Suzuki Grand Vitara JB416 / JB420. Manual - part 271

6C-18 Power Assisted Steering System: 

P/S Pump Removal and Installation for M16 
Engine Model

S5JB0A6306012

Removal

NOTE
Be sure to clean each joint of suction and 
discharge sides thoroughly before removal.

 

1) Disconnect negative (–) cable at battery.
2) Take out P/S fluid in reservoir with syringe or such.
3) Disconnect high pressure pipe and suction hose 

from P/S pump.

NOTE
As fluid flows out of disconnected joints, put 
a receptacle under joints or a plug to pipe.

 

4) Disconnect pressure switch lead wire at switch 

terminal.

5) Remove P/S drive belt referring to “P/S Pump and A/

C Compressor (If Equipped) Drive Belt Removal and 
Installation for M16 Engine Model”.

6) Remove P/S pump mounting bolts (1).
7) Remove P/S pump (2).

NOTE
Plug each port of removed pump to prevent 
dust or any other foreign matter from 
entering.

 

Installation
Reverse removal procedure, and then noting the 
following instructions.

NOTE

• Adjust P/S pump drive belt referring to “P/

S Pump and A/C Compressor (If Equipped) 
Drive Belt Inspection and Adjustment for 
M16 Engine Model”.

• Fill specified power steering fluid after 

installation and bleed air without failure. 
(Refer to “P/S System Air Bleeding 
Procedure”.)

 

Tightening torque
P/S pump mounting bolt:  25 N·m (2.5 kgf-m, 18.0 lb-
ft)
High pressure pipe union bolt:  60 N·m (6.0 kgf-m, 
43.5 lb-ft)

P/S Pump Removal and Installation for J20 
Engine Model

S5JB0A6306021

Removal

CAUTION

!

 

Never disassemble P/S pump for J20 engine 
model. Disassembly will spoil its original 
performance. If faulty condition is found, 
replace it with new one.

 

NOTE
Be sure to clean each joint of suction and 
discharge sides thoroughly before removal.

 

1) Disconnect negative (–) cable at battery.
2) Take out P/S fluid in reservoir with syringe or such.
3) Remove intake manifold referring to “Intake Manifold 

Removal and Installation: For J20 Engine in Section 
1D”.

4) Disconnect high pressure pipe (1) and suction hose 

(2) from power steering pump (3).

NOTE
As fluid flows out of disconnected joints, put 
a receptacle under joints or a plug to pipe.

 

2

1

1

I5JB0A630026-01

1

3

2

I5JB0A630027-02

Power Assisted Steering System:  6C-19

5) Disconnect pressure switch lead wire at switch 

terminal.

6) Remove water pump and generator drive belt 

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

7) Remove P/S pump mounting bolts (1) and then 

remove P/S pump.

NOTE
Plug each port of removed pump to prevent 
dust or any other foreign matter from 
entering.

 

Installation
Reverse removal procedure, and then nothing the 
following instructions.

NOTE
Fill specified power steering fluid after 
installation and bleed air without failure 
referring to “P/S System Air Bleeding 
Procedure”.

 

Tightening torque
P/S pump mounting bolt:  25 N·m (2.5 kgf-m, 18.0 lb-
ft)
High pressure pipe union bolt:  60 N·m (6.0 kgf-m, 
43.5 lb-ft)

P/S Pump Components for M16 Engine Model

S5JB0A6306015

1

1

I5JB0A630028-03

18

13

6

16

1

15

2

3

(c)

2

2

11

2

7

12

10

8

2

5

4

14

(a)

(a)

(b)

17

9

I5JB0A630003-01

1. Suction connector

9. Vane

17. Cover bolt

2. O-ring

10. Rotor

18. Suction connector bolt

3. Pressure switch

11. Snap ring

: 28 N

⋅m (2.8 kgf-m, 20.5 lb-ft)

4. Flow control valve (Relief valve)

12. Side plate

: 60 N

⋅m (6.0 kgf-m, 43.5 lb-ft)

5. Spring

13. Pulley (pump shaft)

: 12 N

⋅m (1.2 kgf-m, 9.0 lb-ft)

6. Plug

14. Oil seal

: Do not reuse.

7. Pump cover

15. Pump body

8. Cam ring

16. Flow control valve assembly

6C-20 Power Assisted Steering System: 

P/S Pump Assembly Components for J20 
Engine Model

S5JB0A6306022

P/S Pump Disassembly and Assembly for M16 
Engine Model

S5JB0A6306013

Disassembly

1) Clean its exterior thoroughly.
2) With aluminum plates placed on vise first, grip pump 

body (15) with it.

3) Remove suction connector bolt, suction connector 

(1) and O-ring (2) from pump body (15).

4) Remove power steering pressure switch (terminal 

set) (3) from pump body (15).

5) Remove plug (6), flow control spring (5) and relief 

valve (flow control valve) (4) from pump body (15).

6) Remove cover bolts, pump cover (7) and O-ring (2) 

from pump body (15).

7) Remove snap ring (11) from pump shaft (13).
8) Remove vanes (9) from rotor (10).
9) Remove cam ring (8), rotor (10), side plate (12) and 

O-rings (2) from pump body (15).

10) Pull out pulley (13) from pump body (15).

11) Remove oil seal (14) from pump body (15).

Assembly

1) Apply grease to oil seal (1) lip and apply P/S fluid to 

sliding surface of the shaft (2) then insert pulley’s 
shaft (2) from oil seal side of the pump body.

“A”:  Grease 99000–25010 (SUZUKI Super 
Grease A) 

2) Apply power steering fluid to O-rings (1) and fit them 

to pump body.

3) Install side plate and cam ring and side plate (1) to 

pump body.

NOTE
Carefully align the dowel pins on the cam 
ring and side plate (1) at bolt hole (2) as 
shown in the figure.

 

1. Suction connector

: 3.7 N

⋅m (0.37 kgf-m, 2.7 lb-ft)

2. O-ring

: 20 N

⋅m (2.0 kgf-m, 14.5 lb-ft)

3. Pressure switch

: Do not reuse.

4. Suction connector bolt

1

4

(a)

3

(b)

2

2

I5JB0A630029-03

1

13

14

6

2

5

4

15

2

12

9

2

3

8

10

11

7

2

I5JB0A630030-02

IYSQ01630041-01

1

I5JB0A630031-01

1

2

I5JB0A630032-01

Power Assisted Steering System:  6C-21

4) Apply power steering fluid to sliding surface of rotor 

(1).

5) Install rotor (1) to shaft, directing dot (3) marked side 

of rotor facing up.

6) Install new snap ring (2) to shaft, then make sure to 

fit snap into shaft groove securely.

NOTE
Never reuse the removed snap ring (2).

 

7) Apply power steering fluid to sliding surface of cam 

ring (1).

8) Apply power steering fluid to each vane (2).
9) Install vanes (2) (10 pieces) to rotor (1).

10) Apply power steering fluid to O-ring (1).

11) Install O-ring (1) to pump body.

12) Apply power steering fluid to sliding surface of pump 

cover and rotor.

13) Match the dowel pins (1) to the holes of the cover 

plate (2) as shown and install pump cover to pump 
body.

14) Gradually tighten pump cover (1) bolts to diagonally 

specified torque.

NOTE
After installing pump cover (1), check to 
make sure that shaft can be turned by hand.

 

Tightening torque
P/S pump cover bolt (a):  28 N·m (2.8 kgf-m, 20.5 
lb-ft)

15) Apply power steering fluid to O-ring (2) of pressure 

switch.

16) Install O-ring (2) to pressure switch.
17) Install pressure switch (1) to pump body.

Tightening torque
Pressure switch for M16 engine model (a):  28 
N·m (2.8 kgf-m, 20.5 lb-ft)

1

3

1

2

I5JB0A630033-01

2

1

I5JB0A630034-01

1

I5JB0A630035-01

1

2

I5JB0A630036-01

IYSQ01630049-01

1, (a)

2

I5JB0A630037-04