2003 SUZUKI GRAND VITARA spring

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
3B1-20 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
POWER STEERING (P / S) SYSTEM 3B1-21
1. Thickness gauge
INSPECTION
Pump Body, Cover, Side Plate and Shaft
Check sliding surfaces of each part for wear and damage.
If any defect is found, replace pump assembly.
Cam Ring
Check vane sliding surface of cam ring for wear and damage.
If any defect is found, replace pump assembly.
Rotor and Vane

Check sliding surfaces of rotor and vane for wear and damage.

Check clearance between rotor and vane.
Clearance: Standard 0.015 mm (0.0006 in.)
Limit 0.027 mm (0.0011 in.)
Replace pump assembly if any defect is found in above checks.
Relief Valve (Flow Control Valve) and Its Spring

Check fluid passage of relief valve and orifice of connector for ob-
struction (clogged).

Check sliding surface of relief valve for wear and damage.

YH4
GRAND
VITARA
3B1-22 POWER STEERING (P / S) SYSTEM
1. Flow control spring
1. Oil seal
2. Shaft (pulley)
1. O-ring
1. Side plate
2. Bolt hole
1. Rotor
2. Snap ring
3. Dot

Check free length of relief valve spring.
Free length: Standard 22.0 mm (0.866 in.)
Limit 19.0 mm (0.748 in.)
Replace if any defective is found.
ASSEMBLY
Reverse disassembly procedure for assembly, noting the following.
1) Apply grease to oil seal lip and apply power steering fluid to slid-
ing surface of the shaft then insert pulley's shaft from oil seal side
of the pump body.
ªAº: Grease 99000-25010
2) Apply power steering fluid to O-rings and fit them to pump body.
3) Install side plate to pump body.
NOTE:
Carefully align the dowel pins on the side plate at bolt hole
as shown in figure.
4) Apply power steering fluid to sliding surface of rotor.
5) Install rotor to shaft, directing dot marked side of rotor facing up.
6) Install new snap ring to shaft, then make sure to fit snap into shaft
groove securely.
NOTE:
Never reuse the removed snap ring.

YH4
GRAND
VITARA
3B1-24 POWER STEERING (P / S) SYSTEM
1. Pump cover
1. Pressure switch
1. Suction connector
2. O-ring
1. Suction connector
15) Gradually tighten new pump cover bolts to specified torque.
NOTE:
After installing pump cover, check to make sure that shaft
can be turned by hand.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
16) Apply power steering fluid to O-ring of terminal switch.
17) Install pressure switch to pump body.
Tightening Torque
(a): 28 N
.m (2.8 kg-m, 20.0 lb-ft)
18) Apply power steering fluid to relief valve (flow control valve).
19) Install relief valve (flow control valve) to pump body.
20) Install flow control spring.
21) Apply power steering fluid to O-rings of plug.
22) Install O-rings to plug.
23) Tighten plug to specified torque.
Tightening Torque
(a): 60 N
.m (6.0 kg-m, 43.5 lb-ft)
24) Apply power steering fluid to O-ring of suction connector.
25) Install O-ring to suction connector.
26) Install suction connector to pump body as shown in figure.
Tighten new suction connector bolts to specified torque.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)

YH4
GRAND
VITARA
3D
FRONT SUSPENSION 3D-1
GENERAL DESCRIPTION3D- 2 . . . . . . . . . . . . . .
DIAGNOSIS3D- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 3D- 3. . . . . . . . . . . . . . . . . . . . . .
Stabilizer Bar and Bushing Check 3D- 3. . . . . .
Strut Damper and / or Coil Spring Check 3D- 3. .
Suspension Arm / Knuckle Check 3D- 3. . . . . . . .
Suspension Control Arm Joint Check 3D- 4. . . .
Suspension Control Arm Bushing Check 3D- 4.
Wheel Disc, Nut & Bearing Check 3D- 4. . . . . .
ON-VEHICLE SERVICE3D- 5 . . . . . . . . . . . . . . . . Stabilizer Bar / Bushings 3D- 5. . . . . . . . . . . . . . .
Strut Damper 3D- 6. . . . . . . . . . . . . . . . . . . . . . . .
Coil Spring 3D- 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Bump Stopper / Spring Rubber Seat 3D-11. . . . .
Wheel Hub (Included Wheel Bearing) 3D-12. . .
Knuckle / Wheel Spindle 3D-17. . . . . . . . . . . . . . . .
Suspension Control Arm / Bushings 3D-21. . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3D-23 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS3D-24 . . . . . .
SPECIAL TOOLS3D-25 . . . . . . . . . . . . . . . . . . . . . .
SECTION 3D
FRONT SUSPENSION
CAUTION:

All front suspension fasteners are an important attaching part in that it 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 replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of this part.

Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or
damage to the part may result.
CONTENTS

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.