belt SUZUKI GRAND VITARA 2001 2.G Service Owner's Manual

YH4
GRAND
VITARA
3-2 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Abnormal or
Excessive Tire Wear
Sagging or broken springs.

Tire out of balance.

Disturbed front end alignment.

Faulty shock absorber.

Hard driving.

Overloaded vehicle.

Tires not rotating.

Worn or loose road wheel bearings.

Wobbly wheel or tires.

Tires not adequately inflated.Replace spring.
Adjust balance or replace tire.
Check front end alignment.
Replace shock absorber.
Replace tire.
Replace tire.
Replace or rotate tire.
Replace wheel bearing.
Replace wheel or tire.
Adjust the pressure.
Wheel Tramp
Blister or bump on tire.

Improper shock absorber action.Replace tire.
Replace shock absorber.
Shimmy, Shake or
Vibration
Tire or wheel out of balance.

Loose wheel bearings.

Worn tie rod ends.

Worn lower ball joints.

Excessive wheel runout.

Blister or bump on tire.

Excessively loaded radial runout of
tire / wheel assembly.

Disturbed front end alignment.

Loose or worn tie-rod end.

Loose steering gear case bolts.Balance wheels or replace tire and /
or wheel.
Replace wheel bearing.
Replace tie rod end.
Replace front suspension control
arm.
Repair or replace wheel and / or tire.
Replace tire.
Replace tire or wheel.
Check front end alignment.
Tighten or replace tie-rod end.
Tighten case bolts.
Hard Steering
Bind in tie rod end ball studs or
lower ball joints.

Disturbed front end alignment.

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

Tire not adequately inflated.

Bind in steering column.

Low fluid level, loose drive belt or
malfunction of power steering system.
(if equipped with P / S)Replace tie rod end or front
suspension control arm.
Check front end alignment.
Check and adjust steering gear box.
Inflate tires to proper pressure.
Repair or replace.
Check and correct.

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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
3-8 STEERING, SUSPENSION, WHEELS AND TIRES
RADIAL TIRE LEAD
ªLeadº is the deviation of the vehicle from a straight path on a level
road with no pressure on the steering wheel.
Lead is usually caused by:
1) Incorrect alignment.
2) Uneven brake adjustment.
3) Tire construction.
The way in which a tire is built can produce lead in a vehicle. An ex-
ample of this is placement of the belt. Off center belts on radial tires
can cause the tire to develop a side force while rolling straight down
the road. If one side of the tire is a little larger diameter than the oth-
er, the tire will tend to roll to one side. This will develop a side force
which can produce vehicle lead.
The procedure on previous page should be used to make sure that
front alignment is not mistaken for tire lead.
1) Part of the lead diagnosis procedure is different from the tire
rotation pattern currently in the owner's and service manuals. If
a medium to high mileage tire is moved to the other side of the
vehicle, be sure to check that ride roughness has not developed.
2) Rear tires will not cause lead.
VIBRATION DIAGNOSIS
Wheel unbalance causes most of the highway speed vibration
problems. If a vibration remains after dynamic balancing, it can be
caused by three things.
1) Tire runout.
2) Wheel runout.
3) Tire stiffness variation.
Measuring tire and / or wheel free runout will uncover only part of the
problem. All three causes, known as loaded radial runout, must be
checked by using a Tire Problem Detector (TPD). If a TPD is not
available, the more time consuming method of substituting known
good tire and wheel assemblies on the problem vehicle can be
used.

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. Suction connector
2. O-ring
3. Pressure switch
4. Flow control valve
(Relief valve)
5. Spring
6. Plug
7. Pump cover
8. Cam ring
9. Vane
10. Rotor
11. Snap ring
12. Side plate
13. Pulley (pump shaft)
14. Oil seal
15. Pump body
16. Flow control valve Assembly
3B1-4 POWER STEERING (P / S) SYSTEM
POWER STEERING (P / S) PUMP
The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft.
ModelVane type
Hydraulic
pressure
controlRelieved
pressure
6500 kPa (65 kg / cm2, 924 psi)
G16 Type engine . . . . . . . . . . . . . . . . . . . . . .
7000 kPa (70 kg / cm
2, 995 psi)
J20 Type engine . . . . . . . . . . . . . . . . . . . . . . .
7350 kPa (73.5 kg / cm
2, 1045 psi)
H25 Type engine . . . . . . . . . . . . . . . . . . . . . .
ControlFlow control valve
deviceRelief valve
Power steering
pressure switch
Switch turns on (closes) when the
pressure is higher than 2500 ± 3500 kPa
(25 ± 35 kg / cm
2, 356 ± 498 psi).
ECM uses this signal for idle speed control.
Capacity0.70 ± 0.75

(1.48 / 1.23 ± 1.58 / 1.32 US / Imp. pt)
Specified fluidDEXRON
II, DEXRON
III A / T fluid
or equivalent
FLOW CONTROL VALVE
As the discharge rate of the P/S pump increases in proportion to the
pump revolution speed, a flow control valve is added to control it so
that the optimum amount of fluid for steering operation is supplied
according to the engine speed (driving condition).
Described below is its operation at different engine speed.

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-5
DIAGNOSIS
GENERAL DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Steering wheel
feels heavy
(at low speed)
Fluid deteriorated, low viscosity, different
type of fluid mixed

Pipes or hoses deformed, air entering
through joint

Insufficient air purging from P / S circuit

P / S belt worn, lacking in tension

Tire inflation pressure excessively low

Front end alignment out of order

Steering wheel installed improperly (twisted)

Bind in tie rod or tie rod end ball joint

P / S pump hydraulic pressure fails to increase

P / S pump hydraulic pressure increases
but slowly

Steering gear box malfunctionReplace fluid.
Replace defective part.
Purge air.
Adjust belt tension or replace
belt as necessary.
Inflate tire.
Check and adjust front end
alignment.
Install steering wheel correctly.
Replace defective part.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.
Steering wheel
feels heavy
momentarily when
turning it to the
left or right
Air drawn in due to insufficient amount
of fluid

Slipping P / S belt

P / S pump hydraulic pressure fails to
increase

P / S pump hydraulic pressure increases
but slowly

Steering gear box malfunctionAdd fluid and purge air.
Adjust belt tension or replace
belt as necessary.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.
Poor recovery
from turnsNOTE:
To check steering wheel for recovery, with vehicle running at 22 mile / h (35 km / h),
turn steering wheel 90 and let it free. It should return more than 60.

Deformed pipes or hoses

Steering column installed improperly

Front end alignment out of order

Ball joints binding

P / S pump hydraulic pressure fails to
increase

P / S pump hydraulic pressure increases
but slowly

Steering gear box malfunctionReplace defective part.
Install steering column correctly.
Check and adjust front end
alignment.
Replace defective part.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.

YH4
GRAND
VITARA
3B1-6 POWER STEERING (P / S) SYSTEM
ConditionPossible CauseCorrection
Vehicle pulls to
one side during
straight driving
Mismatched or uneven tire

Low or uneven tire inflation pressure

Brake dragging in one wheel

Front end alignment out of order

Rear end alignment out of order

Malfunction of control valve in gear boxReplace tire.
Inflate tires to proper pressure or
adjust right & left tires inflation
pressure.
Repair.
Check and adjust front end
alignment.
Check and adjust rear end
alignment.
Replace gear box.
Steering wheel
play is large and
vehicle wanders
Refer to ªDiagnosisº in Section 3.
Fluid leakage
Loose joints of (hydraulic pressure)
pipes and hoses

Deformed or damaged pipes or hosesRetighten.
Replace defective part.
Abnormal noise
Air drawn in due to insufficient amount of fluid

Air mixed into fluid from pipes or hoses

Slipping (loose) P / S belt

Worn P / S belt

Loose gear box fastening bolt

Loose linkage or joints

Pipes or hoses in contact with part of
vehicle body

Vanes of P / S pump defective

Malfunction of control valve in gear box

Bearing of P / S pump shaft defectiveAdd fluid and purge air.
Replace pipes or hoses.
Adjust belt tension.
Replace belt.
Retighten bolts.
Retighten.
Install pipes and hoses correctly.
Replace defective part.
Replace gear box.
Replace bearing.
No idle up
Power steering pressure switch defectiveReplace power steering
pressure switch.

YH4
GRAND
VITARA
[D] [C] [A]
1. P / S pump pulley
2. A / C compressor
pulley (if equipped)
3. Crankshaft pulley
4. Tension pulley
5. Tension pulley bolts[A]: G16 type engine with A / C
[B]: G16 type engine without A / C
[C]: H25 type engine with A / C
[D]: H25 type engine without A / C
[B]
3B1-8 POWER STEERING (P / S) SYSTEM
POWER STEERING PUMP DRIVE BELT
NOTE:
For J20 Type engine, refer to Section 6H ªGENERATOR BELTº.
INSPECTION
Check that belt is free from any damage and properly fitted in pulley
groove.
BELT TENSION CHECK
Check belt tension by measuring how much it deflects when
pushed at intermediate point between pulleys with about 10 kg
(22 lb) force.
Deflection of P / S belt:
6 ± 9 mm (0.24 ± 0.35 in.) G16 Type engine. . . . . . . . . . . . . . . . .
4 ± 7 mm (0.16 ± 0.28 in.) H25 Type engine. . . . . . . . . . . . . . . . .
BELT TENSION ADJUSTMENT
[For G16 Type engine]
a) To adjust P / S pump drive belt tension, use adjusting bolt of com-
pressor for A / C equipped vehicles and that of P / S pump for ve-
hicles without A / C.
b) Adjust belt tension to above specification.
c) Then tighten adjusting and mounting bolts to specified torque.
[For J20 Type engine]
To adjust P / S pump drive belt tension, refer to ªGENERATOR
BELTº in Section 6H.
[For H25 Type engine]
a) To adjust P / S pump drive belt tension, loosen tension pulley
bolts and turn tension pulley using hexagon wrench.
b) Adjust belt tension to above specification.
Then tighten tension pulley bolts to specified torque.
Tightening Torque
Tension pulley bolts: 25 N
.m (2.5 kg-m, 18.5 lb-ft)

YH4
GRAND
VITARA
3B1-20 POWER STEERING (P / S) SYSTEM
1. P/S fluid
reservoir
2. Suction hose
1. P / S pulley
2. Mounting bolt
9. Vane
10. Rotor
11. Snap ring
12. Side plate
13. Pulley (pump shaft)
14. Oil seal
15. Pump body
16. Flow control
valve Assembly 1. Suction connector
2. O-ring
3. Pressure switch
4. Flow control valve
(Relief valve)
5. Spring
6. Plug
7. Pump cover
8. Cam ring
REMOVAL
NOTE:
Be sure to clean each joint of suction and discharge sides
thoroughly before removal.
1) Remove suction hose from pump, then disconnect battery nega-
tive cable.
2) Remove P / S fluid reservoir with suction hose.
3) Remove union bolt. Then disconnect high pressure pipe from
pump.
NOTE:
As fluid flows out of disconnected joints, put a receptacle
under joints or a plug to pipe.
4) Disconnect pressure switch lead wire at switch terminal.
5) Loosen related bolts and remove power steering drive belt.
6) Remove P / S pump mounting bolt (s).
7) Remove P / S pump.
NOTE:
Plug each port of removed pump to prevent dust or any oth-
er foreign matter from entering.
DISASSEMBLY
1) Clean its exterior thoroughly.
2) With aluminum plates placed on vise first, grip pump body with
it.
3) Remove suction connector bolt, suction connector and O-ring
from pump body.
4) Remove power steering pressure switch (terminal set) from
pump body.
5) Remove plug, flow control spring and relief valve (flow control
valve) from pump body.
6) Remove cover bolts, pump cover and O-ring from pump body.
7) Remove snap ring from pump shaft.
8) Remove vanes from rotor.
9) Remove cam ring, rotor, side plate and O-rings from pump
body.
10) Pull out pulley from pump body.
11) Remove oil seal from pump body.

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-25
INSTALLATION
Reverse removal procedure, and then noting the following instruc-
tions.

For tightening torques, refer to structural diagram on previous
page.

Adjust power steering pump drive belt by referring to ªBELT TEN-
SION ADJUSTMENTº under ªPOWER STEERING PUMP
DRIVE BELTº in this section.

Fill specified power steering fluid after installation and bleed air
without failure. (Refer to ªAIR BLEEDING PROCEDUREº in this
section.)