspension Construction”.

Specifications

Tightening Torque Specifications

S5JB0E2207001

I5JB0D220001-01

I5JB0D220002-01

1

I4RH01220007-01

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Tie-rod end lock nut

65

6.5

47.0

)

Strut bracket nut

135

13.5

98.0

)

/ )

Brake hose mounting bolt

25

2.5

18.0

)

Stabilizer joint nut

60

6.0

43.5

)

/ )

Front wheel speed sensor harness clamp bolt

10

1.0

7.5

)

Strut support nut

50

5.0

36.5

)

Wheel nut

100

10.0

72.5

)

/ )

Strut nut

90

9.0

65.0

)

Wheel hub housing bolt

50

5.0

36.5

)

Caliper carrier bolt

85

8.5

61.5

)

Drive shaft nut

220

22.0

159.5

)

Suspension arm ball joint nut

55

5.5

40.0

)

Front wheel speed sensor bolt

10

1.0

7.5

)

Tie-rod end nut

45

4.5

32.5

)

Suspension control arm nut

135

13.5

98.0

)

Stabilizer bar mounting bracket bolt

50

5.0

36.5

)

Suspension frame mounting bolt

135

13.5

98.0

)

Engine front body side mounting nut

55

5.5

40.0

)

Pipe bracket bolt

11

1.1

8.0

)

Union gear box bolt

35

3.5

25.5

)

2B-22 Front Suspension:

NOTE
The specified tightening torque is also described in the following.
“Front Suspension Construction”
“Front Strut Assembly Components”
“Front Wheel Hub Assembly and Steering Knuckle Components”
“Front Suspension Frame, Stabilizer Bar and/or Bushings Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A in related
manual”.

Special Tools and Equipment

Recommended Service Material

S5JB0E2208001

Special Tool

S5JB0E2208002

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Super Grease A

P/No.: 99000–25010

)

09900–00411

09900–00414

Hexagon bit socket

Hexagon bit (6 mm)

)

/ )

)

/ )

09913–75821

09941–56510

Bearing installer attachment

Socket wrench (19 mm)

)

/ )

)

/ )

09943–25010

09945–55410

Spring compressor

Bushing installer

)

)

/ )

Table of Contents 3- i

3

Section 3

CONTENTS

Driveline / Axle

Precautions . . . . . . . . . . . . . 3-*

Precautions. . . . . . . . . . . . . . . .. 3-*

Precautions for Driveline / Axle . . . . . . . .. 3-*

Drive Shaft / Axle . . . . . . . . . ..3A-*

Front . . . . . . . . . . . . . . . . . . . 3A-*

General Description . . . . . . . . . . . . 3A-*

Front Drive Shaft Construction. . . . . . . .3A-*

Diagnostic Information and Procedures. . . 3A-*

Front Drive Shaft Symptom Diagnosis. . . . .3A-*

Repair Instructions . . . . . . . . . . . .. 3A-*

Front Drive Shaft Boot and Joint Check. . . ...3A-*
Front Drive Shaft Components . . . . . . . 3A-*
Front Drive Shaft Assembly Removal and

Installation. . . . . . . . . . . . . . ..3A-*

Front Drive Shaft Disassembly and Assembly . .3A-*

Specifications. . . . . . . . . . . . . ... 3A-*

Tightening Torque Specifications. . . . . . .3A-*

Special Tools and Equipment . . . . . . . . 3A-*

Recommended Service Material. . . . . . ..3A-*
Special Tool . . . . . . . . . . . . . . .3A-*

Rear . . . . . . . . . . . . . . . . . . .. 3A-*

General Description . . . . . . . . . . . . 3A-*

Rear Drive Shaft Construction . . . . . . . .3A-*

Repair Instructions . . . . . . . . . . . .. 3A-*

Rear Drive Shaft Components . . . . . . . .3A-*
Rear Drive Shaft Assembly Removal and

Installation. . . . . . . . . . . . . . ..3A-*

Rear Drive Shaft Disassembly and Assembly. ..3A-*

Specifications. . . . . . . . . . . . . ... 3A-*

Tightening Torque Specifications. . . . . . .3A-*

Special Tools and Equipment . . . . . . . . 3A-*

Recommended Service Material. . . . . . ..3A-*
Special Tool . . . . . . . . . . . . . . .3A-*

Differential. . . . . . . . . . . . .3B-*

Front . . . . . . . . . . . . . . . . . . . 3B-*

General Description . . . . . . . . . . . . 3B-*

Front Differential Construction . . . . . . . .3B-*

Diagnostic Information and Procedures. . . 3B-*

Front Differential Symptom Diagnosis. . . . ..3B-*

Repair Instructions . . . . . . . . . . . .. 3B-*

Front Differential Oil Change . . . . . . . ...3B-*

Front Differential Unit Components. . . . . . 3B-*
Front Differential Dismounting and

Remounting. . . . . . . . . . . . . ... 3B-*

Front Differential Components . . . . . . . 3B-*
Front Differential Assembly Disassembly and

Reassembly . . . . . . . . . . . . . .. 3B-*

Front Differential Inspection . . . . . . . . 3B-*

Specifications. . . . . . . . . . . . . ... 3B-*

Tightening Torque Specifications. . . . . . 3B-*

Special Tools and Equipment . . . . . . . . 3B-*

Recommended Service Material . . . . . . . 3B-*
Special Tool . . . . . . . . . . . . . . 3B-*

Rear . . . . . . . . . . . . . . . . . . .. 3B-*

General Description . . . . . . . . . . . . 3B-*

Rear Differential Construction . . . . . . . . 3B-*

Diagnostic Information and Procedures. . . 3B-*

Rear Differential Symptom Diagnosis . . . . . 3B-*

Repair Instructions . . . . . . . . . . . .. 3B-*

Rear Differential Oil Change . . . . . . . ... 3B-*
Rear Differential Unit Components . . . . . . 3B-*
Rear Differential Dismounting and

Remounting. . . . . . . . . . . . . ... 3B-*

Rear Differential Components. . . . . . . . 3B-*
Rear Differential Assembly Disassembly and

Reassembly . . . . . . . . . . . . . .. 3B-*

Rear Differential Inspection. . . . . . . . . 3B-*

Specifications. . . . . . . . . . . . . ... 3B-*

Tightening Torque Specifications. . . . . . 3B-*

Special Tools and Equipment . . . . . . . . 3B-*

Recommended Service Material . . . . . . . 3B-*
Special Tool . . . . . . . . . . . . . . 3B-*

Transfer . . . . . . . . . . . . . 3C-1

Motor-Shift Type (Transfer with Shift

Actuator) . . . . . . . . . . . . . . . . 3C-1

Precautions. . . . . . . . . . . . . . ...3C-1

Transfer Warning . . . . . . . . . . . . 3C-1
Precautions in Diagnosing Trouble . . . . . .3C-1

General Description . . . . . . . . . . . .3C-2

Transfer Description. . . . . . . . . . . 3C-2
4WD Control System Description. . . . . . 3C-2
Function of 4WD Control System Component . 3C-4
4WD Control System Operation. . . . . . ..3C-4

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.