2003 SUZUKI GRAND VITARA oil pressure

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
2. High pressure side (Delivery side hose)
3. Lower pressure side (Suction side pipe)
AIR CONDITIONING (OPTIONAL) 1B-49
COMPRESSOR ASSEMBLY
CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of A / C:
one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
For identification between these two types, refer to page 1B-2.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A / C installed in the vehicle being serviced.
Use of incorrect refrigerant or compressor oil will result in leakage of refrigerant, damage in parts or
other faulty condition.
PRECAUTION
When servicing the compressor, keep dirt or foreign material away from getting on or into the compressor parts
and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any ªOn-vehicleº repair
or before removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled
should be cleaned with Trichloroethane, naphtha, kerosene or equivalent solvent and dried with dry air. Use only
lint free cloths to wipe parts.
The operations described are based on bench overhaul with compressor removed from the vehicle, except as
noted. They have been prepared in order of accessibility of the components.
When compressor is removed from the vehicle for servicing, the oil remaining in the compressor should be dis-
carded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair procedures re-
quire that the system be discharged of refrigerant.
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.
2) Close Hi (4) and Lo (5) hand valves.
3) Run engine at fast idle.
4) Check compressor assembly for following items.
If any of the above checks indicated a defect, repair compressor
assembly.

High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.

Metallic sound.

Leakage from shaft seal.

YH4
GRAND
VITARA
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
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
3B1-4 POWER STEERING (P / S) SYSTEM
POWER STEERING (P / S) PUMP
The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft.
ModelVane type
Hydraulic
pressure
controlRelieved
pressure
6500 kPa (65 kg / cm2, 924 psi)
G16 Type engine . . . . . . . . . . . . . . . . . . . . . .
7000 kPa (70 kg / cm
2, 995 psi)
J20 Type engine . . . . . . . . . . . . . . . . . . . . . . .
7350 kPa (73.5 kg / cm
2, 1045 psi)
H25 Type engine . . . . . . . . . . . . . . . . . . . . . .
ControlFlow control valve
deviceRelief valve
Power steering
pressure switch
Switch turns on (closes) when the
pressure is higher than 2500 ± 3500 kPa
(25 ± 35 kg / cm
2, 356 ± 498 psi).
ECM uses this signal for idle speed control.
Capacity0.70 ± 0.75

(1.48 / 1.23 ± 1.58 / 1.32 US / Imp. pt)
Specified fluidDEXRON
II, DEXRON
III A / T fluid
or equivalent
FLOW CONTROL VALVE
As the discharge rate of the P/S pump increases in proportion to the
pump revolution speed, a flow control valve is added to control it so
that the optimum amount of fluid for steering operation is supplied
according to the engine speed (driving condition).
Described below is its operation at different engine speed.

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. 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
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.

YH4
GRAND
VITARA
3B1-26 POWER STEERING (P / S) SYSTEM
09915-77420
Oil pressure gauge
attachment and hose set09915-77410
Oil pressure gauge09943-55010
Boot clamp plier
TIGHTENING TORQUE SPECIFICATION
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Gear box mounting bolts555.540.0
Gear box cylinder pipe flare nuts292.921.0
Gear box low pressure pipe union bolt404.029.0
Gear box high pressure pipe union bolt353.525.5
Tie-rod end lock nut656.547.0
G16 Type engine555.540.0
Pump bracket boltJ20 Type engine252.518.5
H25 Type engine454.532.5
Pump union bolt606.043.5
Oil pump mount bolts252.518.5
Pipe clamp bolt / Reservoir bracket bolt111.18.0
Steering shaft joint bolt252.518.0
High pressure flare nuts404.029.0
Pump cover bolts232.317.0
Plug606.043.5
Pressure switch (Terminal)282.820
Suction connector bolt101.07.5
Tie-rod end nut484.835.0
Tie-rod (for canvas top LH model only)858.561.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUPER GREASE (A)
(99000-25010)
Oil seal lip of P / S pump pulley shaft
Power steering fluidAn equivalent of DEXRON
-III or
DEXRON
-II

To fill P / S fluid reservoir

Parts lubrication when installing
SPECIAL TOOL

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to Section 3.
STABILIZER BAR AND BUSHING CHECK
BAR
Inspect for damage or deformation. If defective, replace.
BUSHING
Inspect for damage, wear or deterioration. If defective, replace.
STRUT DAMPER AND / OR COIL SPRING
CHECK
1) Inspect strut for oil leakage. If strut is found faulty, replace it as
an assembly unit, because it can not be disassembled.
2) Strut function check
Check and adjust tire pressures as specified.
Bounce body three or four times continuously by pushing front
end on the side with strut to be checked. Apply the same amount
of force at each push and note strut resistance both when
pushed and rebounding.
Also, note how many times vehicle body rebounds before com-
ing to stop after hands are off. Do the same for strut on the other
side.
Compare strut resistance and number of rebound on the right
with those on the left.
And they must be equal in both. With proper strut, body should
come to stop the moment hands are off or after only one or two
small rebounds. If struts are suspected, compare them with
known good vehicle or strut.
3) Inspect for damage or deformation.
4) Inspect strut boot for damage or crack.
5) Inspect for cracks or deformation in spring seat.
6) Inspect for deterioration of bump stopper.
7) Inspect strut mount for wear, cracks or deformation.
Replace any parts found defective in steps 2) ± 7).
SUSPENSION ARM / KNUCKLE CHECK
Inspect for cracks, deformation or damage.