2001 SUZUKI GRAND VITARA air condition

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

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.

AIR BAG STEERING WHEEL AND COLUMN 3C1-1
3C1
SECTION 3C1
AIR BAG STEERING WHEEL AND COLUMN
CONTENTS
General Description ..................................... 3C1-2
Diagnosis ...................................................... 3C1-3
Inspection and Repair Required after
Accident ..................................................... 3C1-3
On-Vehicle Service....................................... 3C1-3
Service Precautions ................................... 3C1-3
Diagnosis and servicing ......................... 3C1-3
Disabling air bag system ........................ 3C1-3
Enabling air bag system ......................... 3C1-3Handling and storage ............................. 3C1-3
Disposal ................................................. 3C1-3
Steering Column ........................................ 3C1-4
Steering Upper Shaft Assembly ................. 3C1-7
Steering Lower Shaft Assembly ................. 3C1-9
Checking Steering Column and Steering
Upper Shaft for Accident Damage ........... 3C1-11
Tightening Torque Specification .............. 3C1-12

WARNING:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem 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.
The procedures in this section must be followed in the order listed to disable the air bag system
temporarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures
could result in possible activation of the air bag system, personal injury or otherwise unneeded air
bag system repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.
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.

FRONT SUSPENSION 3D-1
3D
SECTION 3D
FRONT SUSPENSION
CONTENTS
On-Vehicle Service......................................... 3D-1
Suspension Control Arm/Bushings .............. 3D-1Tightening Torque Specification .................. 3D-2

On-Vehicle Service
Suspension Control Arm/Bushings
INSTALLATION
For the details, refer to the same item of the same section in the
Service Manual mentioned in the FOREWORD of this manual
noting following point.
Install control arm to chassis.
Tighten suspension arm nuts to specified torque after lower-
ing hoist and vehicle in non-loaded condition.
Tightening torque
Front suspension arm nut (a) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
Front suspension arm nut (b) :
100 N·m (10.0 kg-m, 72.5 lb-ft) CAUTION:
All front suspension fasteners are an important attaching part in that it 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 this part.
Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or
damage to the part may result.
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.
NOTE:
Don’t reuse front suspension arm nut (b).
(b)

BRAKES 5-1
5
SECTION 5
BRAKES
CONTENTS
Diagnosis .......................................................... 5-2
Diagnosis Table ............................................. 5-2
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 description (items) not found in this section refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.
When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E2 first.
All brake 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
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 specified
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.

5-2 BRAKES
Diagnosis
Diagnosis Table
For the item not found in this column, refer to the same item of the same section in the service manual men-
tioned in the FOREWORD of this manual.
Condition Possible Cause Correction
Brake warning light
turns on after engine
startParking brake applied Release parking brake and check
that brake warning light turns off.
Insufficient amount of brake fluid Add brake fluid.
Brake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Brake warning light circuit faulty Repair circuit.
Malfunctioning EBD system Check system referring to “DIAG-
NOSIS” of Section 5E2.
ABS warning light
does not turn on for 2
– 3 sec. after ignition
switch has turned ON.Bulb burnt out Replace bulb.
ABS warning light circuit open (including check
relay)Check system referring to “DIAG-
NOSIS” in Section 5E2.
ABS warning light
remains on after igni-
tion switch has turned
on for 2 – 3 sec.Malfunctioning ABS Check system referring to “DIAG-
NOSIS” in Section 5E2.