Suzuki Grand Vitara JB627. Manual - part 265

6C-21 Power Assisted Steering System: 

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 (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.

 

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) Install cam ring (1) to pump body.

NOTE
Install cam ring by facing side with a mark (2) 
toward pump cover.

 

9) Apply power steering fluid to each vane (2).

10) Install vanes (2) (10 pieces) to rotor (1).

IYSQ01630041-01

I5JB0C630008-01

I5JB0C630009-01

I5JB0C630010-01

I5JB0C630011-01

I5JB0C630012-01

Power Assisted Steering System:  6C-22

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

12) Install O-ring (1) to pump body.

13) Apply power steering fluid to sliding surface of pump 

cover and rotor.

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

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

15) 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)

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

switch.

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

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

19) Apply power steering fluid to relief valve (flow control 

valve).

20) Install relief valve (flow control valve) to pump body.
21) Install flow control spring.
22) Apply power steering fluid to O-rings of plug.
23) Install O-rings to plug.
24) Tighten plug to specified torque.

Tightening torque
Plug (a):  60 N·m (6.0 kgf-m, 43.5 lb-ft)

25) Apply power steering fluid to O-ring (2) of suction 

connector (1).

26) Install O-ring (2) to suction connector (1).

I5JB0C630013-01

1

2

I5JB0A630036-01

IYSQ01630049-01

I5JB0C630014-01

IYSQ01630051-01

I5JB0C630015-01

6C-23 Power Assisted Steering System: 

27) Install suction connector (1) to pump body as shown 

in the figure. Tighten suction connector (1) bolts to 
specified torque.

Tightening torque
Suction connector bolt (a):  12 N·m (1.2 kgf-m, 
9.0 lb-ft)

P/S Pump Inspection

S6JB0B6306020

Pump Body, Cover, Side Plate and Shaft
Check sliding surfaces of each part for wear and 
damage. If any defect is found, replace pump assembly.

Cam Ring
Check vane sliding surface of cam ring for wear and 
damage. If any defect is found, replace pump assembly.

Rotor and Vane
• Check sliding surfaces of rotor and vane for wear and 

damage.

• Check clearance between rotor and vane. Replace 

pump assembly if any defect is found.

Clearance between rotor and vane
Standard: 0.015 mm (0.0004 in.)
Limit: 0.027 mm (0.0008 in.)

Relief Valve (Flow Control Valve) and Its Spring
• Check fluid passage of relief valve and orifice of 

connector for obstruction (clogged).

• Check sliding surface of relief valve for wear and 

damage.

• Check free length of relief valve spring (1). Replace if 

any defective is found.

Free length of relief valve spring
Standard: 22.0 mm (0.866 in.)
Limit: 19.0 mm (0.748 in.)

I5JB0C630016-01

I5JB0A630051-01

IYSQ01630055-01

1. Thickness gauge

IYSQ01630056-01

IYSQ01630057-01

IYSQ01630058-01

IYSQ01630059-01

Power Assisted Steering System:  6C-24

Specifications

Tightening Torque Specifications

S6JB0B6307001

NOTE
The specified tightening torque is also described in the following.
“P/S Gear Case Assembly Components”
“P/S Hose / Pipe Components”
“P/S Pump Components”

 

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

P/S belt tension pulley bolt

25

2.5 

18.5

)

Tie-rod end nut

43

4.3 

31.0

)

Wheel nut

100

10.0 

72.5

)

Tie-rod end lock nut

65

6.5 

47.0

)

Steering lower shaft bolt

25

2.5 

18.5

)

Gear case high pressure pipe union bolt

35

3.5 

25.5

)

Gear case cylinder pipe flare nut

25

2.5 

18.0

)

Gear case mounting bolt

105

10.5 

76

)

Gear case low pressure pipe union bolt

35

3.5 

25.5

)

Stabilizer bar mount bracket mount bolt

60

6.0 

43.0

)

Tie-rod ball nut

90

9.0 

65.0

)

P/S pump mounting bolt

25

2.5 

18.0

)

High pressure pipe union bolt

60

6.0 

43.5

)

P/S pump cover bolt

28

2.8 

20.5

)

Pressure switch

28

2.8 

20.5

)

Plug

60

6.0 43.5

)

Suction connector bolt

12

1.2 

9.0

)