Suzuki Grand Vitara JB416 / JB420. Manual - part 270

6C-14 Power Assisted Steering System: 

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)

• 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”.

Steering Gear Case Mount Bushing Removal 
and Installation

S5JB0A6306024

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

S5JB0A6306025

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

(a)

I5JB0A630021-02

(A)

1

(B)

I5JB0A630053-02

“A”: 6 mm (0.24 in.)

“B”: 80 mm (3.15 in.)

(A)

2

1 

(B)

I5JB0A630055-01

1

1

“B”

“A”

“A”

I5JB0A630056-01

Power Assisted Steering System:  6C-15

Rack Boot / Tie-Rod Removal and Installation

S5JB0A6306010

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).

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

I5JB0A630054-01

3

1

4

2

3

I5JB0A630022-01

2

1, (a), “B”

I5JB0A630023-03

IYSQ01630030-01

IYSQ01630035-01

I5JB0A630058-01

6C-16 Power Assisted Steering System: 

P/S Hose / Pipe Components

S5JB0A6306011

[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

16

16

7

5

2

16

16

3

6

4

9

6

6

11

(a)

15

(a)

14

(a)

(b)

I5JB0A630024-04

Power Assisted Steering System:  6C-17

[C]

[D]

9

(b)

13

5

2

16

16

1

4

3

6

7

11

(a)

(c)

13

6

6

12

(c)

9

10

(b)

13

16

16

12

6

(c)

10

(c)

6

4

5

11

(a)

2

7

1

3

6

I5JB0A630025-05

[A]: M16 engine LH steering vehicle

5. Suction hose

13. Washer

[B]: M16 engine RH steering vehicle

6. Low pressure return hose

14. P/S belt tension pulley bolt

[C]: J20 engine LH steering vehicle

7. P/S fluid reservoir bracket

15. P/S belt tension pulley nut

[D]: J20 engine RH steering vehicle

8. To P/S gear case

16. To P/S gear case assembly

1. P/S pump assembly

9. P/S pump union bolt

: 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

2. Bracket

10. P/S gear case high pressure union bolt

: 60 N

⋅m (6.0 kgf-m, 43.5 lb-ft)

3. P/S fluid reservoir

11. P/S pump mounting bolt

: 35 N

⋅m (3.5 kgf-m, 25.5 lb-ft)

4. High pressure hose and pipe

12. P/S gear case low pressure flare nut

: Do not reuse.