2001 SUZUKI GRAND VITARA service

AIR CONDITIONING (OPTIONAL) 1B-25
On-Vehicle Service
Precaution
When servicing air conditioning system, the following rules must be observed.
Piping
When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling
nuts and O-ring. WARNING:
Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately.
DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S).
Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its
temperature above the freezing point.
Obtain proper treatment as soon as possible from a doctor or eye specialist.
Should liquid refrigerant HFC-134a (R-134a) get on your skin, such affected part should be treated
in the same manner as when skin is frostbitten or frozen.
CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
(For identification between these two types, refer to “REFRIGERANT TYPE” in this section.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
NOTE:
Single A/C model is the same as SQ625 (H25 engine) model. Refer to the same section of the Service
Manual mentioned in FOREWORD of this manual.
[A]: Dual A/C model 1. Suction hose 4. Condenser outlet pipe 7. Front suction pipe
Apply compressor oil (refrigerant oil) to O-ring. 2. Discharge hose 5. Expansion valve 8. Rear liquid pipe
3. Front liquid pipe 6. Dual (refrigerant) pressure switch 9. Rear suction pipe
1
6 43 75
9
8
2 [A]

AIR CONDITIONING (OPTIONAL) 1B-37
Rear A/C No.1 and No.2 Duct
Rear A/C No.1 duct
REMOVAL
1) Remove rear A/C unit referring to “REAR A/C UNIT” in this
section.
2) Remove rear A/C No.1 duct (1).
INSTALLATION
Reverse removal procedure to install rear A/C No.1 duct (1).
Rear A/C No.2 duct
CAUTION:
Never remove rear A/C No.2 duct (2) from head lining.
Performing this prohibited service will break head lining.
1
2

1B-38 AIR CONDITIONING (OPTIONAL)
Compressor Assembly
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.
2) Close Hi (4) and Lo (5) side valves.
3) Run engine at fast idle.
4) Check compressor for the following items.
If any of the above checks indicated a defect, repair com-
pressor.
High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.
Metallic sound.
Leakage from compressor. CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
For identification between these two types, refer to page 66.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect refrigerant or compressor oil will result in leakage of refrigerant, damage in parts or
other faulty condition.
When servicing the compressor, keep dirt or foreign material away from getting on or into the com-
pressor parts and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any “On-
vehicle” repair or before removal of the compressor. The parts must be kept clean at all times and any
parts to be reassembled should be cleaned with Trichloromethane, naphtha, kerosene or equivalent
solvent and dried with dry air. Use only lint free cloths to wipe parts.
The operations described are based on bench overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of accessibility of the components.
When compressor is removed from the vehicle for servicing, the oil remaining in the compressor
should be discarded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair pro-
cedures require that the system be discharged of refrigerant.
2. High pressure side (Delivery side hose)
3. Low pressure side (Suction side pipe)
1
4 5
2
3

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

FRONT END ALIGNMENT 3A-1
3A
SECTION 3A
FRONT END ALIGNMENT
CONTENTS
General Information ........................................3A-1
Alignment Service Data (without Load) ......... 3A-1On-Vehicle Service ......................................... 3A-1
Reference Information .................................. 3A-1

General Information
Alignment Service Data (without Load)
Toe-in (Toe-in gauge measurement) “B” – “A” :
1 ± 2 mm (0.04 ± 0.08 in.)
Camber angle “C” :
0 ± 1° 30’
Caster :
2° 30’ ± 1°
On-Vehicle Service
Reference Information
SIDE SLIP
For inspecting front wheel side slip with side slip tester
Side slip limit :
IN 4 mm/m – OUT 2 mm/m
(IN 0.158 in/3.3 ft – OUT 0.078 in/3.3 ft)
If side slip exceeds above limit, toe-in or front wheel alignment
may out not be correct. NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.
[A] : Top view 1. Center line of wheel✱1. Forward
[B] : Front view✱2. Body center

POWER STEERING (P/S) SYSTEM 3B1-1
3B1
SECTION 3B1
POWER STEERING (P/S) SYSTEM
CONTENTS
General Description ......................................3B1-2
Power Steering (P/S) Pump ........................ 3B1-2
Diagnosis .......................................................3B1-2
Power Steering Pump Drive Belt ................. 3B1-2
Belt inspection ......................................... 3B1-2Belt tension check ................................... 3B1-2
Belt tension adjustment ........................... 3B1-2
Hydraulic Pressure in P/S Circuit ................ 3B1-3
Hydraulic pressure check ........................ 3B1-3 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Man-
ual mentioned in the FOREWORD of this manual.
Some parts in the Power Steering Gear Box cannot be disassembled or adjusted. For detailed infor-
mation, refer to the description of “POWER STEERING GEAR BOX ASSEMBLY”.
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of these parts.

3B1-2 POWER STEERING (P/S) SYSTEM
General Description
Power Steering (P/S) Pump
Power steering (P/S) pump specification :
The specification of this power steering pump is the same as the specification of the same section in the service
manual mentioned in this manual except for data of relieved pressure shown below.
Relieved pressure :
7850 kPa (78.5 kg/cm
2, 1116 psi)
Diagnosis
Power Steering Pump Drive Belt
Belt inspection
Check P/S pump drive belt (1) is free from any damage and prop-
erly fitted in pulley groove.
Belt tension check
Check belt tension by measuring how much it deflects when
pushed at arrow point (2) between pulleys with about 10 kg (22
lb) force.
Deflection of P/S belt :
4 – 7 mm (0.16 – 0.28 in.)
Belt tension adjustment
1) To adjust P/S pump drive belt (1) tension, loosen tension
pulley bolts (3) and turn tension pulley (4) using hexagon
wrench.
2) Adjust belt tension to above specification.
Then tighten tension pulley bolts (3) to specified torque.
Tightening torque
Tension pulley bolts (a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)
5. P/S pump pulley
6. A/C compressor pulley (if equipped)
7. Crankshaft pulley
[A] : With A/C
[B] : Without A/C

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