SUZUKI GRAND VITARA 1999 2.G Manual PDF

3A-2 FRONT END ALIGNMENT

POWER STEERING (P/S) SYSTEM 3B1-1
3B1
SECTION 3B1
POWER STEERING (P/S) SYSTEM
CONTENTS
General Description ......................................3B1-2
Power Steering (P/S) Pump ........................ 3B1-2
Diagnosis .......................................................3B1-2
Power Steering Pump Drive Belt ................. 3B1-2
Belt inspection ......................................... 3B1-2Belt tension check ................................... 3B1-2
Belt tension adjustment ........................... 3B1-2
Hydraulic Pressure in P/S Circuit ................ 3B1-3
Hydraulic pressure check ........................ 3B1-3 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Man-
ual mentioned in the FOREWORD of this manual.
Some parts in the Power Steering Gear Box cannot be disassembled or adjusted. For detailed infor-
mation, refer to the description of “POWER STEERING GEAR BOX ASSEMBLY”.
All steering gear fasteners are important attaching parts in that they 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 speci-
fied during reassembly to assure proper retention of these parts.

3B1-2 POWER STEERING (P/S) SYSTEM
General Description
Power Steering (P/S) Pump
Power steering (P/S) pump specification :
The specification of this power steering pump is the same as the specification of the same section in the service
manual mentioned in this manual except for data of relieved pressure shown below.
Relieved pressure :
7850 kPa (78.5 kg/cm
2, 1116 psi)
Diagnosis
Power Steering Pump Drive Belt
Belt inspection
Check P/S pump drive belt (1) is free from any damage and prop-
erly fitted in pulley groove.
Belt tension check
Check belt tension by measuring how much it deflects when
pushed at arrow point (2) between pulleys with about 10 kg (22
lb) force.
Deflection of P/S belt :
4 – 7 mm (0.16 – 0.28 in.)
Belt tension adjustment
1) To adjust P/S pump drive belt (1) tension, loosen tension
pulley bolts (3) and turn tension pulley (4) using hexagon
wrench.
2) Adjust belt tension to above specification.
Then tighten tension pulley bolts (3) to specified torque.
Tightening torque
Tension pulley bolts (a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)
5. P/S pump pulley
6. A/C compressor pulley (if equipped)
7. Crankshaft pulley
[A] : With A/C
[B] : Without A/C

POWER STEERING (P/S) SYSTEM 3B1-3
Hydraulic Pressure in P/S Circuit
Hydraulic pressure check
1) After cleaning joint of high pressure hose and P/S pump
thoroughly, disconnect hose from pump and install special
tool (oil pressure gauge, attachment and hose).
Special tool
(A) : 09915-77410
(B) : 09915-77420
2) Check each connection for fluid leakage and bleed air.
Refer to “AIR BLEEDING PROCEDURE” in this section.
3) With engine idling, turn steering wheel and warm up engine
till temperature of fluid in P/S fluid reservoir rises to 50 –
60°C (122 – 140°F).
4) Check back pressure by measuring hydraulic pressure with
engine idling and hands off steering wheel.
When back pressure is higher than specified values, check
control valve and piping for clogging.
Back pressure :
Lower than 1000 kPa (10 kg/cm
2, 142 psi) CAUTION:
Take care not to cause damage to A/C condenser during
service operation, if equipped.
1. P/S fluid reservoir
2. Attachment
3. Gasket
4. Union bolt
5. High pressure side
6. Low pressure side
1. P/S fluid reservoir 4. P/S gear box
2. Gauge valve (open) 5. High pressure side
3. P/S pump 6. Low pressure side

3B1-4 POWER STEERING (P/S) SYSTEM
5) Check relief pressure.
a) Increase engine speed to about 1500 r/min (rpm). Close
gauge valve gradually while watching pressure increase
indicated by gauge and take reading of relief pressure
(maximum hydraulic pressure).
When it is higher than specified values, possible cause is
malfunction 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.
Relief pressure (when gauge valve is closed) :
7650 – 8350 kPa (76.5 – 83.5 kg/cm
2, 1088 – 1187 psi)
b) Next, open gauge valve fully and increase engine speed to
about 1500 r/min (rpm). Then turn steering wheel to the left
or right fully and take reading of relief pressure.
When it is higher than specified values, possible cause is
malfunction of relief valve.
When it is lower than specified values, possible cause is
failure in steering gear box. Replace gear box.
Relief pressure (when gauge valve is opened) :
7650– 8350 kPa (76.5 – 83.5 kg/cm
2, 1088 – 1187 psi) CAUTION:
Be sure not to close gauge valve for longer than 10 sec-
onds.
1. P/S fluid reservoir
2. Gauge valve (shut)
3. Oil pressure gauge
4. P/S pump
5. P/S gear box
CAUTION:
Be sure not to hold steering wheel at fully turned position
for longer than 10 seconds.
1. P/S fluid reservoir
2. Gauge valve (open)
3. Oil pressure gauge
4. P/S pump
5. P/S gear box

AIR BAG STEERING WHEEL AND COLUMN 3C1-1
3C1
SECTION 3C1
AIR BAG STEERING WHEEL AND COLUMN
CONTENTS
General Description ..................................... 3C1-2
Diagnosis ...................................................... 3C1-3
Inspection and Repair Required after
Accident ..................................................... 3C1-3
On-Vehicle Service....................................... 3C1-3
Service Precautions ................................... 3C1-3
Diagnosis and servicing ......................... 3C1-3
Disabling air bag system ........................ 3C1-3
Enabling air bag system ......................... 3C1-3Handling and storage ............................. 3C1-3
Disposal ................................................. 3C1-3
Steering Column ........................................ 3C1-4
Steering Upper Shaft Assembly ................. 3C1-7
Steering Lower Shaft Assembly ................. 3C1-9
Checking Steering Column and Steering
Upper Shaft for Accident Damage ........... 3C1-11
Tightening Torque Specification .............. 3C1-12

WARNING:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem components or wiring. Failure to follow WARNINGS could result in unintentional activation of
the system or could render the system inoperative. Either of these two conditions may result in
severe injury.
The procedures in this section must be followed in the order listed to disable the air bag system
temporarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures
could result in possible activation of the air bag system, personal injury or otherwise unneeded air
bag system repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.

3C1-2 AIR BAG STEERING WHEEL AND COLUMN
General Description
This double tube type steering column has the following three important features in addition to the steering func-
tion:
The column is energy absorbing, designed to compress in a front-end collision.
The ignition switch and lock are mounted conveniently on this column.
With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehi-
cle.
To insure the energy absorbing action, it is important that only the specified screws, bolts, and nuts be used as
designated and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the one recom-
mended in this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping
the assembly could shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver’s and passenger’s seat belts by deploying the air bags. The air bag (inflator) module
should be handled with care to prevent accidental deployment. When servicing, be sure to observe all WARN-
INGS in this section. Refer to “SERVICE PRECAUTIONS” in Section 10B.
1. Driver air bag (inflator) module 5. Steering column upper cover 9. Steering column hole cover 13. Steering column lower seal
2. Steering wheel 6. Steering column lower cover 10. Steering shaft joint 14. Cap (if equipped)
3. Steering wheel nut 7. Steering column assembly 11. Steering lower shaft assembly 15. Steering upper shaft assembly
4. Contact coil and combination
switch assembly8. Steering lock assembly 12. Adjustable steering column
release lever

AIR BAG STEERING WHEEL AND COLUMN 3C1-3
Diagnosis
For diagnosis of the steering wheel and steering column, refer to Section 3. For diagnosis of the air bag system,
refer to Section 10B.
Inspection and Repair Required after Accident
After an accident, whether the air bag has been deployed or not, be sure to perform checks, inspections and
repairs described under “CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE” in this section as well
as “REPAIRS AND INSPECTIONS REQUIRED AFTER ACCIDENT” in Section 10B.
On-Vehicle Service
Service Precautions
For service precautions, refer to “SERVICE PRECAUTIONS” under “ON-VEHICLE SERVICE” in Section 10B.
Diagnosis and servicing
For diagnosis and servicing, refer to “DIAGNOSIS AND SERVICING” under “SERVICE PRECAUTIONS” in
Section 10B.
Disabling air bag system
For disabling air bag system, refer to “DISABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in
Section 10B.
Enabling air bag system
For enabling air bag system, refer to “ENABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in
Section 10B.
Handling and storage
For handling and storage, refer to “HANDLING AND STORAGE” under “SERVICE PRECAUTIONS” in Section
10B.
Disposal
For disposal, refer to “DISPOSAL” under “SERVICE PRECAUTIONS” in Section 10B.

3C1-4 AIR BAG STEERING WHEEL AND COLUMN
Steering Column
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “DISABLING AIR BAG SYSTEM” under “SERVICE PRECAUTIONS” in
Section 10B.
3) Remove steering wheel and contact coil and combination switch assembly, if necessary. Refer to “STEER-
ING WHEEL” and “CONTACT COIL AND COMBINATION SWITCH ASSEMBLY” in this section.
Perform the following procedure if not removing steering wheel and/or combination switch.
a) Turn steering wheel so that vehicle’s front tires are at straight-ahead position.
b) Turn ignition switch to “LOCK” position and remove key.
4) Remove steering column hole cover (1).
5) Disconnect all connectors for the following parts.
Contact coil and combination switch
Ignition switch CAUTION:
Once the steering column is removed from the vehicle, the column is extremely susceptible to dam-
age.
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 collapsible design.
When loosening steering column mounting bolts and nuts, make sure that steering column assembly
and steering upper shaft assembly have been separated. Loosening them with steering column
assembly and steering upper shaft assembly assembled could cause damage to upper joint and
mounting bracket in steering upper shaft assembly.
NOTE:
When servicing steering column or any column-mounted component, remove steering wheel. But
when removing steering column simply to gain access to instrument panel components, leave steer-
ing wheel installed on steering column.
WARNING:
Never rest a steering column assembly on the steering wheel with air bag (inflator) module face down
and column vertical. Otherwise personal injury may result.
CAUTION:
Never turn steering wheel while steering column with steering wheel is removed. Turning steering
wheel more than about two and a half turns will break contact coil.

AIR BAG STEERING WHEEL AND COLUMN 3C1-5
6) Remove steering upper shaft upper joint bolt (1) and nut (2)
and disconnect steering upper shaft upper joint removing in
arrow direction in the figure.
7) Remove steering column (1) mounting bolts (2 pieces) (2)
and nuts (2 pieces) (3).
8) If equipped with shift (key) interlock cable (1), remove shift
(key) interlock cable screw (2) and then disconnect its cable
(1) from ignition switch.
9) Remove steering column from vehicle.
INSPECTION
Check steering column for damage and operation referring to
CHECKING STEERING COLUMN AND STEERING UPPER
SHAFT FOR ACCIDENT DAMAGE later in this section.
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight-
ahead position.
2) If equipped with shift (key) interlock cable (1), install shift
(key) interlock cable (1) to ignition switch.
Tightening torque
Shift (key) interlock cable screw (a) :
2.2 N·m (0.22 kg-m, 1.6 lb-ft)
1
2
1
32
CAUTION:
After tightening steering column mounting bolts, steer-
ing shaft joint bolts should be tightened.