2000 SUZUKI GRAND VITARA System

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.

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-19
Tightening Torque
(a): 60 N.m (6.0 kg-m, 43.5 lb-ft)
(b): 25 N.m (2.5 kg-m, 18.5 lb-ft)
(c): 55 N.m (5.5 kg-m, 40.0 lb-ft)
(d): 11 N.m (1.1 kg-m, 8.0 lb-ft)
(e): 35 N.m (3.5 kg-m, 25.5 lb-ft)
( f ): 40 N.m (4.0 kg-m, 29.0 lb-ft)
(g): 45 N.m (4.5 kg-m, 33.0 lb-ft)
1. Power steering pump assembly
2. Bracket
3. P / S fluid reservoir4. High pressure hose & pipe
5. Suction hose
6. Low pressure return hose7. Oil tank bracket
8. To P / S gear box
[G16 ENGINE MODEL]
[J20 ENGINE MODEL][H25 ENGINE MODEL]
POWER STEERING PUMP

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.