1999 SUZUKI GRAND VITARA Stall

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-55
1. Armature plate
4) Clutch pulley (1).
(1) Set clutch pulley squarely over clutch pulley installation boss.
(2) Place special tool (D) onto clutch pulley bearing.
Ensure that edge rests only on inner race of bearing.
(3) Install snap ring.
Special Tool
(D): 09991-06010
CAUTION:
Be careful not to scratch bearing seal.
5) Adjust clearance, between clutch plate (1) and clutch pulley by
putting shim on compressor shaft.
Standard clearance ªaº: 0.3 ± 0.5 mm (0.012 ± 0.02 in.)
6) Tighten new clutch plate bolt as specified below.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
Special Tool
(A): 09991-06020

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-57
3) Using special tool (B), remove clutch plate (1).
Special Tool
(B): 09991-06030
4) Disconnect clutch coil lead wire from compressor thermal switch
led wire.
5) Remove felt ring (if equipped) and shims from shaft.
6) Using special tool (C), remove circlip.
Special Tool
(C): 09900-06107
7) Remove clutch coil lead wire clamp screw.
8) Remove clutch pulley with puller (1) from compressor (2).
NOTE:
Be careful not to damage pulley when tapping magnet
clutch.
9) Remove clutch coil.
INSTALLATION
1) Install clutch coil (2).
Protrusion on under side of clutch coil must match hole in com-
pressor (3) to prevent movement ant correctly locate lead wire.
2) Using special tool (C), install snap ring (1) as shown.
Special Tool
(C): 09990-06107
3) Clamp covering portion of lead wire.

YH4
GRAND
VITARA
3. Washer
(if equipped)
1B-58 AIR CONDITIONING (OPTIONAL)
4) Install clutch pulley (1).
(1) Set clutch pulley squarely over clutch pulley installation boss.
(2) Place special tool (D) onto clutch pulley bearing.
Ensure that edge rests only on inner race of bearing.
(3) Install snap ring.
Special Tool
(D): 09991-06010
CAUTION:
Be careful not to scratch bearing seal.
5) Adjust clearance, between clutch plate and clutch pulley (2) by
putting shim on compressor shaft.
Standard clearance ªaº: 0.3 ± 0.6 mm (0.012 ± 0.024 in.)
6) Tighten new clutch plate (1) bolt (2) as specified below.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
Special Tool
(A): 09991-06020

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-59
PUSH
3. Cylinder
4. Case
5. O-ring
2. Bearing puller
LIP TYPE SEAL (FOR SEIKO SEIKI)
REMOVAL
1) Remove magnet clutch assembly, referring to ªMAGNET
CLUTCH ASSEMBLYº in this section.
2) Remove compressor front head (1) mounting bolt (10 pcs.).
3) Remove compressor front head (1) by pushing cylinder shaft
(2).
NOTE:
Be careful not to remove cylinder from case.
4) Remove O-ring.
5) Remove lip seal from compressor front head (1).
INSTALLATION
1) Press-fit lip seal (1) into compressor front head (2) using special
tool (E).
Special Tool
(E): 09991-06050
CAUTION:
Do not reuse mechanical seal once removed from com-
pressor.

YH4
GRAND
VITARA
1B-60 AIR CONDITIONING (OPTIONAL)
1. Front head
2) Coat special tool (F) surface with oil and place it on the shaft.
Special Tool
(F): 09991-06040
3) Install O-ring (2) to case.
4) Apply compressor (refringent) oil to lip seal and O-ring.
5) Install compressor front head (1).
6) Tighten compressor front head bolt.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
NOTE:

Be sure to use new front head bolt washer.

Tighten bolt (a) first, and next (b).

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-61
09900-06107
Snap ring pliers
(Opening type)09991-06010
Magnet clutch pulley installer09991-06020
Armature plate spanner09991-06030
Armature plate remover
09991-06040
Lip type seal protector09991-06050
Lip type seal installer
REQUIRED SERVICE MATERIAL
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Compressor oil for DENSO
compressor (Refrigerant oil)COMPRESSOR OIL (ND-OIL 8, 250 cc)
99000-27080
O-ring

Each component
Compressor oil for
SEIKO SEIKI compressor
(Refrigerant oil)COMPRESSOR OIL RS20 (150 cc)
99000-99088-00D
O-ring

Each component
RefrigerantREFRIGERANT DRUM (200 g)
95794-50G00
Refrigerant charge
SPECIAL TOOLS

YH4
GRAND
VITARA
INFLATE TIRES TO
RECOMMENDED PRESSURE
ROAD TEST VEHICLE ON LEVEL
UNCROWNED ROAD IN
BOTH DIRECTIONS
SWITCH FRONT TIRES
SIDE TO SIDE AND
ROAD TEST AGAIN
LEADS IN SAME
DIRECTIONLEAD CORRECTED
IF ROUGHNESS RESULTS,
REPLACE TIRESLEAD REVERSES
DIRECTION
PUT TIRES BACK IN
ORIGINAL POSITION
AND CHECK ALIGNMENTINSTALL A KNOWN GOOD TIRE ON
ONE FRONT SIDE
LEAD CORRECTED
REPLACE TIRELEAD REMAINS
INSTALL A KNOWN GOOD TIRE IN
PLACE OF OTHER FRONT TIRE
LEAD CORRECTED
REPLACE TIRELEAD REMAINS
KNOWN GOOD TIRES ARE NOT GOOD
STEERING, SUSPENSION, WHEELS AND TIRES 3-7
1. Ride vehicle to determine if the waddle is coming from the front
or rear.
2. Install tires and wheels that are known to be good (on similar ve-
hicle) in place of those on the offending end of the vehicle. If the
waddle cannot be isolated to front or rear, substitute the rears.
3. Road test again. If improvement is noted, install originals one at
a time until offender is found. If no improvement is noted, install
known good tires in place of all four. Then install originals one
at a time until offender if found.

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-5
DIAGNOSIS
GENERAL DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Steering wheel
feels heavy
(at low speed)
Fluid deteriorated, low viscosity, different
type of fluid mixed

Pipes or hoses deformed, air entering
through joint

Insufficient air purging from P / S circuit

P / S belt worn, lacking in tension

Tire inflation pressure excessively low

Front end alignment out of order

Steering wheel installed improperly (twisted)

Bind in tie rod or tie rod end ball joint

P / S pump hydraulic pressure fails to increase

P / S pump hydraulic pressure increases
but slowly

Steering gear box malfunctionReplace fluid.
Replace defective part.
Purge air.
Adjust belt tension or replace
belt as necessary.
Inflate tire.
Check and adjust front end
alignment.
Install steering wheel correctly.
Replace defective part.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.
Steering wheel
feels heavy
momentarily when
turning it to the
left or right
Air drawn in due to insufficient amount
of fluid

Slipping P / S belt

P / S pump hydraulic pressure fails to
increase

P / S pump hydraulic pressure increases
but slowly

Steering gear box malfunctionAdd fluid and purge air.
Adjust belt tension or replace
belt as necessary.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.
Poor recovery
from turnsNOTE:
To check steering wheel for recovery, with vehicle running at 22 mile / h (35 km / h),
turn steering wheel 90 and let it free. It should return more than 60.

Deformed pipes or hoses

Steering column installed improperly

Front end alignment out of order

Ball joints binding

P / S pump hydraulic pressure fails to
increase

P / S pump hydraulic pressure increases
but slowly

Steering gear box malfunctionReplace defective part.
Install steering column correctly.
Check and adjust front end
alignment.
Replace defective part.
Check pressure and repair or
replace defective part.
Check pressure and repair or
replace defective part.
Replace gear box.