Edited by Foxit PDF Editor

Copyright (c) by Foxit Software Company, 2004

For Evaluation Only.

6C-36 Power Assisted Steering System:

Repair Instructions
Steering Gear Case Assembly Components

S6RW0C6306001

NOTE

The figure shows left-hand steering vehicle. For right-hand steering vehicle the figure is symmetrical.

8
7

(b)

6
5
10

11
13
18

(e)

(b)

19
20
16

21
17

(a)

(d)

1207F

14

15

12

(c)

1
12
3

(c)

(a)

12

(c)

6
8
7

(b)

10
11
9

(b)
I6RW0C630010-01

1. Steering gear case

10. Boot

19. Washer

2. Tie-rod lock washer

11. Clip

20. Spring washer

: Make sure of the direction of installation referring to
Steering Rack Plunger Removal and Installation.

3. Tie-rod

12. Steering gear case mounting bolt

: Refer to Steering Gear Case Assembly
Removal and Installation.

21. O-ring

4. Wire

13. Steering gear case grommet

5. Boot

14. Member bracket

: 75 Nm (7.5 kgf-m, 54.5 lb-ft)

: 45 Nm (4.5 kgf-m, 32.5 lb-ft)

6. Rack boot clip

15. Steering rack plunger

: 70 Nm (7.0 kgf-m, 51.0 lb-ft)

7. Tie-rod end lock nut

16. Steering rack plunger spring

: Refer to Steering Rack Plunger Removal and

Installation.

8. Tie-rod end

17. Steering rack damper screw

: Apply sealant 99000-31250 to all around thread
part of rack damper screw.

: 60 Nm (6.0 kgf-m, 43.5 lb-ft)

9. Tie-rod end nut

18. Steering rack damper lock nut

: Do not reuse.

Edited by Foxit PDF Editor

Power
Assisted
Steering
System: 6C-37
Copyright (c) by Foxit
Software
Company,
2004
For Evaluation Only.
4) For ease of adjustment after installation, make
Tie-Rod End Boot On-Vehicle Inspection
S6RW0C6306002
marking (1) of tie-rod end lock nut (2) position on tieCheck boot for crack and damage. If any defect is found,
rod end thread. Then, loosen lock nut and remove
replace it with a new one.
tie-rod end (3) from tie-rod (4).

I3RM0A630024-01

Tie-Rod End Removal and Installation

S6RW0C6306003

Removal
1) Hoist vehicle, and then remove front wheel.
2) Remove tie-rod end nut (1) from steering knuckle.

I4RS0A630041-01

Installation
1) Install tie-rod end lock nut (1) and tie-rod end (2) to
tie-rod (3). Align lock nut with mark (4) on tie-rod
thread.

I4RS0A630042-01
I3RM0A630025-01

3) Disconnect tie-rod end (1) from knuckle (2) using

puller (3).

2) Connect tie-rod end to knuckle. Tighten tie-rod end

nut (1) to specified torque.
Tightening torque
Tie-rod end nut (a): 45 Nm (4.5 kgf-m, 32.5 lb-ft)

I4RS0A630040-01

I3RM0A630029-01

Edited by Foxit PDF Editor

Copyright (c) by Foxit Software Company, 2004
For Evaluation Only.

6C-38 Power Assisted Steering System:

3) Inspect for proper toe referring to Front Wheel
Alignment Inspection and Adjustment in Section 2B.
4) After confirming proper toe, tighten tie-rod end lock
nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 Nm (4.5 kgf-m, 32.5
lb-ft)

I3RM0A630030-01

5) Tighten wheel bolts to specified torque and lower

hoist.

Steering Gear Case Assembly Removal and

Installation

S6RW0C6306006

Removal
!

CAUTION

Be sure to set front wheels (tires) in straight

direction and remove ignition key from key
cylinder before performing the following
steps, otherwise, contact coil of air bag
system may get damaged.
1) Remove steering joint cover.
2) Make alignment marks (1) on pinion shaft (2) and
joint of steering lower shaft (3) for a guide during
reinstallation.
3) Loosen joint bolt (steering column side) (4) and
remove joint bolt (pinion shaft side) (5) and
disconnect steering lower shaft (3) from pinion shaft
(2).

Tightening torque
Wheel bolt: 85 Nm (8.5 kgf-m, 61.5 lb-ft)

Tie-Rod End Inspection

S6RW0C6306004

Inspect for play in ball joint.

Inspect for play in rack end ball joint.
In either case, if found defective, replace.

3
5

I4RS0B630013-01

I4RS0A630043-01

Steering Shaft Joint On-Vehicle Inspection

S6RW0C6306005

Check shaft joint for wear, breakage and any other

damage and replace if any defect exists.

4) Disconnect torque sensor connector and P/S motor

connector from steering gear case.
5) Remove front suspension frame with steering gear
case referring to Front Suspension Frame,
Stabilizer Bar and/or Bushing Removal and
Installation (2WD Model) in Section 2B or Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation (4WD Model) in Section
2B, and then remove steering gear case.
Installation
1) Install grommet (1) as shown in figure.

1
2

1
I4RS0B630012-01

I5RW0A630018-02

2. Protrusion

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Power
Assisted
Steering
System: 6C-39
Copyright (c) by Foxit
Software
Company,
2004
For Evaluation Only.
2) Install steering gear case to suspension frame (3) as
Steering Rack Boot Inspection
S6RW0C6306007
follows.
Hoist vehicle.
a) Set member bracket (2) to steering gear case
Inspect each boot for tear. A torn boot allows entry of
(1).
dust and water which can cause wear to steering rack
b) Install all steering gear case mounting bolts by
and pinion to produce noise as well as rust to result in
hand.
malfunction of steering system.
Even if boot tear is small, replace with new one.
c) Tighten steering mounting bolts in numerical
Also, check each boot for dent. If there is a dent, keep
order and specified torque.
boot in most compressed state for some seconds to
Tightening torque
correct dent.
Steering gear case mounting bolt (a): 70 Nm (
Boots should be visually inspected for any damage, dent
7.0 kgf-m, 51.0 lb-ft)
and tear during every periodical inspection at specified
intervals and whenever vehicle is hoisted for any other
purpose.

I7RW01632009-01

3) Install front suspension frame with steering gear

case to vehicle referring to Steps 4) 22) of Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation (2WD Model) in Section
2B or Front Suspension Frame, Stabilizer Bar and/
or Bushing Removal and Installation (4WD Model) in
Section 2B, and then install steering gear case to
vehicle.
4) Connect torque sensor connector and P/S motor
connector to steering gear case.
5) Be sure that steering wheel and brake discs (right &
left) are all straight-ahead position and then insert
steering lower shaft (5) into steering pinion shaft (3)
with matching marks (4).
6) Tighten steering shaft joint lower bolt (1) and upper
bolt (2) to specified torque (tighten lower side first
and then tighten upper side).
Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 Nm (2.5 kgf-m, 18.5 lb-ft)
Steering lower shaft assembly lower joint bolt
(b): 25 Nm (2.5 kgf-m, 18.5 lb-ft)

I2RH01630012-01

Tie-Rod / Rack Boot Removal and Installation

S6RW0C6306008

Removal
1) Remove steering gear case assembly referring to
Steering Gear Case Assembly Removal and
Installation.
2) Remove member bracket from steering gear case
assembly.
3) For ease of adjustment after installation, make
marking (1) of tie-rod end lock nut position of tie-rod
thread.

I4RS0A630044-01

4) Loosen tie-rod end lock nut and remove tie-rod end.

5) Remove boot band (2) and clip (1).
6) Remove boot from tie-rod.

5
2, (a)

1, (b)
5
4

1, (b)
3

I5RW0A630020-01

7) Install steering joint cover.

IYSQ01630034-01

6C-40 Power Assisted Steering System:

7) Unbend bent part of tie-rod lock washer (1).
8) Remove tie-rod (3) from rack (2).

Edited by Foxit PDF Editor

Copyright (c) by Foxit Software Company, 2004
For Evaluation Only.
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 wont be crossed. Then
twist the ends 4 5 times, the twisted ends should
be bent in the circumferential direction.
NOTE
After clamping, make sure that the boot
installation part is fixed.
If the boot turns easily by hand, tighten with
higher torque to fix it firmly.

1
I5RW0A630021-01

Installation
1) Install tie-rod (1) and new tie-rod lock washer (3) to
rack (2).
2) Hold rack with soft jawed vise and tighten tie-rod to
specified torque.
Tightening torque
Tie-rod (a): 75 Nm (7.5 kgf-m, 54.5 lb-ft)
IYSQ01630035-01

6) Install tie-rod end lock nut and tie-rod end to tie-rod.

Position lock nut to marking (1) made in removal.

1, (a)

NOTE
2
3

I6RW0B630019-01

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.

3) Bend lock washer at 2 places (1) as shown in figure.

I3RM0A630052-01

7) Install member bracket (1), and then install earth

cable (2) as shown in figure.
I4RS0A630035-01

4) Apply grease A to boot inside as shown in figure.

Position boot properly in grooves of gear case (or
rack side mount) and tie-rod.
After this, check to ensure that boot is free from twist
and dent.

Angle a
: Within 20
Tightening torque
Earth cable bolt (a): 4.0 Nm (0.4 kgf-m, 2.8 lb-ft)
(a)

A: Grease 9900025050 (SUZUKI Super

Grease E)

A
1

I6RW0C630011-01

I7RW01632010-01

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Power
Assisted
Steering
System: 6C-41
Copyright (c) by Foxit
Software
Company,
2004
For Evaluation Only.
3) Pinion rotation torque should be checked with rack
Steering Rack Plunger Removal and Installation
S6RW0C6306009
position centered.
Also, check if rack as a whole moves smoothly.
Removal
Special tool
1) Loosen lock nut (1) with holding damper screw (2).
(A): 0994418220
2) Remove lock nut (1), rack damper screw (2), rack
Tightening torque
plunger spring (3), washer (5), spring washers (6),
Rotation torque of pinion (a): 2.2 Nm (0.22 kgfO-ring (7) and rack plunger (4).
m, 1.5 lb-ft)

I5RW0A630024-02

Installation
1) Install plunger (1), new O-ring (6), washer (4), spring
washers (5) and spring (2) as shown.
NOTE
Do not wipe off grease previously applied to
new plunger.
2) Apply sealant to rack damper screw (3) and tighten
them as follows.
a) Tighten damper screw to 25 Nm (2.5 kgf-m, 18.0
lb-ft).
b) Loosen damper screw until 180.
c) Retighten damper screw to 3.9 Nm (0.39 kgf-m,
3.0 lb-ft).
d) After tightening rack damper screw to specified
torque, turn it back by 10 or less.

I3RM0A630055-02

4) After adjustment, tighten lock nut to specified torque

with holding damper screw at the position.
Tightening torque
Steering rack damper lock nut: 60 Nm (6.0 kgfm, 43.5 lb-ft)

Steering Rack Plunger Inspection

S6RW0C6306010

NOTE
Do not wipe off grease applied to rack
plunger which is removed.
Inspect rack plunger (1) for wear or damage.
Inspect rack plunger spring (2) for deterioration.
If any abnormality is found, replace.

A: Water tight sealant 9900031250

(SUZUKI Bond No.1207F)
Tightening torque
Rack damper screw (a): Tighten 25 Nm (2.5
kgf-m, 18.0 lb-ft) and loosen 180 and then
tighten 3.9 Nm (0.39 kgf-m, 3.0 lb-ft) and turn
it back by 10 or less by the specified
procedure.
I5RW0A630026-02

I5RW0A630025-03