Suzuki Aerio, Verona 2002-06

Removal & Installation

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WARNING
Be sure to set the front wheels straight ahead and remove the ignition key from the cylinder before starting repairs. The contact coil of the air bag system may be damaged if the key is not removed and the wheels are not straight ahead.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Take out fluid in P/S fluid reservoir with syringe or such.
  6.  
  7. Remove or disconnect the following:
    NOTE
    When the lines are disconnected plug the lines or place an oil pan under the vehicle.



    Steering column joint cover
     
    Steering shaft upper joint bolt, loosen but do not remove
     
    Steering shaft lower joint bolt
     
    Lower joint from the pinion
     
    Front wheels
     
    Tie rod ends from the steering knuckles
     
    Exhaust pipe No. 2
     
    Engine rear mounting together with its bracket from engine and member
     
    Engine mounting member
     
    Transfer case (AWD)
     



    Click image to see an enlarged view

    Fig. Fluid pipes and hose to the power steering gear-Aerio



    Cylinder pipes and from steering gear box, using flare nut wrench
     
    High pressure pipe and low pressure hose from steering gear box, using flare nut wrench
     
    Steering gear box mounting bolts and steering gear box
     

  8.  

To install:


WARNING
Be sure to confirm that steering wheel and front tires (wheels) are in straight position when inserting steering lower joint into steering pinion shaft.

  1. Install or connect the following:
    NOTE
    If a plug was put to disconnected pipe when removing steering gear box, remove that plug before reconnecting pipe.



    Steering gear, brackets and mounting bolts. Tighten bolts to 40 ft. lbs. (55 Nm).
     



    Cylinder lines on the rack and pinion and tighten their fittings to 18 ft. lbs. (25 Nm)
     
    High and low pressure lines to the steering gear. Tighten the fittings to 25 ft. lbs. (35 Nm).
     
    Transfer case (AWD)
     
    Engine mounting member
     
    Engine rear mounting together with its bracket to the engine and member
     
    Exhaust pipe No. 2
     
    Tie rod ends to the steering knuckles. Tighten the castle nuts to 25.5-39.5 ft. lbs. (35-55 Nm).
     
    Front wheels
     

  2.  
  3. Be sure the steering wheel is straight and the front wheels are pointing straight ahead.

    Steering shaft to the rack and pinion
     
    Lower steering shaft-to-rack and pinion clinch bolt and tighten both steering joint bolts (upper and lower) to 18 ft. lbs. (25 Nm)
     
    Front wheels
     

  4.  
  5. Lower the vehicle.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Fill the power steering system and then bleed the power steering system.
  10.  
  11. Check and adjust the front wheel alignment.
  12.  


WARNING
Be sure to set the front wheels straight ahead and remove the ignition key from the cylinder before starting repairs. The contact coil of the air bag system may be damaged if the key is not removed and the wheels are not straight ahead.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the front of the vehicle.
  6.  
  7. Remove or disconnect the following:

    Front wheels
     
    Power steering gear fluid inlet pipe
     
    Hose from power steering gear fluid outlet pipe. Place a drain pan under the steering gear to catch the power steering fluid.
     

  8.  
  9. Position the steering gear straight ahead by turning the steering wheel until the steering wheel spokes are vertical and pointed to the left.
  10.  
  11. Scribe a mark on the stub shaft housing that lines up with a mark on the intermediate shaft lower coupling.
    WARNING
    When removing the crossmember assembly it should be supported by Jack stands, in advance. Failure to support the crossmember properly can result in personal injury. In addition, remove the centermember bolt with caution when the exhaust pipe is hot.



    Intermediate shaft pinch bolt
     
    Outer tie rod nuts
     
    Tie rod ends from the strut assembly using ball joint remover KM-507-B
     
    Nuts and bolts from steering gear mounting brackets
     
    Crossmember assembly for easy removal of the rack and pinion assembly
     



    Speed sensitive power steering (SSPS) solenoid valve connector
     
    Rack and pinion assembly from crossmember assembly
     

  12.  

To install:

  1. Install the rack and pinion assembly from below. The steering gear must be in a straight-ahead position, and the steering wheel spokes must be vertical and pointing to the left. Align the marks on the shafts to ensure proper positioning. Seat the stub shaft into the intermediate shaft.
  2.  
  3. Install or connect the following:

    SSPS solenoid valve connector.
     
    Nuts and bolts on the steering gear mounting bracket. Tighten the steering gear mounting bracket bolts and nuts to 44 ft. lbs. (60 Nm).
     
    Tie rod ends to strut assembly
     
    Outer tie rod nuts and tighten to 37 ft. lbs. (50 Nm).
     
    Lower intermediate shaft pinch bolt and tighten to 18 ft. lbs. (25 Nm).
     
    Power steering gear fluid inlet pipe and tighten the steering gear inlet pipe fitting to 21 ft. lbs. (28 Nm).
     
    Hose to power steering gear fluid outlet pipe
     
    Front wheels
     

  4.  
  5. Lower the vehicle.
  6.  
  7. Check and adjust the front wheel alignment.
  8.  
  9. Refill the power steering system and check for leaks. If leaks are found, correct the cause of the leak and bleed the system.
  10.  
  11. Connect the negative battery cable.
  12.  

5- & 6-Cylinder Engines



  1. Set the steering wheel to the straight-ahead position. Remove the key so that the steering wheel lock engages.
  2.  
  3. Remove the battery lead.
  4.  
  5. Install the lock grip pliers on the feeder hose and the return hose for the power steering pump.
  6.  
  7. Remove the bolt on the steering shaft joint mounting in the steering gear from the engine compartment.
  8.  
  9. Remove the sub-frame.
  10.  
  11. Remove:

    The front wheels
     
    The tie rod ends from the steering arms.
     

  12.  
  13. Counterhold using a fixed wrench so that the boot is not damaged.
    NOTE
    On one side, measure the length of the tie rod in relation to the steering gear housing. Note the measurement.



    Click image to see an enlarged view

    Fig. Steering gear mounting bolts-5- & 6-cylinder engines



    Click image to see an enlarged view

    Fig. Measuring tie-rod length in relation to the steering gear housing-5- & 6-cylinder engines

  14.  
  15. Place a container under the steering gear.
  16.  
  17. Remove:

    The return lines from the steering gear and drain the fluid
     
    The delivery line from the steering gear and drain the fluid.
     

  18.  
  19. Remove the clips holding the same lines.
  20.  
  21. Remove the steering gear.
  22.  

To install:

  1. Measure and adjust according to the measurements made earlier between the tie rod end and the steering gear housing on the new steering gear.
  2.  
  3. Install the steering gear. Torque the steering gear fasteners to 37 ft. lbs. (50 Nm).
  4.  
  5. Install the lines according to the noted routing.
  6.  
  7. Tighten the return line and the delivery line to the steering gear. Tighten to 18 ft. lbs. (25 Nm).
    NOTE
    Use a new O-ring on the tube at the steering gear.

  8.  
  9. Install the clips holding the same lines.
  10.  
  11. Install the tie rod ends on the steering arms. Use new nuts. Tighten to 59 ft. lbs. (80 Nm). Counterhold using a fixed wrench so that the boot is not damaged.
  12.  
  13. Install the sub-frame.
  14.  
  15. Expose the steering wheel lock. Turn the steering wheel so that the bolt in the mounting for the steering shaft joint points straight ahead.
  16.  
  17. Tighten the lower bolt on the steering shaft joint mounting in the steering gear from the engine compartment. Tighten to 18 ft. lbs. (25 Nm). Use a new bolt.
  18.  

8-Cylinder Engines



  1. Disconnect the battery.
  2.  
  3. Remove the front wheels.
    WARNING
    Avoid skin contact with the oil.

  4.  
  5. Lift up the power steering reservoir.

    Click image to see an enlarged view

    Fig. Draining the power steering reservoir-V8

  6.  
  7. Place paper under the oil reservoir for any oil spillage. Position a container under the oil reservoir.
  8.  
  9. Remove the hose with the clamp from the oil reservoir.
  10.  
  11. Drain the oil.

    Click image to see an enlarged view

    Fig. Remove the bolts at the suspension turrets on both sides

  12.  
  13. Remove the bolts at the suspension turrets on both sides.
    NOTE
    When raising the engine make sure that the lifting eye does not scratch the torque rod. Tape the torque rod at the lifting eye.



    Click image to see an enlarged view

    Fig. Installing the lifting tool

  14.  
  15. Remove the oil filler cap.
  16.  
  17. Remove the upper front engine casing by pulling it straight up.
  18.  
  19. Install the lifting tool: 999 5716 converted with kit: 999 7070 and the lifting hooks: 999 5460. Raise the engine slightly so that the engine pads are unloaded.

    Click image to see an enlarged view

    Fig. Removing the wing liner

  20.  
  21. Remove the plastic nuts and the wing liner.

    Click image to see an enlarged view

    Fig. Removing the bolts to the engine pad, right

  22.  
  23. Remove the bolts (1) from the right engine pad.

    Click image to see an enlarged view

    Fig. Removing the protective cover under the engine

  24.  
  25. Remove the bolts and the protective cover under the engine.

    Click image to see an enlarged view

    Fig. Removing the exhaust pipes between front and rear catalytic converters

  26.  
  27. Remove both exhaust pipes' nuts and both exhaust pipes.

    Click image to see an enlarged view

    Fig. Removing the lower bolt to the rear engine pad

  28.  
  29. Release the heated oxygen sensor (HO 2 S) connectors from the sub-frame. Fold aside the protective plate under the steering gear to gain access to the engine pad's lower bolt. Remove the engine pad's bolt.
    NOTE
    Turn the steering wheel until optimum access to the bolt is achieved. Lock the steering wheel and take out the ignition key, so that the steering wheel lock is activated.



    Click image to see an enlarged view

    Fig. Removing the steering shaft joint, lower

  30.  
  31. On one side, measure the length of the track rod in relation to the steering gear housing. Make a note of the measurement.

    Click image to see an enlarged view

    Fig. On one side, measure the length of the track rod in relation to the steering gear housing. Make a note of the measurement

  32.  
  33. Remove the bolt to the lower steering shaft joint.
  34.  
  35. Remove the connector to the solenoid.

    Click image to see an enlarged view

    Fig. Removing the track rod ends

  36.  
  37. Make sure that the wheels are in the straight forward position. Lock the steering wheel by removing the ignition key. Do not turn the front wheels so that the position of the steering gear is changed. This could damage the SRS system's contact reel.
  38.  
  39. Remove the track rod ends. Counterhold with a wrench so that the gaiter is not damaged.

    Click image to see an enlarged view

    Fig. Lowering the sub-frame at the rear edge

  40.  
  41. Press the lower steering shaft joint up from the steering gear. Make sure that no pipes or lines are loaded or trapped when lowering.
  42.  
  43. Position a mobile jack at the rear end of the sub-frame.
  44.  
  45. Remove the bolts to the sub-frame's brackets at the rear edge.
  46.  
  47. Remove the bolts to the sub-frame in the rear edge.
  48.  
  49. Remove the sub-frame's brackets.
  50.  
  51. Release the heated oxygen sensor (HO 2 S) lines from the anti-roll bar.
  52.  
  53. Lower the sub-frame carefully.

    Click image to see an enlarged view

    Fig. Removing the pressure pipe and return pipe from the steering gear



    Click image to see an enlarged view

    Fig. Remove the bolt to the bracket holding the pipe to the sub-frame

  54.  
  55. Remove the bolt to the bracket holding the pipe to the sub-frame.
  56.  
  57. Release the pipes from the clips.
  58.  
  59. Place a container under the steering gear.
  60.  
  61. Remove the pipes' bolt on the valve housing and the pipes.

    Click image to see an enlarged view

    Fig. Removing the metal protective cover

  62.  
  63. Remove the bolt holding the protective plate on the steering gear.
  64.  
  65. Remove the bolt holding the protective plate to the sub-frame.
  66.  
  67. Remove the protective plate.

    Click image to see an enlarged view

    Fig. Removing the steering gear

  68.  
  69. Remove the nuts (1) and the bolt (2).
  70.  
  71. Remove the steering gear through the left-hand side of the vehicle.
  72.  

To install:

  1. Install the steering gear. Torque the nuts and bolt to 37 ft. lbs. (50 Nm).
  2.  
  3. Install the metal protective cover.
  4.  
  5. Install the oil pipes to the steering gear. Torque the pressure line to 18 ft. lbs. (25 Nm).
  6.  
  7. Raise the sub-frame's rear edge using a mobile jack.
  8.  
  9. Install the bolts with brackets. Torque to 74 ft. lbs. (100 Nm).
  10.  
  11. Install the front edge bolts to the brackets. Torque to:

    Step 1: 77 ft. lbs. (105 Nm)
     
    Step 2: plus 120°
     

  12.  
  13. Install the heated oxygen sensor lines on the anti-roll bar.
    NOTE
    Unscrew the upper nut in order to facilitate fitting the lower bolt.

  14.  
  15. Install the lower bolt to the engine pad. Torque to 37 ft. lbs. (50 Nm).
  16.  
  17. Connect the heated oxygen sensor connectors on the sub-frame.
  18.  
  19. Refit the protective plate under the steering gear.
  20.  
  21. Install the steering arms to the wheels spindles. Use new lock nuts. Tighten to 37 ft. lbs. (50 Nm) plus 35°.
  22.  
  23. Install the lower steering shaft joint. Torque to 18 ft. lbs. (25 Nm).
  24.  
  25. Install the connector to the solenoid.
  26.  
  27. Connect both exhaust pipes.
  28.  
  29. Install the protective cover under the engine.
  30.  
  31. Install the bolts engine pad upper bolts. Torque to 37 ft. lbs. (50 Nm).
  32.  
  33. Install the wing liner.
  34.  
  35. Remove the lifting tool 999 5716, kit 999 7070 and lifting hooks 999 5460.
  36.  
  37. Install the bolts at the suspension turrets on both sides.
  38.  
  39. Connect the battery.
  40.  
  41. Install the hose with the clamp to the oil reservoir
  42.  
  43. Fill the oil reservoir.
    NOTE
    For the correct oil grade use Volvo power steering fluid, part number 116 1529-1.

  44.  
  45. Turn the steering wheel between both end positions several times.
  46.  
  47. Check and fill with oil as necessary. Apply the parking brake. Start the engine.
    1. Turn the steering wheel slowly to the right, keep it at the end position for 2 seconds.
    2.  
    3. Turn the steering wheel slowly to the left, keep it at the end position for 2 seconds.
    4.  

  48.  
  49. Repeat steps A and B 10 times.
  50.  
  51. Install the upper front engine casing.
  52.  
  53. Install the front wheels on both sides.
  54.  
  55. Carry out wheel alignment.
  56.  

 
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