Suzuki Grand Vitara JB416 / JB420. Manual - part 269

6C-10 Power Assisted Steering System: 

P/S Pump and A/C Compressor (If Equipped) 
Drive Belt Removal and Installation for J20 
Engine Model

S5JB0A6306019

Refer to “Water Pump and Generator Drive Belt 
Removal and Installation (For J20 Engine) in Section 
1J”.

Steering Rack Boot Check

S5JB0A6306005

• 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 seconds to correct dent.

Tie-Rod End Boot Check

S5JB0A6306006

Check boot for crack and damage and if any, replace it 
with a new one.

Tie-Rod End Removal and Installation

S5JB0A6306007

Removal

1) Hoist vehicle and remove wheel.
2) Remove tie-rod end nut (3).

3) Disconnect tie-rod end (1) by using puller (2).

4) To facilitate adjustment after installation, put a mark 

(2) on tie-rod thread indicating position of tie-rod end 
lock nut (3). Then loosen lock nut (3) and remove tie-
rod end (4) from tie-rod (1).

IYSQ01630013-01

IYSQ01630014-01

1. Tie-rod end

2. Knuckle

IYSQ01630015-01

IYSQ01630016-01

IYSQ01630017-01

Power Assisted Steering System:  6C-11

Installation

1) Install tie-rod end lock nut (3) and tie-rod end (4) to 

tie-rod (1). Tighten lock nut (3) to mark (2) on tie-rod 
thread.

2) Install tie-rod end (4) to knuckle (5). Tighten new tie-

rod end nut (6) to specified torque.

Tightening torque
Tie-rod end nut (a):  43 N·m (4.3 kgf-m, 31.0 lb-ft)

3) After installing wheels, lower vehicle and tighten 

wheel nuts to specified torque.

Tightening torque
Wheel nut (a):  100 N·m (10.0 kgf-m, 72.5 lb-ft)

4) Check that proper amount of toe-in is obtained 

referring to “Front Wheel Alignment Inspection and 
Adjustment in Section 2B”.

5) After confirming proper amount of toe-in, tighten tie-

rod end lock nut to specified torque.

Tightening torque
Tie-rod end lock nut (a):  65 N·m (6.5 kgf-m, 47.0 
lb-ft)

Tie-Rod End Ball Joint Inspection

S5JB0A6306008

Inspect for play in tie-rod end ball joint (1). If found 
defective, replace.

IYSQ01630018-01

IYSQ01630019-01

IYSQ01630020-01

IYSQ01630021-01

6C-12 Power Assisted Steering System: 

P/S Gear Case Assembly Components

S5JB0A6306020

7

8

(b)

8

(b)

6

(d)

6

(d)

4

3

5

5

2

(c)

7

4

3

10

[A]

(a)

10

(a)

9

(e)

1

1

10

(a)

10

(a)

[B]

2

(c)

11

11

11

11

I5JB0A630016-06

[A]: LH steering vehicle

6. Tie-rod end lock nut

: 43 N

⋅m (4.3 kgf-m, 31.0 lb-ft)

[B]: RH steering vehicle

7. Tie-rod end

: 90 N

⋅m (9.0 kgf-m, 65.0 lb-ft)

1. Steering gear case

8. Tie-rod end nut

: 65 N

⋅m (6.5 kgf-m, 47.0 lb-ft)

2. Tie-rod

: Apply thread rock cement 99000-32100 to thread of 
tie-rod boll nut.

9. Steering gear case mounting bolt

: 105 N

⋅m (10.5 kgf-m, 76.0 lb-ft)

3. Band

10. Gear case cylinder pipe

: Do not reuse.

4. Boot

11. Steering gear case mount bushing

5. Rack boot clip

: 25 N

⋅m (2.5 kgf-m, 18.5 lb-ft)

Power Assisted Steering System:  6C-13

P/S Gear Case Assembly Removal and 
Installation

S5JB0A6306009

CAUTION

!

 

Never disassemble P/S gear case assembly. 
Disassembling will adversely affect original 
performance of P/S gear case assembly.

 

Removal

1) Disconnect negative (–) cable at battery.
2) Take out P/S fluid in reservoir with syringe or such.
3) Hoist vehicle and remove both right and left wheels.
4) Disconnect both right and left tie-rod ends from 

knuckle referring to Step 2) to 3) of “Removal” in 
“Tie-Rod End Removal and Installation”.

5) Disconnect steering lower shaft assembly (1) from 

pinion shaft of P/S gear case assembly (2) referring 
to Step 5) of “Removal” in “Steering Lower Shaft 
Assembly Removal and Installation in Section 6B”.

6) Disconnect high pressure pipe (3) from P/S gear 

case assembly.

7) Disconnect low pressure pipe (4) from P/S gear case 

assembly.

8) Remove P/S gear case cylinder pipes (5) from P/S 

gear case assembly.

9) Remove stabilizer bar mount bolt and stabilizer joint.

NOTE
Do not remove stabilizer bar from vehicle.

 

10) Remove stabilizer bar mount bracket (2) from left 

side of front suspension frame.

11) Remove bolts (1) and then take off P/S gear case 

assembly from left side of vehicle.

NOTE
P/S gear case assembly cannot be removed 
from the right side of vehicle.

 

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.

1

2

3

5

4

I5JB0A630017-01

1

2

I5JB0A630018-01

1

1

I5JB0A630019-01

2

1

I5JB0A630020-01