YH4
GRAND
VITARA
3B1
POWER STEERING (P / S) SYSTEM 3B1-1
GENERAL DESCRIPTION3B1- 2 . . . . . . . . . . . . . .
Power Steering System 3B1- 2. . . . . . . . . . . . . . . . .
Steering Gear Box 3B1- 3. . . . . . . . . . . . . . . . . . . . . .
Power Steering (P / S) Pump 3B1- 4. . . . . . . . . . . . . .
DIAGNOSIS3B1- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Table 3B1- 5. . . . . . . . . . . . . . . .
Steering Wheel 3B1- 7. . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Play Check 3B1- 7. . . . . . . . . . . .
Steering Force Check 3B1- 7. . . . . . . . . . . . . . . . .
Power Steering Fluid 3B1- 7. . . . . . . . . . . . . . . . . . . .
Power Steering Fluid Level Check 3B1- 7. . . . . .
Power Steering Pump Drive Belt 3B1- 8. . . . . . . . .
Belt Tension Check 3B1- 8. . . . . . . . . . . . . . . . . . .
Belt Tension Adjustment 3B1- 8. . . . . . . . . . . . . . .
Idle Up System 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . .
Idle Up System Check 3B1- 9. . . . . . . . . . . . . . . .
Fluid 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Leakage Check 3B1- 9. . . . . . . . . . . . . . . . . Hydraulic Pressure in P / S Circuit 3B1-10. . . . . . . . .
Hydraulic Pressure Check 3B1-10. . . . . . . . . . . . .
Boot 3B1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Rack Boot Check 3B1-11. . . . . . . . . . . . .
Tie-Rod End Boot Check 3B1-12. . . . . . . . . . . . . .
Air Bleeding Procedure 3B1-12. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3B1-13 . . . . . . . . . . . . . . . .
Tie-Rod End 3B1-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Gear Box Assembly 3B1-14. . . . . .
Rack Boot and Tie-Rod (Except Canvas
Top LH Model) 3B1-16. . . . . . . . . . . . . . . . . . . . . . . .
Rack Boot and Tie-Rod (For Canvas
Top LH Model) 3B1-17. . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump 3B1-19. . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATION3B1-26 . . .
REQUIRED SERVICE MATERIAL3B1-26 . . . . . . . .
SPECIAL TOOL3B1-26 . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3B1
POWER STEERING (P/S) SYSTEM
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components 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.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
Some parts in the Power Steering Gear Box cannot be disassembled or adjusted. For detailed informa-
tion, refer to the description of ªPOWER STEERING GEAR BOX ASSEMBLYº.
All steering gear fasteners are important attaching 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 or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.
Although the figures in this section show only the left-hand steering vehicle, the same work procedure
and data apply to the right-hand steering vehicle.
CONTENTS
YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-15
1. Booster piston rod
2. Master cylinder piston
1. Master cylinder
2. Piston
3. Pin head
1. Booster body
2. Piston rod
1. Booster piston rod
2. Master cylinder piston
CLEARANCE BETWEEN BOOSTER PISTON ROD AND
MASTER CYLINDER PISTON ADJUSTMENT
The length of booster piston rod is adjusted to provide specified
clearance ªaº between piston rod end and master cylinder piston.
Before measuring clearance, push piston rod several times so as
to make sure reaction disc is in place.
Keep inside of booster at atmospheric pressure for measure-
ment.
1) Set special tool (A) on master cylinder and push pin until con-
tacts piston.
Special Tool
(A): 09950-96010
2) Turn special tool upside down and place it on booster. Adjust
booster piston rod length until rod end contacts pin head.
Special Tool
(A): 09950-96010
Clearance ªbº: 0 mm (0 in.)
NOTE:
Take measurement with booster set vertically and rod at the
center.
3) Adjust clearance by turning adjusting screw of piston rod.
Special Tool
(F): 09952-16010
Reference
When adjusted as above, its negative pressure is applied to boost-
er with engine at idle, piston to piston rod clearance ªaº should be-
come below.
Clearance ªaº: 0.25 ± 0.5 mm (0.010 ± 0.020 in.)
