Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 368

6C-15 Power Assisted Steering System:

Installation
Reverse removal procedure for installation of P/S gear
case, noting the following points.
• After confirming that front tire is in straight position,

install P/S gear case to body temporarily. Next, with
tie-rod end installed to knuckle, set rack in position
close to neutral. Then obtain the neutral state by
aligning match marks (1) on pinion shaft and steering
gear case (2) and insert steering lower joint into pinion
shaft.
Refer to Step 3) of “Installation” in “Steering Lower
Shaft Assembly Removal and Installation in Section
6B”.

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 case, remove that plug before
reconnecting pipe.

• Use specified torque as given below.

Tightening torque
Steering lower shaft bolt: 25 N·m (2.5 kgf-m, 18.5
lb-ft)
Gear case high pressure pipe union bolt: 35 N·m
(3.5 kgf-m, 25.5 lb-ft)
Gear case cylinder pipe flare nut: 25 N·m (2.5 kgf-
m, 18.0 lb-ft)
Gear case mounting bolt: 105 N·m (10.5 kgf-m, 76
lb-ft)
Gear case low pressure pipe union bolt: 40 N·m (
4.0 kgf-m, 29.0 lb-ft)
Stabilizer bar mount bracket mount bolt (a): 60
N·m (6.0 kgf-m, 43.0 lb-ft)
Gear case low pressure pipe flare nut: 35 N·m (
3.5 kgf-m, 25.5 lb-ft) (F9Q engine model)
P/S pump bracket bolt: 55 N·m (5.5 kgf-m, 40.0 lb-
ft) (F9Q engine model)

• After installation, be sure to fill specified P/S fluid and

bleed air. Refer to “P/S System Air Bleeding
Procedure”.

• Check toe setting. Adjust as required. Refer to “Front

Wheel Alignment Inspection and Adjustment in
Section 2B”.

2

1

I5JB0A630020-01

(a)

I5JB0A630021-02

Power Assisted Steering System: 6C-16

Steering Gear Case Mount Bushing Removal
and Installation

S6JB0A6306015

Removal

1) Remove P/S gear case assembly referring to “P/S

Gear Case Assembly Removal and Installation”.

2) Push out bushing using hydraulic press (1) and

special tools.

Special tool
(A): 09943–88211
(B): 09945–55410

Installation

CAUTION

!

Be sure to use new bushing.

1) Press-fit bushing (1) using special tools and press

(2).

Special tool
(A): 09913–75821
(B): 09945–55410

NOTE
Before installing bushing, apply soap water
on its circumference to facilitate installation.

2) Press-fit bushing (1) so that dimensions and in figure

become equal.

3) Install P/S gear case assembly referring to “P/S

Gear Case Assembly Removal and Installation”.

Steering Gear Case Mount Bushing Inspection

S6JB0A6306016

Inspect for looseness, cracks, deformation or damage.
Replace any defective part.

Rack Boot / Tie-Rod Removal and Installation

S6JB0A6306017

Removal

1) Remove P/S gear case assembly, referring to “P/S

Gear Case Assembly Removal and Installation”.

2) For ease of adjustment after installation, make

marking (4) of tie-rod end lock nut position of tie-rod
thread.

3) Loosen tie-rod end lock nut (2) and remove tie-rod

end.

4) Remove boot wire and clip.
5) Remove boot (3) from tie-rod (1).

(A)

1

(B)

I5JB0A630053-02

(A)

2

1

(B)

I5JB0A630055-01

“A”: 6 mm (0.24 in.)

“B”: 80 mm (3.15 in.)

1

1

“B”

“A”

“A”

I5JB0A630056-01

I5JB0A630054-01

6C-17 Power Assisted Steering System:

6) Remove tie-rod (1) from steering gear case (2).

Installation

1) Clean threads of both tie-rod and steering gear case

(2).

2) Apply thread lock cement to thread of tie-rod ball nut

(1) and then tighten it to specified torque.

“B”: Thread lock cement 99000–32100 (Thread
Lock Cement 1305)

Tightening torque
Tie-rod ball nut (a): 90 N·m (9.0 kgf-m, 65.0 lb-ft)

3) Apply grease to boot inside “A” indicated in the

figure.

4) Position boot properly in grooves of gear case and

tie-rod. Check to ensure that boot is free from twist
and dent.

5) Clamp boot with clip and wire. Wire should be new

and should go around the boot twice.
Pull its both ends together by screwdriver 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.

6) Install tie-rod end lock nut and tie-rod end to tie-rod.

Position lock nut to marking (1) made in removal.

NOTE
When tie-rod was replaced, measure length
“a” on removed tie-rod and use it on new
replacement tie-rod so as to position lock nut
properly.

7) Install steering gear case. Refer to “P/S Gear Case

Assembly Removal and Installation”.

3. Aluminium plate

4. Vise

3

1

4

2

3

I5JB0A630022-01

2

1, (a), “B”

I5JB0A630023-03

IYSQ01630030-01

IYSQ01630035-01

I5JB0A630058-01

Power Assisted Steering System: 6C-18

P/S Hose / Pipe Components

S6JB0A6306018

[A]

[B]

7

1

6

4

2

11

9

3

5

6

6

(b)

13

13

13

1

10

(a)

15

(a)

14

(a)

(c)

10

(c)

12

(c)

12

(c)

13

8

8

7

5

2

8

8

3

6

4

9

6

6

11

(a)

15

(a)

14

(a)

(b)

I6JB0A630004-02