power steering rack SUZUKI GRAND VITARA 2000 2.G Service User Guide

YH4
GRAND
VITARA
1. Steering gear box mounting bolts
1. Mark
2. Gear case
3. Pinion shaft
POWER STEERING (P / S) SYSTEM 3B1-15
7) Remove steering gear box mounting bolts and then remove
steering gear box from vehicle.
Steering gear box found to be in defective condition should be
replaced with a new one.
CAUTION:
Never disassemble P / S gear box. If perform this prohib-
ited service, it will affect original performance.
INSTALLATION
Reverse removal procedure for installation of steering gear box
noting the following points.

After confirming that front tire is in straight position, install steering
gear box to body temporarily. Next, with tie-rod end installed to
knuckle, set rack in position close to neutral. Then obtain the neu-
tral state by aligning match marks on pinion shaft and steering
gear case and insert steering lower joint into pinion shaft.
CAUTION:
Be sure to confirm that steering wheel and front tires
(wheels) are in straight position when inserting steering
lower joint into steering pinion shaft.

If a plug was put to disconnected pipe when removing steering
gear box, remove that plug before reconnecting pipe.

Use specified torque as given below.
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
(b): 40 N
.m (4.0 kg-m, 29.0 lb-ft)
(c): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
(d): 55 N
.m (5.5 kg-m, 40.0 lb-ft)

After installation, be sure to fill specified power steering fluid and
bleed air.

Check toe setting. Adjust as required. (Refer to Front End Align-
ment.)

YH4
GRAND
VITARA
3B1-16 POWER STEERING (P / S) SYSTEM
1. Clip
2. Wire
Make marking here
RACK BOOT AND TIE-ROD (EXCEPT CANVAS
TOP LH MODEL)
REMOVAL
CAUTION:
Never disassemble tie-rod except for canvas top LH model.
Performing this prohibited service will affect original per-
formance.
1) Remove steering gear box by referring to ªPOWER STEERING
GEAR BOX ASSEMBLY REMOVALº in this section.
2) For ease of adjustment after installation, make marking of tie-rod
end lock nut position of tie-rod end thread.
3) Loosen tie-rod end lock nut and remove tie-rod end.
4) Remove boot wire and clip.
5) Remove boot from tie-rod.
INSTALLATION
1) Visually inspect that rack and rack end ball joint are free from dirt
or foreign matters. Clean thoroughly with cloth or such.
Position boot properly in grooves of gear case and tie-rod and
clamp it with wire and clip.
Wire should be new and should go around twice.
Pull its both ends together by screw driver or such and make
sure that the wire won't be crossed. Then twist the ends several
times, the twisted ends should be bent in the circumferential
direction.
After this, check to ensure that wire is tight and boot is free from
twist and dent.

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-17
1. Tie-rod
2. Steering rack
3. Boot
4. Mark
1. Tie-rod lock washer
2. Tie-rod
3. Steering rack
4. Aluminium plate
5. Vise
1. Tie-rod
2. Mark
3. Lock nut
4. Tie-rod end
5. Knuckle
6. Nut
2) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock
nut to the mark made in removal.
3) Install steering gear box assembly by referring ªPOWER
STEERING GEAR BOX ASSEMBLY INSTALLATIONº in this
section.
After installation, fill specified P / S fluid and bleed air from sys-
tem. Then check toe setting and adjust as required.
RACK BOOT AND TIE-ROD
(FOR CANVAS TOP LH MODEL)
REMOVAL
1) Remove steering gear case, refer to ªPOWER STEERING
GEAR BOX ASSEMBLY REMOVALº in this section.
2) For ease of adjustment after installation, make marking of tie-rod
end lock nut position of tie-rod thread.
3) Loosen tie-rod end lock nut and remove tie-rod end.
4) Remove boot band and clip.
5) Remove boot from tie-rod.
6) Unbend washer (2 places), and remove tie-rod from rack.

YH4
GRAND
VITARA
3B1-18 POWER STEERING (P / S) SYSTEM
ªAº
1
1
1. Mark
1. Tie-rod lock washer
(A)
INSTALLATION
1) Install new tie-rod lock washer and tie-rod to rack.
2) Tighten tie-rod ball nut to specified torque.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
3) Bend lock washer 2 place at the flat part of tie-rod ball nut.
4) Apply grease to ªAº indicated in figure.
5) Position boot properly in grooves of gear case and tie-rod.
Check to ensure that boot is free from twist and dent.
6) Fasten boot with new clamp and clip securely.
Special Tool
(A): 09943-55010
7) Install tie-rod end lock nut and tie-rod end to tie-rod.
Position lock nut to marking made in removal.
NOTE:
When tie-rod was replaced, measure length ªAº on re-
moved tie-rod and use it on new replacement tie-rod so as
to position lock nut properly.
8) Install steering gear case. Refer to ªPOWER STEERING GEAR
BOX ASSEMBLY INSTALLATIONº in this section.

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. Yellow connector of passenger air bag (inflator) module
2. Steering support member
3. Air bag harness
AIR BAG SYSTEM 10B-57
3) Connect Yellow connector of passenger air bag (inflator) mod-
ule, and be sure to lock connector with lock lever.
ii) Connect connector.
ii) Lock connector with lock lever.
4) Install glove box.
5) Install ªAIR BAGº fuse to ªAIR BAGº fuse box.
6) Turn ignition switch to ON and verify that ªAIR BAGº warning
lamp flashes 6 times and then turns off.
If it does not operate as described, perform ªAir Bag Diagnostic
System Checkº in this section.
HANDLING AND STORAGE
SDM
WARNING:
Never power up air bag system when SDM is not rigidly at-
tached to the vehicle. Otherwise, personal injury may result.
CAUTION:
After detecting one time of such collision as to meet deploy-
ment conditions, the SDM must not be used.
Refer to ªDiagnosisº when checking the SDM.

Never attempt disassembly of SDM.

When storing SDM, select a place where neither high tempera-
ture nor high humidity is anticipated and oil, water and dust are
kept off.

If SDM was dropped from a height of 90 cm (3 ft) or more or if it
is found to be damaged or deformed, replace it with a new one.

If installation part of SDM was damaged, repair that part com-
pletely before reinstallation.

All SDM and mounting bracket fasteners must be carefully
torqued and the arrow must be pointed toward the front of the ve-
hicle to ensure proper operation of the air bag system.