Suzuki Aerio, Verona 2002-06

Removal & Installation

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

  1. Remove engine under cover (right side only) and loosen generator belt tensioner pulley then remove generator belt.
  2.  
  3. Remove air cleaner outlet hose (1).
  4.  
  5. Empty power steering fluid from reservoir (2) using syringe or such.

    Click image to see an enlarged view

    Fig. Remove air cleaner outlet hose and empty power steering fluid from reservoir

  6.  
  7. Disconnect high pressure hose (1) and suction hose (2) from power steering pump. As fluid flows out of disconnected joints, put a container under joints or a plug to hose.
    NOTE
    When disconnecting, take care not to cause damage to generator.



    Click image to see an enlarged view

    Fig. Disconnect the high pressure hose and suction hose from the power steering pump

  8.  
  9. Remove pump mount bolts (1) and detach power steering pump from bracket, while detaching, do not forget to disconnect lead wire from the pump.
    NOTE
    Plug each port of removed pump to prevent dust or any other foreign matter from entering.



    Click image to see an enlarged view

    Fig. Remove the pump mount bolts and detach the power steering pump from the bracket

  10.  

To install:

Reverse removal procedure.



Fill specified power steering fluid after installation and bleed air without failure.
 
For tightening torques, refer to the graphic below.
 
Check power steering belt (generator belt) tension.
 
Bleed air from P/S system.

Click image to see an enlarged view

Fig. Install the power steering pump

 

5- & 6-Cylinder Engines




WARNING
Used fluid is considerably more dangerous than new fluid. Avoid skin contact with the oil.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the accessory drive belt. Refer to Accessory Drive Belts removal and installation.
  4.  
  5. Drain the power steering pump oil:
    1. Install a lock-grip pliers on the hose from the fluid reservoir as close to the power steering pump as possible.
    2.  
    3. Extract the oil.
      NOTE
      Place paper over the alternator as protection against oil.

    4.  

  6.  
  7. Remove or disconnect the following:

    The pressure hose
     
    The feeder hose

    Click image to see an enlarged view

    Fig. Removing hoses from power steering pump with lock-grip pliers in place

     

  8.  
  9. Remove the 3 mounting bolts from power steering pump.
  10.  
  11. Remove the power steering pump.
  12.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Install the power steering pump with the 3 M8 mounting bolts. Tighten to 18 ft. lbs. (24 Nm).
  4.  
  5. Install the pressure hose and feeder hose with the M6 bolts. Tighten to 88 inch lbs. (10 Nm).
    NOTE
    Use a new O-ring.

  6.  
  7. Install the accessory drive belt. Refer to Accessory Drive Belts removing and installation.
  8.  
  9. Refill oil using Volvo power steering fluid, P/N 1161529.
  10.  
  11. Bleed the power steering system. Refer to Power Steering Pump bleeding.
  12.  

8-Cylinder Engines




WARNING
Used fluid is considerably more dangerous than new fluid. Avoid skin contact with the oil.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Lift up the oil reservoir. Place paper under the oil reservoir to catch any oil spillage.
  4.  
  5. Position a container under the oil reservoir. Remove the hose from the oil reservoir.
  6.  
  7. Drain the oil.

    Click image to see an enlarged view

    Fig. Location of power steering oil reservoir-8-Cylinder Engine

  8.  
  9. Remove the intake manifold. Refer to Intake Manifold removal and installation.
  10.  
  11. Remove the accessory drive belt. Refer to Accessory Drive Belts removal and installation.
  12.  
  13. Remove or disconnect the following:

    The bolt to the power steering pressure pipe (1)
     
    The pressure pipe
     
    The delivery hose with the clamp (2)
     
    The 3 bolts from the power steering pump
     
    The power steering pump

    Click image to see an enlarged view

    Fig. Location of power steering pressure pipe, delivery hose, and bolts-8-Cylinder Engine

     

  14.  

To install:

  1. Install or connect the following:

    The power steering pump with the 3 M8 bolts. Tighten to 18 ft. lbs. (24 Nm)
     
    The pressure pipe. Use a new O-ring
     
    The bolt for the pressure pipe (1). Tighten to 24 ft. lbs. (32 Nm)
     
    The delivery hose with the clamp (2).
     
    The accessory drive belt. Refer to Accessory Drive Belts removing and installation.
     
    The intake manifold. Refer to Intake Manifold removing and installation
     
    The hose and clamp to the oil reservoir
     
    The oil reservoir
     

  2.  
  3. Bleed the power steering system. Refer to Power Steering Pump bleeding.
  4.  

 
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