2000 SUZUKI GRAND VITARA Crank

YH4
GRAND
VITARA
0B-24 MAINTENANCE AND LUBRICATION
FINAL INSPECTION
Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
If ªREPLACE BELTº label on front seat belt is visible,
replace belt.
Check that seat belt is securely locked.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat-
tery condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by and other part.
Engine Start
Check engine start for readiness.
On automatic transmission vehicles, try to start the
engine in each select lever position. The starting mo-
tor should crank only in ªPº (Park) or ªNº (Neutral).
On manual transmission vehicles, place the shift le-
ver in ªNeutral,º depress clutch pedal fully and try to
start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (For Manual transmission)
Check for the following:

Clutch is completely released when depressing
clutch pedal.

No slipping clutch occurs when releasing pedal and
accelerating.

Clutch itself is free from any abnormal condition.
Gearshift or Select Lever (Transmission)
Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis-
sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.
With automatic transmission equipped vehicle, make
sure that vehicle is at complete stop when shifting se-
lect lever to ªPº range position and release all brakes.
Brake
[Foot brake]
Check the following:

that brake pedal has proper travel,

that brake works properly,

that it is free from noise,

that braking force is applied equally on all wheels,

and that brake do not drag.
[Parking brake]
Check that lever has proper travel.
WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly
even if vehicle should start to move.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.
WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the vehicle could move without warn-
ing and possibly cause personal injury or
property damage.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-9
ABNORMAL NOISE FROM CRANKSHAFT PULLEY
ConditionPossible CauseCorrection

A large rattling noise is heard at
idle or sudden acceleration.
Loosen pulley mounting bolt.

Worn or broken bearings.
Retighten bolt.

Replace bearings.
ABNORMAL NOISE FROM TENSION PULLEY
ConditionPossible CauseCorrection

Clattering noise is heard from
pulley.

Pulley cranks upon contact.
Worn or damaged bearings.

Cracked or loose bracket.
Replace bearings.

Replace or retighten bracket.
ABNORMAL NOISE FROM EVAPORATOR
ConditionPossible CauseCorrection

Whistling sound is heard from
evaporator.
Depending on the combination of
the interior / exterior
temperatures, engine rpm and
refrigerant pressure, the
refrigerant flowing out of the
expansion valve may, under
certain conditions, make a
whistling sound.
At times, slightly decreasing
refrigerant volume may stop this
noise.

Inspect expansion valve and
replace if faulty.
ABNORMAL NOISE FROM BLOWER MOTOR
ConditionPossible CauseCorrection

Blower motor emits a chirping
sound in proportion to its speed of
rotation.

Fluttering noise or large droning
noise is heard from blower motor.
Worn or damaged motor brushes
or commutator.

Leaves or other debris
introduced from fresh air inlet to
blower motor.
Repair or replace blower motor.

Remove debris and make sure
that the screen at fresh air inlet is
intact.

YH4
GRAND
VITARA
J20 engine
H25 engine G16 engine
1. Generator belt
2. Compressor drive belt3. Compressor pulley
4. Crankshaft pulley
1B-22 AIR CONDITIONING (OPTIONAL)
DRIVE BELT
INSPECTION
For G16 and H25 engines
Refer to Section 3B1 for details.
For J20 engine
Refer to Section 6H for details.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-51
G16 engine
J20 engine
H25 engine
3. Compressor pulley
4. Crankshaft pulley
INSTALLATION
FOR IWATA PRODUCTION VEHICLE
1) Pour new compressor oil. The amount must be the same with
the amount measured in REMOVAL.
NOTE:
Compressor assembly supplied from factory is filled up
with following amount of oil.
Amount of oil in compressor: 120 cm
3 (120 cc, 7.5 in3)
2)For G16 engine:
Install compressor assembly temporarily to bracket, then install
compressor drive belt (2).
For J20 and H25 engines:
Install compressor assembly to its bracket.
Tighten bolts (a) first, then (b).
Tightening Torque
(a), (b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Connect suction and discharge hoses to compressor assembly.
4)For G16 engine:
Tension compressor drive belt (2) by tightening compressor as-
sembly mounting bolts. Refer to Section 3B1 for drive belt ten-
sion.
Tighten bolt (a) first, then (b).
Tightening Torque
(a), (b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
For J20 engine:
Install generator belt (1). Refer to Section 6H for details.
For H25 engine:
Install compressor drive belt (2). Refer to Section 3B1 for instal-
lation and belt tension.
5) Connect thermal protector lead wire.
6) Evacuate and charge system according to previously described
procedure.
CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.

YH4
GRAND
VITARA
1B-52 AIR CONDITIONING (OPTIONAL)
G16 engine
J20 engine
3. Compressor pulley
4. Crankshaft pulley
FOR CAMI PRODUCTION VEHICLE
1) Pour new compressor oil. The amount must be the same with
the amount measured in REMOVAL.
NOTE:
Compressor assembly supplied from factory is filled up
with the following amount of oil.
Amount of oil in compressor: 120 cm
3 (120 cc, 7.5 in3)
2)For G16 engine:
Install compressor assembly temporarily to bracket, then install
compressor drive belt (2).
For J20 engine:
Install compressor assembly to its bracket.
Tighten bolts (a).
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Connect suction and discharge hoses to compressor assembly.
4)For G16 engine:
Tension compressor drive belt (2) by tightening compressor as-
sembly mounting bolts. Refer to Section 3B1 for drive belt ten-
sion.
Tighten bolt (a) first, then (b).
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
For J20 engine:
Install generator belt (1). Refer to Section 6H for details.
5) Connect thermal protector lead wire.
6) Evacuate and charge system according to previously described
procedure.
CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.

YH4
GRAND
VITARA
1. Suction connector
2. O-ring
3. Pressure switch
4. Flow control valve
(Relief valve)
5. Spring
6. Plug
7. Pump cover
8. Cam ring
9. Vane
10. Rotor
11. Snap ring
12. Side plate
13. Pulley (pump shaft)
14. Oil seal
15. Pump body
16. Flow control valve Assembly
3B1-4 POWER STEERING (P / S) SYSTEM
POWER STEERING (P / S) PUMP
The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft.
ModelVane type
Hydraulic
pressure
controlRelieved
pressure
6500 kPa (65 kg / cm2, 924 psi)
G16 Type engine . . . . . . . . . . . . . . . . . . . . . .
7000 kPa (70 kg / cm
2, 995 psi)
J20 Type engine . . . . . . . . . . . . . . . . . . . . . . .
7350 kPa (73.5 kg / cm
2, 1045 psi)
H25 Type engine . . . . . . . . . . . . . . . . . . . . . .
ControlFlow control valve
deviceRelief valve
Power steering
pressure switch
Switch turns on (closes) when the
pressure is higher than 2500 ± 3500 kPa
(25 ± 35 kg / cm
2, 356 ± 498 psi).
ECM uses this signal for idle speed control.
Capacity0.70 ± 0.75

(1.48 / 1.23 ± 1.58 / 1.32 US / Imp. pt)
Specified fluidDEXRON
II, DEXRON
III A / T fluid
or equivalent
FLOW CONTROL VALVE
As the discharge rate of the P/S pump increases in proportion to the
pump revolution speed, a flow control valve is added to control it so
that the optimum amount of fluid for steering operation is supplied
according to the engine speed (driving condition).
Described below is its operation at different engine speed.

YH4
GRAND
VITARA
[D] [C] [A]
1. P / S pump pulley
2. A / C compressor
pulley (if equipped)
3. Crankshaft pulley
4. Tension pulley
5. Tension pulley bolts[A]: G16 type engine with A / C
[B]: G16 type engine without A / C
[C]: H25 type engine with A / C
[D]: H25 type engine without A / C
[B]
3B1-8 POWER STEERING (P / S) SYSTEM
POWER STEERING PUMP DRIVE BELT
NOTE:
For J20 Type engine, refer to Section 6H ªGENERATOR BELTº.
INSPECTION
Check that belt is free from any damage and properly fitted in pulley
groove.
BELT TENSION CHECK
Check belt tension by measuring how much it deflects when
pushed at intermediate point between pulleys with about 10 kg
(22 lb) force.
Deflection of P / S belt:
6 ± 9 mm (0.24 ± 0.35 in.) G16 Type engine. . . . . . . . . . . . . . . . .
4 ± 7 mm (0.16 ± 0.28 in.) H25 Type engine. . . . . . . . . . . . . . . . .
BELT TENSION ADJUSTMENT
[For G16 Type engine]
a) To adjust P / S pump drive belt tension, use adjusting bolt of com-
pressor for A / C equipped vehicles and that of P / S pump for ve-
hicles without A / C.
b) Adjust belt tension to above specification.
c) Then tighten adjusting and mounting bolts to specified torque.
[For J20 Type engine]
To adjust P / S pump drive belt tension, refer to ªGENERATOR
BELTº in Section 6H.
[For H25 Type engine]
a) To adjust P / S pump drive belt tension, loosen tension pulley
bolts and turn tension pulley using hexagon wrench.
b) Adjust belt tension to above specification.
Then tighten tension pulley bolts to specified torque.
Tightening Torque
Tension pulley bolts: 25 N
.m (2.5 kg-m, 18.5 lb-ft)

YH4
GRAND
VITARA
1. Crankshaft
2. Flywheel
3. Clutch disc
4. Pressure plate
5. Clutch cover
6. Diaphragm spring
7. Release bearing
8. Input shaft bearing
9. Input shaft
10. Operating cylinder
11. Clutch housing
12. Release fork
7C1-2 CLUTCH
The clutch is a diaphragm-spring clutch of a dry single
disc type. The diaphragm spring is of a tapering-finger
type, which is a solid ring in the outer diameter part,
with a series of tapered fingers pointing inward.
The disc, carrying torsional coil springs, is positioned
on the transmission input shaft with an involute spline
fit.
The clutch cover is secured to the flywheel, and car-
ries the diaphragm spring in such a way that the pe-
ripheral edge part of the spring pushes on the pres-
sure plate against the flywheel (with the disc in be-
tween), when the clutch release bearing is held back.
This is the engaged condition of the clutch.Depressing the clutch pedal causes the release bear-
ing to advance and pushes on the tips of the tapered
fingers of the diaphragm spring. When this happens,
the diaphragm spring pulls the pressure plate away
from the flywheel, thereby interrupting the flow of
drive from flywheel through clutch disc to transmis-
sion input shaft.
GENERAL DESCRIPTION