2001 SUZUKI GRAND VITARA clutch

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

1B-42 AIR CONDITIONING (OPTIONAL)
5) Using special tool, remove circlip.
Special tool
(A) : 09900-06107
6) Remove magnet clutch lead wire clamp screw, and remove
magnet clutch read wire ground terminal.
7) Remove magnet clutch with puller.
8) Remove circlip using special tool.
Special tool
(A) : 09900-06107
9) Remove magnet clutch coil (1).
INSTALLATION
1) Install magnet clutch coil (2).
2) Using special tool, install new circlip (1) as shown.
Special tool
(A) : 09990-06107
3) Install clamp portion and ground terminal of lead wire.
NOTE:
Be careful not to damage pulley when tapping magnet
clutch.
1. Puller
2. Compressor
NOTE:
Protrusion on under side of magnet clutch coil (2) must
match hole in compressor assembly (3) to prevent move-
ment and correctly locate lead wire.

AIR CONDITIONING (OPTIONAL) 1B-43
4) Install magnet clutch (1).
a) Set magnet clutch squarely over clutch installation boss.
b) Place special tool onto clutch bearing.
Ensure that edge rests only on inner race of bearing.
Special tool
(A) : 09991-06010
c) Install new circlip.
5) Adjust clearance between armature plate (1) and magnet
clutch (2) by putting shim(s) on compressor shaft.
Standard clearance between armature plate and magnet
clutch “a” :
0.35 - 0.6 mm (0.014 - 0.023 in.)
6) Tighten new armature plate nut (1) to specified torque.
Tightening torque
Armature plate nut (a) :18 N·m (1.8 kg-m, 13.0 lb-ft)
Special tool
(A) : 09920-53740
7) Install compressor to vehicle. Refer to “COMPRESSOR
ASSEMBLY” in this section. CAUTION:
Be careful not to scratch bearing seal.
“a”
1
2
2. Armature plate
1, (a)
2(A)

1B-44 AIR CONDITIONING (OPTIONAL)
Required Service Materials
Tightening Torque Specification
Special Tools
MaterialRecommended SUZUKI product
(Part Number)Use
Compressor oil (refrigerant oil) COMPRESSOR OIL (ND-OIL8, 250 cc)
(99000-27080)O-ring
Each component
Fastening partTightening torque
Nm kg-m lb-ft
Refrigerant pipe (8 mm (0.31 in.)) 13 1.3 9.5
Refrigerant pipe (12.7 mm (0.5 in.)) 22 2.2 16.0
Refrigerant pipe (16 mm (0.63 in.)) 33 3.3 24.0
Armature plate nut 18 1.8 13.0
09900-06107 09920-53740 09990-06010
Snap ring pliers
(Opening type)Armature plate holder Manifold gauge set
See NOTE below.
09990-86011 09991-06010
Gas leak detector Magnet clutch pulley
installer
NOTE:
This kit includes the following items.
1. Manifold gauge, 2. Changing hose, 3. Quick connector, 4. Refrigerant container tap valve,
5. Refrigerant container T joint, 6. Packing set

6-1-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
PNP SIGNAL (Transmis-
sion Range Switch) (for 4-
A/T)With ignition switch ON, selector lever in “P”
or “N” positionP/N Range
✱
With ignition switch ON, selector lever in “R”,
“D”, “2” or “L” positionD Range
FUEL TANK LEVEL Ignition switch ON 0 – 100 %✱
ELECTRIC LOAD Ignition ON, small light OFF OFF✱
Ignition switch ON, small light ON ON✱
VSS (Vehicle speed sen-
sor) (for 4-A/T)At stop.
0 km/h 0 MPH✱
GEAR POSITION (for 4-
A/T)Ignition switch ON, selector lever is shifted at
“R”, “D”, “2” or “L” range and vehicle stops.1st✱
THROT POS LEVEL
(Throttle position level for
4-A/T)“0” (about idle position), “1”,“2”,“3”,“4”,“5”,“6” or “7” (about full open)
appears according to throttle valve opening.✱
SHIFT SOL #1 (A)
CON (Shift solenoid #1
command signal)
MON (Shift solenoid #1
monitor) (for 4-A/T)Ignition switch ON
Selector lever is shifted at “P”, “R”, “N”, “D”,
“2” or “L” range.
Vehicle stops.ON✱
SHIFT SOL #2 (B)
CON (Shift solenoid #2
command signal)
MON (Shift solenoid #2
monitor) (for 4-A/T)Ignition switch ON
Selector lever is shifted at “P”, “R”, “N”, “D”,
“2” or “L” range.
Vehicle stops.OFF✱
TCC SOL (for 4-A/T)
CON (Torque converter
clutch solenoid command
signal)
MON (Torque converter
clutch solenoid monitor)Ignition switch ON
Selector lever is shifted at “P”, “R”, “N”, “D”,
“2” or “L” range.
Vehicle stops.OFF✱
TRANS RANGE
(for 4-A/T)Ignition switch ON, selector lever is at “P”,
“R”, “N”, “D”, “2” or “L” range.P, R, N, D, 2 or L✱
BRAKE SW
(Brake, stop lamp, switch)
(for 4-A/T)Ignition switch ON, Brake pedal is released. OFF
✱
Ignition switch ON, Brake pedal is
depressed.ON
O/D OFF SW
(Overdrive cut switch)Ignition switch ON, Overdrive cut switch OFF OFF
✱
Ignition switch ON, Overdrive cut switch ON ON
MODE SELECT SW
(Power/Normal change
switch) (for 4-A/T)Ignition switch ON, P/N change switch is at
normal position.NORMAL
✱
Ignition switch ON, P/N change switch is at
power position.POWER
4WD-L SW
(4WD low switch)Ignition switch ON, Transfer lever is shifted
at “4H” or “2H” position.OFF
✱
Ignition switch ON, Transfer lever is shifted
at “4L” position.ON SCAN TOOL DATA CONDITIONNORMAL CONDITION/
REFERENCE VALUEOTHER

6-1-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
SHIFT SOL #2 CON/MON (Shift Solenoid #2, B Command/monitor, ON/OFF)
CON-ON : ON command being output to shift solenoid #2, B.
CON-OFF : ON command not being output.
MON-ON : Electricity being passed to shift solenoid #2, B.
MON-OFF : Electricity not being passed.
TCC SOL CON/MON (Torque Converter Clutch Solenoid Command/monitor, ON/OFF)
CON-ON : ON command being output to TCC solenoid.
CON-OFF : ON command not being output.
MON-ON : Electricity being passed to TCC solenoid.
MON-OFF : Electricity not being passed.
TRANS RANGE (Transmission Range, P, R, N, D, 2 or L)
It indicates transmission range according to transmission range switch signal.
BRAKE SW (Brake, Stop Lamp, Switch, ON/OFF)
OFF : Brake pedal is released.
ON : Brake pedal is depressed.
O/D OFF SW (Overdrive Cut Switch, ON/OFF)
OFF : Overdrive cut switch OFF.
ON : Overdrive cut switch ON.
MODE SELECT SW (Power/normal Change Switch, Power/normal)
POWER : Switch button is at POWER position.
NORMAL : Switch button is at NORMAL position.
4WD-L SW (4WD-LOW Switch, ON/OFF)
ON : Transfer lever is shifted to 4L position.
OFF : Transfer lever is shifted to 4H or 2H position.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-31
Engine Diagnosis Table
Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality
has been found in visual inspection and engine basic inspection previously.
Condition Possible Cause Correction
Hard starting
(Engine cranks OK)Faulty idle air control system “DIAG. FLOW TABLE B-4” in this
section.
Faulty ECT sensor or MAF sensor ECT sensor or MAF sensor in Sec-
tion 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Low compression Compression check in Section
6A2.
Faulty hydraulic valve lash adjuster Valve lash adjuster in Section 6A2.
Compression leak from valve seat Valves inspection in Section 6A2.
Sticky valve stem Valves inspection in Section 6A2.
Weak or damaged valve springs Valves spring inspection in Section
6A2.
Compression leak at cylinder head gasket Cylinder head inspection in Section
6A2.
Sticking or damaged piston ring Piston ring inspection in Section
6A2.
Worn piston, ring or cylinder Cylinders, pistons and piston rings
inspection in Section 6A2.
Malfunctioning PCV valve PCV system inspection in Section
6E2.
Engine has no power
Engine overheating Refer to “OVERHEATING” in this
table.
Defective spark plug Spark plugs in Section 6F2.
Faulty ignition coil with ignitor Ignition coil in Section 6F2.
Fuel pressure out of specification
(dirty fuel filter, dirty or clogged fuel hose or
pipe, malfunctioning fuel pressure regulator,
malfunctioning fuel pump)“DIAG. FLOW TABLE B-3” in this
section.
Maladjusted TP sensor installation angle TP sensor in Section 6E2.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty injector Fuel injector in Section 6E2.
Faulty TP sensor, ECT sensor or MAF sensor TP sensor, ECT sensor or MAF
sensor in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Low compression Refer to the same item in “HARD
STARTING” of this table.
Dragging brakes Diagnosis in Section 5.
Slipping clutch Diagnosis in Section 7C1.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-33
Surges
(Engine power varia-
tion under steady
throttle or cruise.
Feels like the vehicle
speeds up and down
with no change in the
accelerator pedal.)Defective spark plug
(excess carbon deposits, improper gap, and
burned electrodes, etc.)Spark plugs in Section 6F2.
Variable fuel pressure
(clogged fuel filter, kinky or damaged fuel hose
and line, faulty fuel pressure regulator)“DIAG. FLOW TABLE B-3” in this
section.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty MAF sensor MAF sensor in Section 6E2.
Faulty injector Fuel injector in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Excessive detonation
(The engine makes
sharp metallic knocks
that change with throt-
tle opening. Sounds
like pop corn pop-
ping.)Engine overheating Refer to “OVERHEATING” in this
table.
Faulty spark plug Spark plugs in Section 6F2.
Improper ignition timing Ignition timing in Section 6F2.
Clogged fuel filter and fuel lines Fuel pressure check in Section
6E2.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty ECT sensor or MAF sensor ECT sensor or MAF sensor in Sec-
tion 6E2.
Faulty injector Fuel injector in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Excessive carbon deposits in combustion
chamberPiston and cylinder head cleaning
in Section 6A2.
Poor knock sensor performance “DTC P0325 DIAG. FLOW TABLE”
in this section.
Overheating
Inoperative thermostat Thermostat in Section 6B.
Poor water pump performance Water pump in Section 6B.
Clogged or leaky radiator Radiator in Section 6B.
Improper engine oil grade Engine oil and oil filter change in
Section 0B.
Clogged oil filter or oil strainer Oil pressure check in Section 6A2.
Poor oil pump performance Oil pressure check in Section 6A2.
Dragging brakes Diagnosis in Section 5.
Slipping clutch Diagnosis in Section 7C1.
Blown cylinder head gasket Cylinder head inspection in Section
6A2. Condition Possible Cause Correction