2002 SUZUKI GRAND VITARA compressor

YH4
GRAND
VITARA
1B-56 AIR CONDITIONING (OPTIONAL)
1. Clutch plate bolt
2. Clutch plate
3. Circlip
4. Clutch pulley
5. Washer
6. Shim
7. Oil felt ring
8. Clutch coil
9. Lip type seal
10. Compressor front head
11. Compressor body component
12. O-ring
13. Compressor thermal switch
3. Washer
(if equipped)1. Thermal switch
2. Ohmmeter
MAGNET CLUTCH ASSEMBLY (FOR SEIKO SEIKI)
INSPECTION
MAGNET CLUTCH

Inspect clutch plate and clutch pulley for signs of oil.

Check clutch pulley bearings for noise and grease leakage.

Using and ohmmeter, measure resistance of clutch coil between
clutch coil lead wire (1) and compressor body.
If measured resistance is not within tolerance, replace coil.
Standard resistance: 2.5 ± 4.5
at 20C, 68F
COMPRESSOR THERMAL SWITCH
Use an ohmmeter to check thermal switch for continuity. If there is
no continuity, replace it.
REMOVAL
1) Remove compressor assembly from vehicle. Refer to COM-
PRESSOR ASSEMBLY in this section.
2) Fix clutch plate (1) with special tool (A) and remove clutch plate
bolt (2).
Special Tool
(A): 09991-06020
NOTE:
Do not reuse armature plate nut.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-57
3) Using special tool (B), remove clutch plate (1).
Special Tool
(B): 09991-06030
4) Disconnect clutch coil lead wire from compressor thermal switch
led wire.
5) Remove felt ring (if equipped) and shims from shaft.
6) Using special tool (C), remove circlip.
Special Tool
(C): 09900-06107
7) Remove clutch coil lead wire clamp screw.
8) Remove clutch pulley with puller (1) from compressor (2).
NOTE:
Be careful not to damage pulley when tapping magnet
clutch.
9) Remove clutch coil.
INSTALLATION
1) Install clutch coil (2).
Protrusion on under side of clutch coil must match hole in com-
pressor (3) to prevent movement ant correctly locate lead wire.
2) Using special tool (C), install snap ring (1) as shown.
Special Tool
(C): 09990-06107
3) Clamp covering portion of lead wire.

YH4
GRAND
VITARA
3. Washer
(if equipped)
1B-58 AIR CONDITIONING (OPTIONAL)
4) Install clutch pulley (1).
(1) Set clutch pulley squarely over clutch pulley installation boss.
(2) Place special tool (D) onto clutch pulley bearing.
Ensure that edge rests only on inner race of bearing.
(3) Install snap ring.
Special Tool
(D): 09991-06010
CAUTION:
Be careful not to scratch bearing seal.
5) Adjust clearance, between clutch plate and clutch pulley (2) by
putting shim on compressor shaft.
Standard clearance ªaº: 0.3 ± 0.6 mm (0.012 ± 0.024 in.)
6) Tighten new clutch plate (1) bolt (2) as specified below.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
Special Tool
(A): 09991-06020

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-59
PUSH
3. Cylinder
4. Case
5. O-ring
2. Bearing puller
LIP TYPE SEAL (FOR SEIKO SEIKI)
REMOVAL
1) Remove magnet clutch assembly, referring to ªMAGNET
CLUTCH ASSEMBLYº in this section.
2) Remove compressor front head (1) mounting bolt (10 pcs.).
3) Remove compressor front head (1) by pushing cylinder shaft
(2).
NOTE:
Be careful not to remove cylinder from case.
4) Remove O-ring.
5) Remove lip seal from compressor front head (1).
INSTALLATION
1) Press-fit lip seal (1) into compressor front head (2) using special
tool (E).
Special Tool
(E): 09991-06050
CAUTION:
Do not reuse mechanical seal once removed from com-
pressor.

YH4
GRAND
VITARA
1B-60 AIR CONDITIONING (OPTIONAL)
1. Front head
2) Coat special tool (F) surface with oil and place it on the shaft.
Special Tool
(F): 09991-06040
3) Install O-ring (2) to case.
4) Apply compressor (refringent) oil to lip seal and O-ring.
5) Install compressor front head (1).
6) Tighten compressor front head bolt.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
NOTE:

Be sure to use new front head bolt washer.

Tighten bolt (a) first, and next (b).

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-61
09900-06107
Snap ring pliers
(Opening type)09991-06010
Magnet clutch pulley installer09991-06020
Armature plate spanner09991-06030
Armature plate remover
09991-06040
Lip type seal protector09991-06050
Lip type seal installer
REQUIRED SERVICE MATERIAL
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Compressor oil for DENSO
compressor (Refrigerant oil)COMPRESSOR OIL (ND-OIL 8, 250 cc)
99000-27080
O-ring

Each component
Compressor oil for
SEIKO SEIKI compressor
(Refrigerant oil)COMPRESSOR OIL RS20 (150 cc)
99000-99088-00D
O-ring

Each component
RefrigerantREFRIGERANT DRUM (200 g)
95794-50G00
Refrigerant charge
SPECIAL TOOLS

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
DIFFERENTIAL (FRONT) 7E-11
1. Differential housing
2. Adjusting screw
3. To air compressor
Actuator
1) Disconnect air hose from pump assembly and install special tool
to air hose as shown in figure. Loosen adjusting screw of special
tool.
Special Tool
(A): 09918-18110
2) Connect compressor air hose to special tool.
Blow air and turn adjusting screw to obtain specified pressure.
Specified pressure: 30.0 kPa (0.3 kg / cm
2, 4.25 psi)
CAUTION:
Do not apply a pressure exceeding 200 kPa (2.0 kg / cm
2,
28.4 psi) which may cause damage to diaphragm.
3) With the vehicle lifted so that both of the front wheels are off the
ground, turn one of the front wheels by hand and check the other
wheel, which should act as described below.

When the pressure from compressor is applied to actuator:
The other front wheel should turn in the direction opposite to
the wheel being turned by hand.

When the pressure from compressor is not applied to actuator:
The other front wheel should remain stationary while the wheel
pushed by hand is turning.
If the result is not satisfactory, inspect differential assembly. Re-
fer to ªINSPECTIONº of SECTION 7E in UNIT REPAIR MANU-
AL.