1999 SUZUKI GRAND VITARA Stall

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
1. P / S fluid reservoir
2. Attachment
3. Gasket4. Union bolt
5. High pressure side
6. Low pressure side
1. P / S fluid reservoir
2. Gauge valve (open)
3. P / S pump4. P / S gear box
5. High pressure side
6. Low pressure side
3B1-10 POWER STEERING (P / S) SYSTEM
HYDRAULIC PRESSURE IN P / S CIRCUIT
HYDRAULIC PRESSURE CHECK
1) After cleaning joint of high pressure hose and P / S pump thor-
oughly, disconnect hose from pump and install special tool (oil
pressure gauge, attachment and hose).
Tighten each flare nut to specified torque.
CAUTION:
Take care not to cause damage to A / C condenser during
service operation, if equipped.
Special Tool
(A): 09915-77410 (Oil pressure gauge)
(B): 09915-77420
2) Check each connection for fluid leakage and bleed air.
Refer to ªAIR BLEEDING PROCEDUREº in this section.
3) With engine idling, turn steering wheel and warm up engine till
temperature of fluid in P/S fluid reservoir rises to 50 ± 60
C (122
± 140
F).
4) Check back pressure by measuring hydraulic pressure with en-
gine idling and hands off steering wheel.
Back pressure: Lower than 1000 kPa (10 kg / cm
2, 142 psi)
When back pressure is higher than specified values, check con-
trol valve and piping for clogging.

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.)

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.