Steering wheel remove SUZUKI GRAND VITARA 2001 2.G Service Workshop Manual

YH4
GRAND
VITARA
1. Air bag wire harness
2. Passenger air bag
(inflator) module
3. SDM
4. DLC5. Contact coil
6. Driver air bag (inflator)
module
7. Seat belt pretensioner
(if equipped)
GENERAL INFORMATION 0A-3
PRECAUTIONS
PRECAUTION FOR VEHICLES EQUIPPED
WITH A SUPPLEMENTAL RESTRAINT
(AIR BAG) SYSTEM
WARNING:

The configuration of air bag system parts are as shown in
the figure. When it is necessary to service (remove, rein-
stall and inspect) these parts, be sure to follow proce-
dures described in SECTION 10B. Failure to follow proper
procedures could result in possible air bag system activa-
tion, personal injury, damage to parts or air bag system
being unable to activate when necessary.

If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag system
be repaired first, to help avoid unintended air bag system
activation.

Do not modify the steering wheel, dashboard, or any other
air bag system components. Modifications can adversely
affect air bag system performance and lead to injury.

If the vehicle will be exposed to temperatures over 93
C
(200
F) (for example, during a paint baking process), re-
move the air bag system components beforehand to avoid
component damage or unintended air bag system activa-
tion.
DIAGNOSIS

When troubleshooting air bag system, be sure to follow
ªDIAGNOSISº in SECTION 10B. Bypassing these proce-
dures may result in extended diagnostic time, incorrect diag-
nosis, and incorrect parts replacement.

Never use electrical test equipment other than that specified
in this manual.
WARNING:
Never attempt to measure the resistance of the air bag (in-
flator) modules (driver and passenger) and seat belt preten-
tioners (driver and passenger). It is very dangerous as the
electric current from the tester may deploy the air bag or ac-
tivate the pretensioner.

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VITARA
HEATER AND VENTILATION 1A-17
1. Dash panel (engine room) 2. Nuts
REMOVAL
WARNING:
Failure to follow the following procedure and WARNING
may cause air bag deployment, personal injury, damage to
parts, or air bag being unable to deploy.

Never rest a steering column assembly on steering wheel
with air bag (inflator) module face down and column verti-
cal.

When handling the air bag (inflator) modules (driver and
passenger), be careful not to drop it or apply an impact to
it. If an excessive impact was applied (e.g., dropped from
a height of 91.4 cm (3 feet) or more, never attempt disas-
sembly or repair but replace it with a new one.

When grease, cleaning agent. Oil, water, etc. has got onto
air bag (inflator) modules (driver and passenger), wipe off
immediately with a dry cloth.
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Drain engine coolant and disconnect heater hose (1) from
heater unit.
4) Remove instrument panel, refer to item INSTRUMENT PANEL
REMOVAL in Section 9.
5) Remove cooling unit (If equipped).
Refer to item EVAPORATOR (COOLING UNIT) REMOVAL in
Section 1B.
6) Disconnect rear duct (4) from heater unit.
7) Disconnect heater mode control actuator lead wire (1) at cou-
plers.
8) Remove A / C controller (2) (If equipped).
9) Remove SDM (3) (If equipped).
10) Remove heater unit.

YH4
GRAND
VITARA
1. Tie-rod end
2. Knuckle
3. Nut
1. Tie-rod
2. Mark
3. Lock nut
4. Tie-rod end
1. Tie-rod end ball joint
1. Tie-rod
2. Mark
3. Lock nut
4. Tie rod end
5. Knuckle
6. Nut6, (a)
POWER STEERING (P / S) SYSTEM 3B1-13
ON-VEHICLE SERVICE
TIE-ROD END
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove tie-rod end nut.
3) Disconnect tie-rod end by using puller.
4) To facilitate adjustment after installation, put a mark on tie-rod
thread indicating position of tie-rod end lock nut. Then loosen
lock nut and remove tie rod end from tie rod.
INSPECTION
Tie-rod End Ball Joint
Inspect for play in tie-rod end ball joint. If found defective, replace.
INSTALLATION
1) Install tie-rod end lock nut and tie rod end to tie-rod. Tighten lock
nut to mark on tie-rod thread.
2) Install tie-rod end to knuckle. Tighten tie-rod end nut to specified
torque.
Tightening Torque
(a): 48 N
.m (4.8 kg-m, 35.0 lb-ft)

YH4
GRAND
VITARA
1. High pressure pipe
2. Union bolt3. Low pressure hose
4. Steering lower shaft bolt
3B1-14 POWER STEERING (P / S) SYSTEM
3) After installing wheels, lower vehicle and tighten wheel nuts to
specified torque.
Tightening Torque
(a): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
4) Check that proper amount of toe-in is obtained by referring to
ªFRONT WHEEL ALIGNMENTº.
5) After confirming proper amount of toe-in, tighten tie-rod end lock
nut to specified torque.
Tightening Torque
(a): 65 N
.m (6.5 kg-m, 47.0 lb-ft)
POWER STEERING GEAR BOX
ASSEMBLY
REMOVAL
1) Take out fluid in P / S fluid reservoir with syringe or such.
2) Disconnect high pressure pipe from steering gear box by remov-
ing union bolt.
NOTE:
As fluid flows out of disconnected joints, put a receptacle
under joints or a plug to pipe.
3) Disconnect low pressure hose from steering gear box.
NOTE:
As fluid flows out of disconnected joints, put a receptacle
under joints or a plug to hose.
4) Remove steering lower shaft bolt.
5) Hoist vehicle and remove both right and left wheels.
6) Disconnect both right and left tie rod ends from knuckle, refer to
steps 2) to 3) of ªTIE-ROD END REMOVALº in this section.

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.)

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VITARA
3C
STEERING WHEEL AND COLUMN 3C-1
SECTION 3C
STEERING WHEEL AND COLUMN
(NOT EQUIPPED WITH AIR BAG)
NOTE:
All steering wheel and column fasteners are important 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 of substitute design. Torque values must be used as specified during reassemb-
ly to assure proper retention of this part.
CONTENTS
GENERAL DESCRIPTION3C- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS3C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and repair required after accident 3C- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering wheel3C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Combination switch3C- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering column assembly3C- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering lock assembly (ignition switch) 3C-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering lower shaft assembly3C-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking steering column for accident damage 3C-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable steering column release lever 3C-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS3C-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL3C-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 bolts 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.

YH4
GRAND
VITARA
1. Steering wheel
2. Steering wheel pad
3. Screw
1. Steering shaft nut
1. Steering wheel
1. Lugs
2. Grooves
3. Alignment marks
STEERING WHEEL AND COLUMN 3C-3
ON-VEHICLE SERVICE
STEERING WHEEL
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Remove steering wheel pad screw.
3) Remove steering wheel pad and disconnect horn harness.
4) Remove steering shaft nut.
5) Make alignment marks on steering wheel and shaft for a guide
during reinstallation.
6) 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.
INSTALLATION
1) Install steering wheel to steering shaft with 2 lugs on combina-
tion switch fitted in two grooves in the back of steering wheel and
also aligning marks on steering wheel and steering shaft.
2) Tighten steering shaft nut to specified torque.
Tightening Torque
(a): 33 N
.m (3.3 kg-m, 23.5 lb-ft)
3) Connect horn harness and install steering wheel pad.
4) Tighten steering wheel pad screw.
5) Connect negative battery cable.

YH4
GRAND
VITARA
1. Combination switch
1. Steering column hole cover
: If equipped
2. Screw
1. Combination switch 2. Screw1. Steering column cover screw
2. Steering column lower cover
*
3. Steering column
upper cover
3C-4 STEERING WHEEL AND COLUMN
COMBINATION SWITCH
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Remove steering wheel from steering column. Refer to
ªSTEERING WHEELº in this section.
3) Remove steering column hole cover.
4) Remove steering column cover screws (3 pieces).
5) Separate upper cover and lower cover, then remove them.
6) Disconnect all connectors for combination switch.
7) Remove combination switch from steering column.
INSPECTION
Check combination switch wire harness for any signs of scorching,
melting or other damage. If it is damaged, replace.
INSTALLATION
1) Install combination switch to steering column.
2) Connect all connectors that have been removed in removal.

YH4
GRAND
VITARA
1. Steering column hole cover
2. If equipped
1. Steering column cover screw
2. Steering column lower cover
3. Steering column upper cover: Tapping screw
: Standard screw
*
* *
STEERING WHEEL AND COLUMN 3C-5
3) Install steering column upper and lower cover.
4) Tighten steering column cover screws.
CAUTION:
When installing lower cover and upper cover, be careful
so that combination switch lead wire is not caught be-
tween covers.
5) Install steering column hole cover.
6) Install steering wheel to steering column. Refer to ªSTEERING
WHEELº in this section.
7) Connect battery negative cable.
STEERING COLUMN ASSEMBLY
CAUTION:
Once the steering column is removed from the vehicle, the
column is extremely susceptible to damage.
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 col-
lapsible design.
When loosening steering column mounting bolts, make
sure that steering column assembly and steering shaft low-
er assembly have been separated. Loosening them with
steering column assembly and steering shaft lower assem-
bly assembled could cause damage to bearing in steering
shaft lower assembly.
NOTE:
When servicing steering column or any column-mounted
component, remove steering wheel. But when removing steer-
ing column simply to gain access to instrument panel compo-
nents, leave steering wheel installed on steering column.
REMOVAL
1) Disconnect negative battery cable at battery terminal.

YH4
GRAND
VITARA
1. Steering column assembly
2. Steering shaft joint
3. Marks
1. Steering column assembly
2. Steering shaft joint
3. Steering lower shaft assembly
4. Bolt (column side)
5. Bolt (lower shaft assembly side)1. Steering column hole cover
: If equipped
*
3C-6 STEERING WHEEL AND COLUMN
2) Remove steering wheel and combination switch, if necessary.
Refer to ªSTEERING WHEELº and ªCOMBINATION SWITCHº
in this section.
Perform the following procedure if not removing steering wheel
and / or combination switch.
i) Turn steering wheel so that vehicle's front tires are at straight-
ahead position.
ii) Turn ignition switch to ªLOCKº position and remove key.
3) Remove steering column hole cover.
4) Disconnect all connectors for the following parts.

Combination switch

Ignition switch

Immobilizer control system parts (if equipped)
5) Make alignment marks on shaft joint and shaft (column side) for
a guide during reinstallation.
6) After removing bolt on column side of shaft joint and loosening
bolt on its lower shaft assembly side, move shaft joint to lower
shaft assembly side (in arrow direction in the figure).