1999 SUZUKI GRAND VITARA steering rack

YH4
GRAND
VITARA
1. Pin
2. Stub shaft (Rotor)
3. Torsion bar
4. Sleeve
5. Bearing
6. Pinion
7. Gear box
8. Rack
9. Ferrule
10. Valve case
POWER STEERING (P / S) SYSTEM 3B1-3
STEERING GEAR BOX
The steering gear box consists of two sections: one including a cyl-
inder and the other a valve. Main components of the cylinder sec-
tion are a gear box, a rack and a tube and those of the valve section
are a valve case, a sleeve and a stub shaft. The sleeve is linked with
the pinion through a pin and the valve and stub shaft are integrated
into one unit. Then the pinion and the stub shaft are linked to each
other by means of the torsion bar.
Thus, when the stub shaft moves, the valve changes its position,
thereby switching the hydraulic passage from the pump to the cylin-
der to help steering operation.
When turning the steering wheel feels heavy due to P / S fluid leak-
age or for some other reason (i.e., when in the manual steering
mode), the stub shaft and pinion are in direct linkage and the force
is output directly through the pinion and rack.

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-7
STEERING WHEEL
STEERING WHEEL PLAY CHECK
Check steering wheel for looseness or rattle by trying to move it in
its shaft direction and lateral direction.
If found defective, repair or replace.
Check steering wheel for play, holding car in straight forward condi-
tion on the ground and with engine stopped.
Steering wheel play ªaº: 0 ± 30 mm (0 ± 1.2 in.)
If steering wheel play is not within specification, inspect as follows
and replace if found defective.

Tie-rod end ball stud for wear

Lower ball joint for wear

Steering shaft joint for wear

Steering pinion or rack gear for wear or breakage

Each part for looseness
STEERING FORCE CHECK
1) Place vehicle on level road and set steering wheel at straight-
ahead position.
2) Check that tire inflation pressure is as specified. (Refer to tire
placard.)
3) Start engine and keep it running till power steering fluid is
warmed to 50 to 60C (122 to 140F).
4) With engine idling, measure steering force by pulling spring ba-
lancer hooked on steering wheel in tangential direction.
Steering force: Less than 50 N (5.0 kg, 11.0 lb)
POWER STEERING FLUID
POWER STEERING FLUID LEVEL CHECK
With engine stopped, check fluid level indicated on P / S fluid reser-
voir, which should be between ªMAXº and ªMINº marks. If it is lower
than ªMINº mark, fill fluid up to ªMAXº mark.
NOTE:

Be sure to use an specified power steering fluid.

Fluid level should be checked when fluid is cool.

YH4
GRAND
VITARA
1. P / S fluid reservoir
2. Gauge valve (shut)
3. Oil pressure gauge
4. P / S pump
5. P / S gear box
1. P / S fluid reservoir
2. Gauge valve (open)
3. Oil pressure gauge
4. P / S pump
5. P / S gear box
POWER STEERING (P / S) SYSTEM 3B1-11
5) Check relief pressure

Increase engine speed to about 1,500 r / min (rpm). Close
gauge valve gradually while watching pressure increase indi-
cated by gauge and take reading of relief pressure (maximum
hydraulic pressure).
Relief pressure:
6200 ± 7000 kPa
(62 ± 70 kg / cm
2, 882 ± 995 psi) G16 Type engine. . . . . . .
6700 ± 7500 kPa
(67 ± 75 kg / cm
2, 953 ± 1067 psi) J20 Type engine. . . . . . .
7050 ± 7850 kPa
(70.5 ± 78.5 kg / cm
2, 1003 ± 1116 psi) H25 Type engine. .

When it is higher than specified values, possible cause is mal-
function of relief valve.

When it is lower than specified values, possible cause is either
failure of P / S pump or settling of relief valve spring.
CAUTION:
Be sure not to close gauge valve for longer than 10 se-
conds.

Next, open gauge valve fully and increase engine speed to
about 1,500 r / min (rpm). Then turn steering wheel to the left
or right fully and take reading of relief pressure.
Relief pressure:
6200 ± 7000 kPa
(62 ± 70 kg / cm
2, 882 ± 995 psi) G16 Type engine. . . . . . .
6700 ± 7500 kPa
(67 ± 75 kg / cm
2, 953 ± 1067 psi) J20 Type engine. . . . . . .
7050 ± 7850 kPa
(70.5 ± 78.5 kg / cm
2, 1003 ± 1116 psi) H25 Type engine. .

When it is higher than specified values, possible cause is mal-
function of relief valve.

When it is lower than specified values, possible cause is failure
in steering gear box. Replace gear box.
CAUTION:
Be sure not to hold steering wheel at fully turned posi-
tion for longer than 10 seconds.
BOOT
STEERING RACK BOOT CHECK
Check boot for crack and damage which, if any, means possibility
of rusty gear, entry of dust or lack of grease. Also, check if any of
such faulty conditions exists.
Check steering rack boot for dent or breakage.
If there is a dent, keep boot in most compressed state for some se-
conds to correct dent.

YH4
GRAND
VITARA
3B1-12 POWER STEERING (P / S) SYSTEM
TIE-ROD END BOOT CHECK
Check boot for crack and damage and if any, replace it with a new
one.
AIR BLEEDING PROCEDURE
1) Hoist the front end of vehicle and apply safety stands.
2) Fill P / S fluid reservoir with fluid up to specified level.
NOTE:
Before starting engine, place transmission gear shift lever
in ªNeutralº (shift selector lever to ªPº range for A / T mod-
el), and set parking brake.
3) After running engine at idling speed for 3 to 5 seconds, stop it
and add fluid to satisfy specification.
4) With engine stopped, turn steering wheel to the right and left as
far as it stops, repeat it a few times and fill fluid to specified level.
5) With engine running at idling speed, repeat stop-to-stop turn of
steering wheel till all foams in P / S fluid reservoir are gone.
NOTE:
Make sure to bleed air completely. If air remains in fluid, P / S
pump may make humming noise or steering wheel may feel
heavy.
6) Finally check to make sure that fluid is filled to specified level.

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.