Suzuki Vitara, Grand Vitara, XL7 2000-06

Removal & Installation

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Lower Shaft




WARNING
Never turn steering wheel while steering column is removed or shafts are removed. Turning steering wheel more than about two and a half turns will break contact coil.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Turn steering wheel so that vehicle-s front tires are at straight-ahead position.
  4.  
  5. Turn ignition switch to LOCK position and remove key.
  6.  
  7. Make alignment marks on shaft joint and shaft (upper shaft assembly side) for a guide during reinstallation.
  8.  
  9. After removing bolt on upper shaft assembly side of shaft joint and loosening bolt on its lower shaft assembly side, move shaft joint to lower shaft assembly side.
  10.  
  11. Remove lower shaft assembly lower joint bolt and then remove lower shaft assembly.
  12.  
  13. Remove shaft joint bolt (lower shaft assembly side) from shaft joint and then remove shaft joint from lower shaft assembly.

    Click image to see an enlarged view

    Fig. Lower shaft assembly

  14.  

To install:

  1. Be sure that front wheels and steering wheel are in straight-ahead position.
  2.  
  3. Align flat part of lower shaft assembly with bolt hole of shaft joint as shown in the figure. Then insert shaft joint into lower shaft assembly.
  4.  
  5. Install shaft joint bolt (lower shaft assembly side) to shaft joint. Then tighten it by hand.
  6.  
  7. Insert pinion shaft into lower shaft assembly lower joint with slit of lower joint and yellow marks on pinion shaft and gear case aligned.
  8.  
  9. And then install lower shaft assembly lower joint bolt to lower shaft assembly lower joint. Tighten it to 18 ft. lbs. (25 Nm).
  10.  
  11. Install steering shaft joint to steering upper shaft by matching it to marks made before removal.
    NOTE
    Be sue that front wheels and steering wheel are in straight-ahead position.

  12.  
  13. Install shaft joint bolt (upper shaft assembly side) to shaft joint.
  14.  
  15. Tighten shaft joint bolt (upper shaft assembly side) to 18 ft. lbs. (25 Nm), first and then shaft joint bolt (lower shaft assembly side) to 18 ft. lbs. (25 Nm).
  16.  

Upper Shaft




WARNING
Never turn steering wheel while steering column is removed or shafts are removed. Turning steering wheel more than about two and a half turns will break contact coil.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Turn steering wheel so that vehicle-s front tires are at straight-ahead position.
  4.  
  5. Turn ignition switch to LOCK position and remove key.
  6.  
  7. Make alignment marks on shaft joint and shaft (upper shaft assembly side) for a guide during reinstallation.

    Click image to see an enlarged view

    Fig. Steering shaft alignment marks

  8.  
  9. After removing bolt on upper shaft assembly side of shaft joint and loosening bolt on its lower shaft assembly side, move shaft joint to lower shaft assembly side.

    Click image to see an enlarged view

    Fig. Sliding shaft joint

  10.  
  11. Remove steering upper shaft upper joint bolt and nut and disconnect steering upper shaft upper joint.
  12.  
  13. Remove steering upper shaft mounting bolts.
  14.  
  15. Remove steering upper shaft assembly from vehicle.

    Click image to see an enlarged view

    Fig. Upper shaft assembly

  16.  

To install:

  1. Be sure that front tires and steering wheel are in straight-ahead position.
  2.  
  3. Install steering upper shaft assembly to dash panel.
  4.  
  5. Tighten steering upper shaft mounting bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. Align cutting point A of steering column assembly with bolt hole A of steering upper shaft upper joint as shown in the figure. Then connect steering upper shaft upper joint.

    Click image to see an enlarged view

    Fig. Column cutting point A-bolt hole B

  8.  
  9. Install new steering upper shaft upper joint bolt and nut. Tighten steering upper shaft upper joint nut to 17 ft. lbs. (23 Nm).
    NOTE
    Do not reuse steering upper shaft upper joint bolt and nut. Be sure to use new bolt and nut when installing.

  10.  
  11. Install steering shaft joint to steering upper shaft by matching it to marks made before removal.
  12.  
  13. Install shaft joint bolt (upper shaft assembly side) to steering shaft joint.
  14.  
  15. Tighten shaft joint bolt (upper shaft assembly side) 17 ft. lbs. (23 Nm), first and then shaft joint bolt (lower shaft assembly side) to 18 ft. lbs. (25 Nm).
  16.  

 
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