2001 SUZUKI GRAND VITARA Operation

AIR CONDITIONING (OPTIONAL) 1B-41
Magnet Clutch
INSPECTION
Check the following items.
Check no sigh of compressor oil leakage
Check magnet clutch pulley bearing for noise and grease
leakage.
Check magnet clutch operation as follows :
a) Connect battery (1) and ammeter (2) to compressor (3) as
shown.
b) Check that steadily locks between armature plate (4) and
magnet clutch pulley (5).
c) Check that ammeter (2) indicates specified current.
Specified current of magnet clutch :
4A MAX at 12V
If any detects are found, repair or replace magnet clutch assem-
bly.
REMOVAL
1) Remove compressor from vehicle. Refer to “COMPRESSOR
ASSEMBLY” in this section.
2) Fix armature plate (1) with special tool and remove armature
plate bolt.
Special tool
(A) : 09920-53740
3) Remove armature plate (1).
4) Remove shims from shaft.
1. Armature plate bolt 3. Circlip 5. Shim (s) 7. Compressor body assembly
2. Armature plate 4. Magnet clutch 6. Magnet clutch coil 8. Magnet clutch assembly
1234367
5
8
3
2
1 5 4
NOTE:
Do not reuse armature plate bolt.
(A)1

POWER STEERING (P/S) SYSTEM 3B1-3
Hydraulic Pressure in P/S Circuit
Hydraulic pressure check
1) After cleaning joint of high pressure hose and P/S pump
thoroughly, disconnect hose from pump and install special
tool (oil pressure gauge, attachment and hose).
Special tool
(A) : 09915-77410
(B) : 09915-77420
2) Check each connection for fluid leakage and bleed air.
Refer to “AIR BLEEDING PROCEDURE” in this section.
3) With engine idling, turn steering wheel and warm up engine
till temperature of fluid in P/S fluid reservoir rises to 50 –
60°C (122 – 140°F).
4) Check back pressure by measuring hydraulic pressure with
engine idling and hands off steering wheel.
When back pressure is higher than specified values, check
control valve and piping for clogging.
Back pressure :
Lower than 1000 kPa (10 kg/cm
2, 142 psi) CAUTION:
Take care not to cause damage to A/C condenser during
service operation, if equipped.
1. P/S fluid reservoir
2. Attachment
3. Gasket
4. Union bolt
5. High pressure side
6. Low pressure side
1. P/S fluid reservoir 4. P/S gear box
2. Gauge valve (open) 5. High pressure side
3. P/S pump 6. Low pressure side

3C1-2 AIR BAG STEERING WHEEL AND COLUMN
General Description
This double tube type steering column has the following three important features in addition to the steering func-
tion:
The column is energy absorbing, designed to compress in a front-end collision.
The ignition switch and lock are mounted conveniently on this column.
With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehi-
cle.
To insure the energy absorbing action, it is important that only the specified screws, bolts, and nuts be used as
designated and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the one recom-
mended in this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping
the assembly could shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver’s and passenger’s seat belts by deploying the air bags. The air bag (inflator) module
should be handled with care to prevent accidental deployment. When servicing, be sure to observe all WARN-
INGS in this section. Refer to “SERVICE PRECAUTIONS” in Section 10B.
1. Driver air bag (inflator) module 5. Steering column upper cover 9. Steering column hole cover 13. Steering column lower seal
2. Steering wheel 6. Steering column lower cover 10. Steering shaft joint 14. Cap (if equipped)
3. Steering wheel nut 7. Steering column assembly 11. Steering lower shaft assembly 15. Steering upper shaft assembly
4. Contact coil and combination
switch assembly8. Steering lock assembly 12. Adjustable steering column
release lever

AIR BAG STEERING WHEEL AND COLUMN 3C1-5
6) Remove steering upper shaft upper joint bolt (1) and nut (2)
and disconnect steering upper shaft upper joint removing in
arrow direction in the figure.
7) Remove steering column (1) mounting bolts (2 pieces) (2)
and nuts (2 pieces) (3).
8) If equipped with shift (key) interlock cable (1), remove shift
(key) interlock cable screw (2) and then disconnect its cable
(1) from ignition switch.
9) Remove steering column from vehicle.
INSPECTION
Check steering column for damage and operation referring to
CHECKING STEERING COLUMN AND STEERING UPPER
SHAFT FOR ACCIDENT DAMAGE later in this section.
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight-
ahead position.
2) If equipped with shift (key) interlock cable (1), install shift
(key) interlock cable (1) to ignition switch.
Tightening torque
Shift (key) interlock cable screw (a) :
2.2 N·m (0.22 kg-m, 1.6 lb-ft)
1
2
1
32
CAUTION:
After tightening steering column mounting bolts, steer-
ing shaft joint bolts should be tightened.

3C1-8 AIR BAG STEERING WHEEL AND COLUMN
INSPECTION
Check steering shaft damage and operation referring to CHECK
STEERING COLUMN AND STEERING UPPER SHAFT FOR
ACCIDENT DAMAGE later in this section.
INSTALLATION
1) Be sure that front tires and steering wheel are in straight
ahead position.
2) Install steering upper shaft assembly to dash panel. Tighten
steering upper shaft mounting bolts (1) to specified torque.
Tightening torque
Steering upper shaft mounting bolts (a) :
23 N·m (2.3 kg-m, 17.0 lb-ft)
3) Install steering shaft joint (1) to steering upper shaft (2) by
matching it to marks (3) made before removal.
4) Install shaft joint bolt (upper shaft assembly side) (2) to
steering shaft joint (1). Tighten shaft joint bolt (upper shaft
assembly side) (2) to specified torque first and then shaft
joint bolt (lower shaft assembly side) (3) to specified torque.
Tightening torque
Steering shaft joint bolt (c) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
5) Align cutting point “A” of steering column assembly (1) with
bolt hole “B” of steering upper shaft upper joint as shown in
the figure. Then connect steering upper shaft upper joint.
1, (a)
“B”
“A”
1

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-3
On-Vehicle Service
Front Brake Hose/Pipe
REMOVAL
1) Raise and suitably support vehicle. Remove tire and wheel.
This operation is not necessary when removing pipes connecting master cylinder and flexible hose.
2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.
INSTALLATION
1) Reverse removal procedure for brake hose and pipe installation procedure.
For installation, make sure that steering wheel is in straightforward position and hose has no twist or kink.
Check to make sure that hose doesn't contact any part of suspension, both in extreme right and extreme left
turn conditions. If it does at any point, remove and correct. Fill and maintain brake fluid level in reservoir.
Bleed brake system.
2) Perform brake test and check installed part for fluid leakage.
Tightening torque
Brake pipe flare nut (a) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
Brake flexible hose bolt (brake caliper/2 joint) (b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
2-way joint mounting bolt (c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Brake hose/pipe bracket bolt (c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
ABS actuator bracket bolt (c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
ABS actuator mounting bolt (d) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
NOTE:
Insert E-ring till its end surface is flush with or lower than bracket end surface.

5C-2 PARKING AND REAR BRAKE
General Description
Drum Brake Assembly
The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main-
tained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is
depressed and when parking brake is applied on level road.
It also uses duo servo operation when parking brake is applied on gradient road and load is applied in longitudi-
nal direction of vehicle.
NOTE:
Replace all components included in repair kits to service this drum brake. Lubricate parts as speci-
fied.
WARNING:
If any hydraulic component is removed or brake line disconnected, bleed the brake system. The
torque values specified are for dry, unlubricated fasteners.
1. Brake back plate 6. Adjuster lever 11. Link
2. Brake shoe 7. Adjuster spring 12. Brake strut
3. Shoe return upper spring 8. Shoe hold down spring Tightening torque
4. Adjuster 9. Shoe hold down pin
5. Shoe return lower spring 10. Wheel cylinder

5C-6 PARKING AND REAR BRAKE
4) Tighten brake back plate nuts to specified torque.
Tightening torque
Brake back plate nut (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
5) Install wheel cylinder, and tighten wheel cylinder bolts and
brake pipe flare nut (or nuts) to specified torque.
Tightening torque
Wheel cylinder bolt :
13.5 N·m (1.35 kg-m, 10.0 lb-ft)
Brake pipe flare nut : 16 N·m (1.6 kg-m, 12.0 lb-ft)
6) Install parking brake cable (3) to brake back plate (1) and
tighten parking brake cable nut (2) to specified torque.
Tightening torque
Parking brake cable nut (a) : 10 N·m (10 kg-m, 7.5 lb-ft)
7) Install brake shoes, referring to steps 1) to 4) of “INSTALLA-
TION” under “BRAKE SHOE” in this section.
8) Install brake drum. Refer to steps 1) to 2) of “INSTALLA-
TION” under “BRAKE DRUM” in this section.
9) Refill differential housing with new specified gear oil. Refer to
“ON-VEHICLE SERVICE” in Section 7F for refill.
10) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “BLEEDING BRAKE” in Section
5).
11) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nut (b) : 100 N·m (10.0 kg-m, 72.5 lb-ft)
12) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load 3 to 10 times so as to obtain proper drum-
to shoe clearance.
Adjust parking brake cable. (For adjustment, refer to “PARK-
ING BRAKE CHECK AND ADJUSTMENT” in Section 5).
13) Tighten parking brake lever cover screws.
14) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
15) Check each installed part for oil leakage.
(a)