SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

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 lower shaft assembly
2. Steering lower shaft assembly lower joint bolt
3. Steering shaft joint
STEERING WHEEL AND COLUMN 3C-11
STEERING LOWER SHAFT ASSEMBLY
REMOVAL
1) Turn steering wheel so that vehicle's front tires are at straight-
ahead position.
2) Turn ignition switch to ªLOCKº position and remove key.
3) Make alignment marks on shaft joint and shaft (column side) for
a guide during reinstallation.
4) 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 figure).
5) Make alignment marks on lower shaft assembly lower joint and
pinion shaft for a guide during reinstallation.
6) Remove lower shaft assembly lower joint bolt and then remove
lower shaft assembly.
7) Remove shaft joint bolt (lower shaft assembly side) from shaft
joint and then remove shaft joint from lower shaft assembly.

YH4
GRAND
VITARA
1. Steering shaft joint
2. Bolt (steering column assembly side)
3. Bolt (lower steering shaft assembly side)1. Steering column assembly
2. Steering shaft joint
3. Marks 1. Steering lower shaft assembly
2. Steering lower shaft assembly lower joint bolt
3. Steering shaft joint1. Steering shaft joint
2. Steering lower shaft assembly
2
1 2, (a)
3C-12 STEERING WHEEL AND COLUMN
INSTALLATION
1) Be sure that front wheels and steering wheel are in straightfor-
ward position.
2) Align flat part ªAº of lower shaft assembly with bolt hole ªBº of
shaft joint as shown. Then insert shaft joint into lower shaft as-
sembly.
3) Install shaft joint bolt (lower shaft assembly side) to shaft joint.
Then tighten it by hand.
4) Insert pinion shaft into lower shaft assembly lower joint by
matching it to marks made before removal. And then install low-
er shaft assembly lower joint bolt to lower shaft assembly lower
joint. Tighten it to specified torque.
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
5) Install steering shaft joint to steering shaft by matching it to
marks made before removal.
NOTE:
Be sure that front wheels and steering wheel are in straight-
ahead position.
6) Install shaft joint bolt (column side) to shaft joint. Tighten shaft
joint bolt (column side) to specified torque first and then shaft
joint bolt (lower shaft assembly side) to specified torque.
Tightening Torque
(b): 25 N
.m (2.5 kg-m, 18.0 lb-ft)

YH4
GRAND
VITARA
STEERING WHEEL AND COLUMN 3C-13
1. Capsule
2. Steering column bracket
3. Plate
1. Steering column assembly
1. Steering column lower seal ªaº
CHECKING STEERING COLUMN FOR
ACCIDENT DAMAGE
NOTE:
Vehicles involved in accidents resulting in body damage,
where steering column has been impacted, may have a dam-
aged or misaligned steering column.
CHECKING PROCEDURE
1) Check that two capsules are attached to steering column brack-
et securely. Check clearance between capsules and steering
column bracket. Clearance should be 0 mm (0 in.) on both sides.
If found loose or clearance, replace steering column assembly.
2) Check two plates for any damages such as crack or breakage.
If anything is found faulty, replace as steering column assembly.
3) Take measurement ªaº as shown. If it is shorter than specified
length, replace column assembly with new one.
Length ªaº: 895
0.8 mm (35.24
0.03 in.)
4) Check steering column lower seal for breakage or deformation.
If found defective, replace.
5) Check steering shaft joints and shaft for any damages such as
crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as steering shaft lower assem-
bly or steering column assembly.
6) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
7) Check steering shaft and column for bend, cracks or deforma-
tion.
If found defective, replace as column assembly.

YH4
GRAND
VITARA
1. Lower position
2. Upper position
3C-14 STEERING WHEEL AND COLUMN
09944-36011
Steering wheel remover
ADJUSTABLE STEERING COLUMN RELEASE
LEVER
INSPECTION
Check to make sure that the following:

Steering column moves smoothly when adjustable steering col-
umn release lever is at lower position (i.e., steering column is not
locked).

Steering column is fixed securely when adjustable steering col-
umn release lever is at higher position (i.e., steering column is
locked).
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Steering shaft nut333.323.5
Steering column mounting bolt232.317.0
Steering shaft joint bolt252.518.0
Steering lower shaft assembly lower joint bolt252.518.0
SPECIAL TOOL

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
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
ªCHECKING STEERING COLUMN FOR ACCIDENT DAMAGEº in
this section as well as ªREPAIRS AND INSPECTIONS REQUIRED
AFTER ACCIDENTº in Section 10B.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
For service precautions, refer to ªSERVICE PRECAUTIONSº un-
der ªON-VEHICLE SERVICEº in Section 10B.
DIAGNOSIS AND SERVICING
For diagnosis and servicing, refer to ªDIAGNOSIS AND SERVIC-
INGº under ªSERVICE PRECAUTIONSº in Section 10B.
DISABLING AIR BAG SYSTEM
For disabling air bag system, refer to ªDISABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
ENABLING AIR BAG SYSTEM
For enabling air bag system, refer to ªENABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
HANDLING AND STORAGE
For handling and storage, refer to ªHANDLING AND STORAGEº
under ªSERVICE PRECAUTIONSº in Section 10B.
DISPOSAL
For disposal, refer to ªDISPOSALº under ªSERVICE PRECAU-
TIONSº 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.