2004 SUZUKI GRAND VITARA Air condition
[x] Cancel search: Air conditionPage 142 of 801
YH4
GRAND
VITARA
3A
Alignment service data (without load)
Toe-in (Toe-in gauge measurement)
ªBº ± ªAº: 0 2 mm (0 0.08 in.)
Camber angle ªCº: 0' 1
Caster: 240' 1
*1. Forward
*2. Body center[A] : Top view
[B] : Front view
1. Center line of wheel
FRONT END ALIGNMENT 3A-1
SECTION 3A
FRONT END ALIGNMENT
CONTENTS
DIAGNOSIS3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toe-Setting3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camber3A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Checks Prior to Adjusting Front Alignment 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toe Adjustment3A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camber and Caster Adjustment 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Angle3A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts
and the ground. Generally, the only adjustment required for front alignment is toe setting.
Camber and caster can't be adjusted. Therefore, should camber or caster be out of specification due to the damage
caused by hazardous road conditions or collision, whether the damage is in body or in suspension should be deter-
mined. If the body is damaged, it should be repaired and if suspension is damaged, it should replaced.
TOE SETTING
Toe is the turning in or out of the front wheels. The purpose of a toe specification is to ensure parallel rolling of the
front wheels (Excessive toe-in or toe-out may increase tire wear).
Amount of toe can be obtained by subtracting ªAº front ªBº as shown in above figure and therefore is given in mm
(in.).
Page 143 of 801
YH4
GRAND
VITARA
3A-2 FRONT END ALIGNMENT
CAMBER
Camber is the tilting of the front wheels from the vertical, as viewed from the front of the vehicle. When the wheels
tilt outward at the top, the camber is positive. When the wheels tilt inward at the top, the camber is negative. The
amount of tilt is measured in degrees.
PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT
Steering and vibration complaints are not always the result of improper alignment. An additional item to be checked
is the possibility of tire lead due to worn or improperly manufactured tires. ªLeadº is the deviation of the vehicle from
a straight path on a level road without hand pressure on the steering wheel.
Section 3 of this manual contains a procedure for determining the presence of a tire lead problem.
Before making any adjustment affecting toe setting, the following checks and inspections should be made to en-
sure correctness of alignment readings and alignment adjustments:
1) Check all tires for proper inflation pressures and approximately the same tread wear.
2) Check for loose ball joints. Check tie rod ends; if excessive looseness is noted, it must be corrected before ad-
justing.
3) Check for run-out of wheels and tires.
4) Check vehicle trim heights; if out of limits and a correction is to be made, it must be made before adjusting toe.
5) Check for loose control arms.
6) Check for loose or missing stabilizer bar attachments.
7) Consideration must be given to excess loads, such as tool boxes. If this excess load is normally carried in ve-
hicle, it should remain in vehicle during alignment checks.
8) Consider condition of equipment being used to check alignment and follow manufacturer's instructions.
9) Regardless of equipment used to check alignment, vehicle must be on a level surface both fore and aft and
transversely.
TOE ADJUSTMENT
Toe is adjusted by changing tie rod length. Loosen right and left tie
rod end lock nuts first and then rotate right and left tie rods by the
same amount to align toe-in to specification.
In this adjustment, right and left tie rods should become equal in
length.
After adjustment, tighten lock nuts to specified torque.
Tightening Torque
(a): 65 N
.m (6.5 kg-m, 47.0 lb-ft)
CAMBER AND CASTER ADJUSTMENT
Should camber or caster be found out of specifications upon in-
spection, locate its cause first. If it is in damaged, loose, bent,
dented or worn suspension parts, they should be replaced. If it is
in body, repair it so as to attain specifications.
To prevent possible incorrect reading of camber or caster, vehicle
front end must be moved up and down a few times before inspec-
tion.
Page 145 of 801
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
Page 149 of 801
YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-5
DIAGNOSIS
GENERAL DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Steering wheel
feels heavy
(at low speed)Fluid deteriorated, low viscosity, different
type of fluid mixed
Pipes or hoses deformed, air entering
through joint
Insufficient air purging from P / S circuit
P / S belt worn, lacking in tension
Tire inflation pressure excessively low
Front end alignment out of order
Steering wheel installed improperly (twisted)
Bind in tie rod or tie rod end ball joint
P / S pump hydraulic pressure fails to increase
P / S pump hydraulic pressure increases
but slowly
Steering gear box malfunctionReplace fluid.
Replace defective part.
Purge air.
Adjust belt tension or replace
belt as necessary.
Inflate tire.
Check and adjust front end
alignment.
Install steering wheel correctly.
Replace defective part.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.
Steering wheel
feels heavy
momentarily when
turning it to the
left or rightAir drawn in due to insufficient amount
of fluid
Slipping P / S belt
P / S pump hydraulic pressure fails to
increase
P / S pump hydraulic pressure increases
but slowly
Steering gear box malfunctionAdd fluid and purge air.
Adjust belt tension or replace
belt as necessary.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.
Poor recovery
from turnsNOTE:
To check steering wheel for recovery, with vehicle running at 22 mile / h (35 km / h),
turn steering wheel 90 and let it free. It should return more than 60.
Deformed pipes or hoses
Steering column installed improperly
Front end alignment out of order
Ball joints binding
P / S pump hydraulic pressure fails to
increase
P / S pump hydraulic pressure increases
but slowly
Steering gear box malfunctionReplace defective part.
Install steering column correctly.
Check and adjust front end
alignment.
Replace defective part.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.
Page 150 of 801
YH4
GRAND
VITARA
3B1-6 POWER STEERING (P / S) SYSTEM
ConditionPossible CauseCorrection
Vehicle pulls to
one side during
straight drivingMismatched 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 wandersRefer to ªDiagnosisº in Section 3.
Fluid leakageLoose joints of (hydraulic pressure)
pipes and hoses
Deformed or damaged pipes or hosesRetighten.
Replace defective part.
Abnormal noiseAir 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 upPower steering pressure switch defectiveReplace power steering
pressure switch.
Page 159 of 801
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.)
Page 185 of 801
YH4
GRAND
VITARA
3C1
AIR BAG STEERING WHEEL AND COLUMN 3C1-1
GENERAL DESCRIPTION3C1- 2 . . . . . . . . . . . . .
DIAGNOSIS3C1- 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair Required after
Accident 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3C1- 3 . . . . . . . . . . . . . . .
Service Precautions 3C1- 3. . . . . . . . . . . . . . . . .
Diagnosis and Servicing 3C1- 3. . . . . . . . . . . .
Disabling Air Bag System 3C1- 3. . . . . . . . . . .
Enabling Air Bag System 3C1- 3. . . . . . . . . . .
Handling and Storage 3C1- 3. . . . . . . . . . . . . .
Disposal 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Air Bag (Inflator) Module 3C1- 4. . . . . . . .
Steering Wheel 3C1- 6. . . . . . . . . . . . . . . . . . . . . . Centering Contact Coil 3C1- 6. . . . . . . . . . . . .
Contact Coil and Combination Switch
Assembly 3C1- 7. . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column 3C1- 9. . . . . . . . . . . . . . . . . . . .
Steering Lock Assembly (Ignition
Switch) 3C1-14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Lower Shaft Assembly 3C1-15. . . . . . .
Checking Steering Column for Accident
Damage 3C1-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable Steering Column Release
Lever 3C1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3C1-18 . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL3C1-18 . . . . . . . . . . . . . . . . . . . . . .
SECTION 3C1
AIR BAG STEERING WHEEL AND COLUMN
WARNING:
Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Please observe all WARNINGS and ªService Precautionsº under ªOn-Vehicle
Serviceº in air bag system section before performing service on or around the air bag system compo-
nents 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.
The procedures in this section must be followed in the order listed to disable the air bag system tem-
porarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could
result in possible activation of the air bag system, personal injury or otherwise unneeded air bag sys-
tem repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called
out. The correct torque value must be used when installing fasteners that require it. If the above proce-
dures are not followed, parts or system damage could result.
CONTENTS
Page 191 of 801
YH4
GRAND
VITARA
1
1. Lugs
2. Grooves
3. Alignment marks
2. Steering column upper cover
3. Steering column lower cover 1. Steering column
cover screw
(a)
1. Steering column hole cover
AIR BAG STEERING WHEEL AND COLUMN 3C1-7
INSTALLATION
1) Check that vehicle's front tires are at straight-ahead position and
contact coil is centered. Refer to ªCENTERING CONTACT
COILº in this section.
CAUTION:
These two conditions are prerequisite for installation of
steering wheel. If steering wheel has been installed with-
out these conditions, contact coil will break when steer-
ing wheel is turned.
2) Install steering wheel to steering shaft with 2 lugs on contact coil
fitted in two grooves in the back of steering wheel and also align-
ing marks on steering wheel and steering shaft.
3) Tighten steering shaft nut to specified torque.
Tightening Torque
(a): 33 N
.m (3.3 kg-m, 23.5 lb-ft)
4) Install driver air bag (inflator) module to steering wheel. Refer to
ªDRIVER AIR BAG (INFLATOR) MODULEº in this section.
CONTACT COIL AND COMBINATION SWITCH
ASSEMBLY
CAUTION:
Do not turn contact coil (on combination switch) more than
allowable number of turns (about two and a half turns from
the center position clockwise or counterclockwise respec-
tively), or coil will break.
REMOVAL
1) Remove steering wheel from steering column. Refer to
ªSTEERING WHEELº in this section.
2) Remove steering column hole cover.
3) Remove steering column cover screws (3 pieces).
4) Separate upper cover and lower cover, then remove them.
5) Disconnect all connectors for contact coil and combination
switch assembly.