4 wheel drive SUZUKI GRAND VITARA 2001 2.G Service User Guide

YH4
GRAND
VITARA
STEERING, SUSPENSION, WHEELS AND TIRES 3-3
ConditionPossible CauseCorrection
Too Much Play in
Steering
Wheel bearings worn.

Loose steering gear case bolts.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)

Worn steering shaft joints.

Worn tie rod ends or tie rod
inside ball joints.

Worn lower ball joints.Replace wheel bearing.
Tighten.
Check and adjust rack and pinion
torque.
Replace joint.
Replace tie rod end or steering
gear case.
Replace front suspension control
arm.
Poor Returnability
Bind in tie rod end ball studs.

Bind in ball joints.

Bind in steering column.

Poorly lubricated rack and pinion.
(if equipped with manual steering gear
case)

Disturbed front end alignment.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)

Tires not adequately inflated.Replace tie rod end.
Replace ball joint.
Repair or replace.
Check, repair or lubricate rack and
pinion.
Check and adjust front end
alignment.
Check and adjust rack and pinion
torque.
Adjust pressure.
Steering Noise
(Rattle or Chuckle)
Loose bolts and nuts.

Broken or otherwise damaged wheel
bearings.

Worn or sticky tie rod ends.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)Retighten.
Replace.
Replace.
Check and adjust rack and pinion
torque.
Abnormal Noise,
Front End
Worn, sticky or loose tie rod
ends, lower ball joints, tie rod
inside ball joints or drive shaft
joints.

Damaged shock absorbers, struts
or mountings.

Worn control arm bushings.

Loose stabilizer bar.

Loose wheel nuts.

Loose suspension bolts or nuts.

Broken or otherwise damaged
wheel bearings.

Broken suspension springs.

Poorly lubricated or worn strut
bearings.Replace tie rod end, control arm,
steering gear case or drive shaft
joint.
Replace or repair.
Replace.
Tighten bolts or replace bushes.
Tighten wheel nuts.
Tighten suspension bolts or nuts.
Replace wheel bearing.
Replace spring.
Lubricate or replace strut bearing.

YH4
GRAND
VITARA
[A]
[B]

Hard Cornering

Under-Inflation

Lack of Rotation
Incorrect Wheel Alignment

Tire Construction Non-Uniformity

Wheel Heavy Acceleration [A] [B]
3-6 STEERING, SUSPENSION, WHEELS AND TIRES
TIRE DIAGNOSIS
IRREGULAR AND / OR PREMATURE WEAR
Irregular and premature wear has many possible causes. Some of
them are: incorrect inflation pressures, lack of tire rotation, driving
habits, improper alignment.
If the following conditions are noted, rotation is in order:
1. Front tire wear is different from rear.
2. Uneven wear exists across the tread of any tire.
3. Left front and right front tire wear is unequal.
4. Left rear and right rear tire wear is unequal.
5. There is cupping, flat spotting, etc.
A wheel alignment check is in order if the following conditions are
noted:
1. Left front and right front tire wear is unequal.
2. Wear is uneven across the tread of any front tire.
3. Front tire treads have scuffed appearance with ªfeatherº edges
on one side of tread ribs or blocks.
WEAR INDICATOR
The original equipment tires have built-in tread wear indicators to
show when tires need replacement. These indicators will appear as
12 mm (0.47 in.) wide bands when the tire tread depth becomes 1.6
mm (0.063 in.). When the indicators appear in 3 or more grooves
at 6 locations, tire replacement is recommended.
RADIAL TIRE WADDLE
Waddle is side to side movement at the front and / or rear of the ve-
hicle. It is caused by the steel belt not being straight within the tire.
It is most noticeable at low speed, 8 to 48 km / h (5 to 30 mph). It is
possible to road test a vehicle and tell on which end of the vehicle
the faulty tire is located. If the waddle tire is on the rear, the rear end
of the vehicle will shake from side to side or ªwaddleº. From the driv-
er's seat it feels as though someone is pushing on the side of the
vehicle. If the faulty tire is on the front, the waddle is more visual.
The front sheet metal appears to be moving back and forth and the
driver feels as though he is at the pivot point in the vehicle.
Waddle can be quickly diagnosed by using a Tire Problem Detector
(TPD) and following the equipment manufacturer's recommenda-
tions.
If a TPD is not available, the more time consuming method of sub-
stituting known good tire / wheel assemblies on the problem vehicle
can be used as follows:

YH4
GRAND
VITARA
3B1
POWER STEERING (P / S) SYSTEM 3B1-1
GENERAL DESCRIPTION3B1- 2 . . . . . . . . . . . . . .
Power Steering System 3B1- 2. . . . . . . . . . . . . . . . .
Steering Gear Box 3B1- 3. . . . . . . . . . . . . . . . . . . . . .
Power Steering (P / S) Pump 3B1- 4. . . . . . . . . . . . . .
DIAGNOSIS3B1- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Table 3B1- 5. . . . . . . . . . . . . . . .
Steering Wheel 3B1- 7. . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Play Check 3B1- 7. . . . . . . . . . . .
Steering Force Check 3B1- 7. . . . . . . . . . . . . . . . .
Power Steering Fluid 3B1- 7. . . . . . . . . . . . . . . . . . . .
Power Steering Fluid Level Check 3B1- 7. . . . . .
Power Steering Pump Drive Belt 3B1- 8. . . . . . . . .
Belt Tension Check 3B1- 8. . . . . . . . . . . . . . . . . . .
Belt Tension Adjustment 3B1- 8. . . . . . . . . . . . . . .
Idle Up System 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . .
Idle Up System Check 3B1- 9. . . . . . . . . . . . . . . .
Fluid 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Leakage Check 3B1- 9. . . . . . . . . . . . . . . . . Hydraulic Pressure in P / S Circuit 3B1-10. . . . . . . . .
Hydraulic Pressure Check 3B1-10. . . . . . . . . . . . .
Boot 3B1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Rack Boot Check 3B1-11. . . . . . . . . . . . .
Tie-Rod End Boot Check 3B1-12. . . . . . . . . . . . . .
Air Bleeding Procedure 3B1-12. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3B1-13 . . . . . . . . . . . . . . . .
Tie-Rod End 3B1-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Gear Box Assembly 3B1-14. . . . . .
Rack Boot and Tie-Rod (Except Canvas
Top LH Model) 3B1-16. . . . . . . . . . . . . . . . . . . . . . . .
Rack Boot and Tie-Rod (For Canvas
Top LH Model) 3B1-17. . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump 3B1-19. . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATION3B1-26 . . .
REQUIRED SERVICE MATERIAL3B1-26 . . . . . . . .
SPECIAL TOOL3B1-26 . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3B1
POWER STEERING (P/S) SYSTEM
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 autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº 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
ªLOCKº 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:

Some parts in the Power Steering Gear Box cannot be disassembled or adjusted. For detailed informa-
tion, refer to the description of ªPOWER STEERING GEAR BOX ASSEMBLYº.

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 replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.

Although the figures in this section show only the left-hand steering vehicle, the same work procedure
and data apply to the right-hand steering vehicle.
CONTENTS

YH4
GRAND
VITARA
1. Power steering gear box
2. Power steering pump
3. P / S fluid reservoir
1. Power steering pump
2. Valve section
3. P / S fluid reservoir
4. Rack
5. Pinion
6. Cylinder
3B1-2 POWER STEERING (P / S) SYSTEM
GENERAL DESCRIPTION
POWER STEERING SYSTEM
The power steering (P / S) system in this vehicle reduces the driver's effort needed in turning the steering wheel
by utilizing the hydraulic pressure generated by the power steering (P / S) pump which is driven by the engine.
It is an integral type with the rack and pinion gears and the control valve unit, hydraulic pressure cylinder unit all
built in the steering gear box.

YH4
GRAND
VITARA
3C1
AIR BAG STEERING WHEEL AND COLUMN 3C1-1
GENERAL DESCRIPTION3C1- 2 . . . . . . . . . . . . .
DIAGNOSIS3C1- 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair Required after
Accident 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3C1- 3 . . . . . . . . . . . . . . .
Service Precautions 3C1- 3. . . . . . . . . . . . . . . . .
Diagnosis and Servicing 3C1- 3. . . . . . . . . . . .
Disabling Air Bag System 3C1- 3. . . . . . . . . . .
Enabling Air Bag System 3C1- 3. . . . . . . . . . .
Handling and Storage 3C1- 3. . . . . . . . . . . . . .
Disposal 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Air Bag (Inflator) Module 3C1- 4. . . . . . . .
Steering Wheel 3C1- 6. . . . . . . . . . . . . . . . . . . . . . Centering Contact Coil 3C1- 6. . . . . . . . . . . . .
Contact Coil and Combination Switch
Assembly 3C1- 7. . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column 3C1- 9. . . . . . . . . . . . . . . . . . . .
Steering Lock Assembly (Ignition
Switch) 3C1-14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Lower Shaft Assembly 3C1-15. . . . . . .
Checking Steering Column for Accident
Damage 3C1-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable Steering Column Release
Lever 3C1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3C1-18 . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL3C1-18 . . . . . . . . . . . . . . . . . . . . . .
SECTION 3C1
AIR BAG STEERING WHEEL AND COLUMN
WARNING:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Please observe all WARNINGS and ªService Precautionsº under ªOn-Vehicle
Serviceº in air bag system section before performing service on or around the air bag system compo-
nents 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 tem-
porarily 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 sys-
tem repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. 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 proce-
dures are not followed, parts or system damage could result.
CONTENTS

YH4
GRAND
VITARA
14
15
1. Driver air bag (inflator) module
2. Steering wheel
3. Steering wheel nut
4. Contact coil and combination switch assembly
5. Steering column upper cover
6. Steering column lower cover
7. Steering column assembly
8. Steering lock assembly
9. Steering column hole cover
10. Steering shaft joint
11. Steering lower shaft assembly
12. Adjustable steering column release lever
(if equipped)
13. Steering column lower seal
14. With adjustable steering column release lever type
15. Without adjustable steering column release lever type
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 function:

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 vehicle.
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 recommended
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 WARNINGS in this
section. Refer to ªSERVICE PRECAUTIONSº in Section 10B.

YH4
GRAND
VITARA
1 11
1. Mounting bolt
1. Driver air bag (inflator) module connector
2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel
3C1-4 AIR BAG STEERING WHEEL AND COLUMN
DRIVE AIR BAG (INFLATOR) MODULE
WARNING:
When handling an air bag (inflator) module, be sure to read
ªSERVICE PRECAUTIONSº under ªON-VEHICLE SERVICEº
in Section 10B and observe each instruction. Failure to fol-
low them could cause a damage to the air bag (inflator) mod-
ule or result in personal injury.
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to ªDISABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
3) Loosen 2 bolts mounting driver air bag (inflator) module till it
turns freely, pull them out and fix them to bolt clamps.
4) Remove air bag (inflator) module from steering wheel.
5) Remove driver air bag (inflator) module (yellow) connector and
horn connector from steering wheel.
6) Disconnect driver air bag (inflator) module (yellow) connector of
driver air bag (inflator) module and horn connector as shown in
the figure.
ii) Release locking of lever.
ii) After unlocked, disconnect connector.
WARNING:
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) module. Observe
ªSERVICE PRECAUTIONSº under ªON-VEHICLE SER-
VICEº in Section 10B. Otherwise, personal injury may re-
sult.

YH4
GRAND
VITARA
6, (a)
1. Trim cover (pad surface)
2. Inflator case
3. Wire harness
1. Driver air bag (inflator) module connector
2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel
5. Mounting bolt (left side)
6. Mounting bolt (right side)
AIR BAG STEERING WHEEL AND COLUMN 3C1-5
INSPECTION
WARNING:
Never disassemble air bag (inflator) module or measure its
resistance. Otherwise, personal injury may result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.
Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.

Air bag being deployed.

Trim cover (pad surface) being cracked.

Wire harness or connector being damaged.

Air bag (inflator) module being damaged or having been exposed
to strong impact (dropped).
INSTALLATION
1) Connect horn connector securely.
2) Connect yellow connector of driver air bag (inflator) module con-
nector as shown in the figure securely.
ii) Connect connector.
ii) Lock connector with lock lever.
3) Install horn connector and driver air bag (inflator) module con-
nector.
4) Install driver air bag (inflator) module to steering wheel, taking
care so that no part of wire harness is caught between them.
5) Make sure that clearance between module and steering wheel
is uniform all the way.
6) Tighten driver air bag (inflator) module mounting bolt (left side)
to specified torque first and then driver air bag (inflator) module
mounting bolt (right side) to specified torque.
Tightening Torque
(a): 9 N
.m (0.9 kg-m, 6.5 lb-ft)
7) Connect negative battery cable.
8) Enable air bag system. Refer to ªENABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.

YH4
GRAND
VITARA
(A)
1
1. Make alignment marks
1. Steering wheel
Turn slowly till coil stops
Turn contact coil back about 2 and
a half turns
1. Align marks
3C1-6 AIR BAG STEERING WHEEL AND COLUMN
STEERING WHEEL
CAUTION:
Removal of the steering wheel allows the contact coil to turn
freely but do not turn the contact coil (on the combination
switch) more than allowable number of turns (about two and
a half turns from the center position clockwise or counter-
clockwise respectively), or coil will break.
REMOVAL
1) Remove driver air bag (inflator) module from steering wheel re-
ferring to ªDRIVER AIR BAG (INFLATOR) MODULEº earlier in
this section.
2) Remove steering shaft nut.
3) Make alignment marks on steering wheel and shaft for a guide
during reinstallation.
4) Remove steering wheel with special tool.
Special Tool
(A): 09944-36011
CAUTION:
Do not hammer the end of the shaft. Hammering it will
loosen the plastic shear pins which maintain the column
length and impair the collapsible design of the column.
CENTERING CONTACT COIL
1) Check that vehicle's wheels (front tires) are set at straight-ahead
position.
2) Check that ignition switch is at ªLOCKº position.
3) Turn contact coil counterclockwise slowly with a light force till
contact coil will not turn any further.
NOTE:
Contact coil can turn about 5 turns at maximum, that is, if
it is at the center position, can turn about two and a half
turns both clockwise and counterclockwise.
4) From the position where contact coil became unable to turn any
further (it stopped), turn it back clockwise about two and a half
rotations and align center mark with alignment mark.

YH4
GRAND
VITARA
1
1. Lugs
2. Grooves
3. Alignment marks
2. Steering column upper cover
3. Steering column lower cover 1. Steering column
cover screw
(a)
1. Steering column hole cover
AIR BAG STEERING WHEEL AND COLUMN 3C1-7
INSTALLATION
1) Check that vehicle's front tires are at straight-ahead position and
contact coil is centered. Refer to ªCENTERING CONTACT
COILº in this section.
CAUTION:
These two conditions are prerequisite for installation of
steering wheel. If steering wheel has been installed with-
out these conditions, contact coil will break when steer-
ing wheel is turned.
2) Install steering wheel to steering shaft with 2 lugs on contact coil
fitted in two grooves in the back of steering wheel and also align-
ing marks on steering wheel and steering shaft.
3) Tighten steering shaft nut to specified torque.
Tightening Torque
(a): 33 N
.m (3.3 kg-m, 23.5 lb-ft)
4) Install driver air bag (inflator) module to steering wheel. Refer to
ªDRIVER AIR BAG (INFLATOR) MODULEº in this section.
CONTACT COIL AND COMBINATION SWITCH
ASSEMBLY
CAUTION:
Do not turn contact coil (on combination switch) more than
allowable number of turns (about two and a half turns from
the center position clockwise or counterclockwise respec-
tively), or coil will break.
REMOVAL
1) Remove steering wheel from steering column. Refer to
ªSTEERING WHEELº in this section.
2) Remove steering column hole cover.
3) Remove steering column cover screws (3 pieces).
4) Separate upper cover and lower cover, then remove them.
5) Disconnect all connectors for contact coil and combination
switch assembly.