Suzuki Grand Vitara JB627. Manual - part 263

6C-13 Power Assisted Steering System: 

P/S Gear Case Assembly Components

S6JB0B6306011

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]: LHD model

6. Tie-rod end lock nut

: 43 N

⋅m (4.3 kgf-m, 31.0 lb-ft)

[B]: RHD model

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-14

P/S Gear Case Assembly Removal and 
Installation

S6JB0B6306012

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 (1) 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.

 

1

2

3

5

4

I5JB0A630017-01

1

2

I5JB0A630018-01

1

1

I5JB0A630019-01

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:  35 N·m (
3.5 kgf-m, 25.5 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”.

2

1

I5JB0A630020-01

(a)

I5JB0A630021-02

Power Assisted Steering System:  6C-16

Steering Gear Case Mount Bushing Removal 
and Installation

S6JB0B6306013

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

S6JB0B6306014

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

Rack Boot / Tie-Rod Removal and Installation

S6JB0B6306015

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”

I6JB01630007-01

I5JB0A630054-01