2005 SUZUKI GRAND VITARA lock

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.

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
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
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
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