Engine SUZUKI GRAND VITARA 1999 2.G Service Repair Manual

YH4
GRAND
VITARA
1. P / S fluid reservoir
2. Gauge valve (shut)
3. Oil pressure gauge
4. P / S pump
5. P / S gear box
1. P / S fluid reservoir
2. Gauge valve (open)
3. Oil pressure gauge
4. P / S pump
5. P / S gear box
POWER STEERING (P / S) SYSTEM 3B1-11
5) Check relief pressure

Increase engine speed to about 1,500 r / min (rpm). Close
gauge valve gradually while watching pressure increase indi-
cated by gauge and take reading of relief pressure (maximum
hydraulic pressure).
Relief pressure:
6200 ± 7000 kPa
(62 ± 70 kg / cm
2, 882 ± 995 psi) G16 Type engine. . . . . . .
6700 ± 7500 kPa
(67 ± 75 kg / cm
2, 953 ± 1067 psi) J20 Type engine. . . . . . .
7050 ± 7850 kPa
(70.5 ± 78.5 kg / cm
2, 1003 ± 1116 psi) H25 Type engine. .

When it is higher than specified values, possible cause is mal-
function of relief valve.

When it is lower than specified values, possible cause is either
failure of P / S pump or settling of relief valve spring.
CAUTION:
Be sure not to close gauge valve for longer than 10 se-
conds.

Next, open gauge valve fully and increase engine speed to
about 1,500 r / min (rpm). Then turn steering wheel to the left
or right fully and take reading of relief pressure.
Relief pressure:
6200 ± 7000 kPa
(62 ± 70 kg / cm
2, 882 ± 995 psi) G16 Type engine. . . . . . .
6700 ± 7500 kPa
(67 ± 75 kg / cm
2, 953 ± 1067 psi) J20 Type engine. . . . . . .
7050 ± 7850 kPa
(70.5 ± 78.5 kg / cm
2, 1003 ± 1116 psi) H25 Type engine. .

When it is higher than specified values, possible cause is mal-
function of relief valve.

When it is lower than specified values, possible cause is failure
in steering gear box. Replace gear box.
CAUTION:
Be sure not to hold steering wheel at fully turned posi-
tion for longer than 10 seconds.
BOOT
STEERING RACK BOOT CHECK
Check boot for crack and damage which, if any, means possibility
of rusty gear, entry of dust or lack of grease. Also, check if any of
such faulty conditions exists.
Check steering rack boot for dent or breakage.
If there is a dent, keep boot in most compressed state for some se-
conds to correct dent.

YH4
GRAND
VITARA
3B1-12 POWER STEERING (P / S) SYSTEM
TIE-ROD END BOOT CHECK
Check boot for crack and damage and if any, replace it with a new
one.
AIR BLEEDING PROCEDURE
1) Hoist the front end of vehicle and apply safety stands.
2) Fill P / S fluid reservoir with fluid up to specified level.
NOTE:
Before starting engine, place transmission gear shift lever
in ªNeutralº (shift selector lever to ªPº range for A / T mod-
el), and set parking brake.
3) After running engine at idling speed for 3 to 5 seconds, stop it
and add fluid to satisfy specification.
4) With engine stopped, turn steering wheel to the right and left as
far as it stops, repeat it a few times and fill fluid to specified level.
5) With engine running at idling speed, repeat stop-to-stop turn of
steering wheel till all foams in P / S fluid reservoir are gone.
NOTE:
Make sure to bleed air completely. If air remains in fluid, P / S
pump may make humming noise or steering wheel may feel
heavy.
6) Finally check to make sure that fluid is filled to specified level.

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-19
Tightening Torque
(a): 60 N.m (6.0 kg-m, 43.5 lb-ft)
(b): 25 N.m (2.5 kg-m, 18.5 lb-ft)
(c): 55 N.m (5.5 kg-m, 40.0 lb-ft)
(d): 11 N.m (1.1 kg-m, 8.0 lb-ft)
(e): 35 N.m (3.5 kg-m, 25.5 lb-ft)
( f ): 40 N.m (4.0 kg-m, 29.0 lb-ft)
(g): 45 N.m (4.5 kg-m, 33.0 lb-ft)
1. Power steering pump assembly
2. Bracket
3. P / S fluid reservoir4. High pressure hose & pipe
5. Suction hose
6. Low pressure return hose7. Oil tank bracket
8. To P / S gear box
[G16 ENGINE MODEL]
[J20 ENGINE MODEL][H25 ENGINE MODEL]
POWER STEERING PUMP

YH4
GRAND
VITARA
3B1-26 POWER STEERING (P / S) SYSTEM
09915-77420
Oil pressure gauge
attachment and hose set09915-77410
Oil pressure gauge09943-55010
Boot clamp plier
TIGHTENING TORQUE SPECIFICATION
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Gear box mounting bolts555.540.0
Gear box cylinder pipe flare nuts292.921.0
Gear box low pressure pipe union bolt404.029.0
Gear box high pressure pipe union bolt353.525.5
Tie-rod end lock nut656.547.0
G16 Type engine555.540.0
Pump bracket boltJ20 Type engine252.518.5
H25 Type engine454.532.5
Pump union bolt606.043.5
Oil pump mount bolts252.518.5
Pipe clamp bolt / Reservoir bracket bolt111.18.0
Steering shaft joint bolt252.518.0
High pressure flare nuts404.029.0
Pump cover bolts232.317.0
Plug606.043.5
Pressure switch (Terminal)282.820
Suction connector bolt101.07.5
Tie-rod end nut484.835.0
Tie-rod (for canvas top LH model only)858.561.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUPER GREASE (A)
(99000-25010)
Oil seal lip of P / S pump pulley shaft
Power steering fluidAn equivalent of DEXRON
-III or
DEXRON
-II

To fill P / S fluid reservoir

Parts lubrication when installing
SPECIAL TOOL

YH4
GRAND
VITARA
1. Steering column
2. Mounting bolt
3. Steering column lower seal
4. Dash panel
1. Steering column lower seal
In engine room
In cabin
3C-8 STEERING WHEEL AND COLUMN
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 lower shaft 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.
INSTALLATION
CAUTION:

After tightening steering column mounting bolts, steering
shaft joint bolts should be tightened.

After tightening steering column lower bolts, steering col-
umn upper bolts should be tightened.
1) Be sure that front wheels and steering wheel are in straight-
ahead position.
2) If equipped with shift (key) interlock cable, install shift (key) inter-
lock cable to ignition switch.
3) Install steering column assembly to dash panel and upper
bracket so that boss of steering column lower seal and all around
it project out of hole in dash panel into engine room. Tighten
steering column lower bolts (4 pieces) first and then upper bolts
(2 pieces) to specified torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
1. Steering column
2. Mounting bolt
3. Steering column lower seal
4. Dash panel
1. Steering column lower seal
In engine room
In cabin
1. Shift (key) interlock cable
2. Screw
3C1-12 AIR BAG STEERING WHEEL AND COLUMN
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 lower shaft 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.
INSTALLATION
CAUTION:
After tightening steering column mounting bolts, steering
shaft joint bolts should be tightened.
1) Be sure that front wheels and steering wheel are in straight-
ahead position.
2) If equipped with shift (key) interlock cable, install shift (key) inter-
lock cable to ignition switch.
Tightening Torque
(a): 2.2 N
.m (0.22 kg-m, 1.6 lb-ft)
3) Install steering column assembly to dash panel and upper
bracket so that boss of steering column lower seal and all around
it project out of hole in dash panel into engine room. Tighten
steering column lower bolts (4 pieces) first and then upper bolts
(2 pieces) to specified torque.
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
1. Boot
2. Boot band
1. Circlip1. Cage Wheel side
ªAº Fill grease 85g (3.0 oz)
4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
ASSEMBLY
CAUTION:

To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with cloth
is allowed.

For M / T vehicle with H25 engine
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint. i.e. yellow
grease to wheel side joint and black one to differential
side.

Bend each boot band against forward rotation.

Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its du-
rability.
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part.
2) Fit wheel side boot on shaft.
Fill up inside of boot with joint grease of about 90 gram.
Before fixing boot band, insert screwdriver into boot on joint side
and allow air to enter boot so that air pressure in boot becomes
the same as atmospheric pressure.
3) Fixing boot band.
4) Install boot onto drive shaft till its small diameter side fits to shaft
groove and fix there with boot band.
5) Install cage to shaft.
CAUTION:
Install cage directing smaller outside diameter side to
shaft end.
6) Install circlip by using snap ring plier.

YH4
GRAND
VITARA
ªAº: Fill grease 90 ± 95 g (3.2 ± 3.4 oz)
1. Circlip
[LH] [RH] Differential side
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-7
7) Apply grease to entire surface of cage.
Use joint grease in tube included in spare part or joint grease
(99000-25120).
8) Insert cage into outer race and fit circlip into groove of outer
race.
CAUTION:
Position opening of circlip ªaº so that it will not be lined
up with a ball.
9) Apply grease to inside of outer race, and fit boot to outer race.
Fill up inside of boot with joint grease.
ªAº: Joint Grease 99000-25120
(about 90 ± 95g / 3.2 ± 3.4 oz)
10) Fitting boot to outer race, adjust so that measurements ªbº and
ªcº become as indicated in figure.
Length ªbº: 203.2 ± 213.2 mm
(8.00 ± 8.40 in.)
196.8 ± 206.8 mm
(7.75 ± 8.14 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
ªcº: 125.5 ± 135.5 mm
(4.94 ± 5.33 in.)
127.5 ± 137.5 mm
(5.02 ± 5.41 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
Before fixing boot band, insert screwdriver into boot on joint
side and allow air to enter boot so that air pressure in boot be-
comes the same as atmospheric pressure.
11) Clamp boot band. Check boots for distortion or dent.

YH4
GRAND
VITARA
4B-2 PROPELLER SHAFTS
DIAGNOSIS
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Abnormal noise
Loose universal joint bolt.

Spider bearing worn out or stuck.

Wear spider.Tighten universal joint bolt.
Replace.
Replace propeller shaft.
Vibration
Deformed propeller shaft.Replace.
PROPELLER SHAFT JOINT CHECK
If universal joints are suspected of producing chattering or rattling
noise, inspect them for wear. Check to see if cross spider rattles in
yokes or if splines are worn down and replace defective propeller
shaft with new one.
Noise coming from universal joint can be easily distinguished from
other noises because rhythm of chattering or rattling is in step with
cruising speed. Noise is pronounced particularly on standing start
or in coasting condition (when braking effect of engine is showing
in the drive line).

YH4
GRAND
VITARA
5-6 BRAKES
ConditionPossible CauseCorrection
Brake warning light
turns on after
engine start
Parking brake applied.

Insufficient amount of brake fluid.

Brake fluid leaking from brake line.

Brake warning light circuit faulty.

Malfunctioning EBD system, if equipped
with ABS.Release parking brake and check
that brake warning light turns off.
Add brake fluid.
Investigate leaky point, correct it and
add brake fluid.
Repair circuit.
Check system referring to
ªDIAGNOSISº of ABS section.
Brake warning light
turns on when
brake is applied
Brake fluid leaking from brake line.

Insufficient amount of brake fluid.Investigate leaky point, correct it and
add brake fluid.
Add brake fluid.
Brake warning light
fails to turn on
even when parking
brake is applied
Bulb burnt out.

Brake warning light circuit open.Replace bulb.
Repair circuit.
ABS warning light
does not turn on
for 2 sec. after
ignition switch has
turned ON
Bulb burnt out.

ABS warning light circuit open, if equipped
with ABS. (including check relay)Replace bulb.
Check system referring to
ªDIAGNOSISº of ABS section.
ABS warning light
remains on after
ignition switch has
turned on for 2 sec.
Malfunctioning ABS, if equipped with ABS.Check system referring to
ªDIAGNOSISº of ABS section.