2002 SUZUKI GRAND VITARA ten

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-9
1. LO
2. M1
3. M2
4. HI
BLOWER MOTOR RESISTOR
REMOVAL
1) Disconnect negative (±) cable (2) at battery (1).
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Open glove box (1), then remove screw (2).
4) Remove glove box.
5) Disconnect blower motor resistor (1) at coupler.
6) Remove heater blower resistor (1) by removing its fastening
screw (2).
INSPECTION
Measure each terminal-to-terminal resistance on resistor.
Resistance H-LO: Approx. 2.0

H-M1: Approx. 1.0

H-M2: Approx. 0.4

If measured resistance is incorrect, replace heater blower resistor.
INSTALLATION
1) Install heater blower resistor with screws.
2) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.

YH4
GRAND
VITARA
1B
AIR CONDITIONING (OPTIONAL) 1B-1
GENERAL DESCRIPTION1B- 3 . . . . . . . . . . . . . .
Identification of Refrigerating System 1B- 3. . . .
Refrigerant Flow of Air Conditioning
System 1B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Components and Location 1B- 5. . . . . . .
DIAGNOSIS1B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 1B- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis of Abnormal Noise 1B- 8. . . . . . . . . .
Quickly Checking of Refrigerant Charge
(If Equipped with Sight Glass) 1B-10. . . . . . . . .
Compression System Diagnosis 1B-11. . . . . . . .
Performance Diagnosis 1B-12. . . . . . . . . . . . . . .
Wiring Circuit 1B-16. . . . . . . . . . . . . . . . . . . . . . . .
Inspection of A / C Controller and Its
Circuits 1B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERANT RECOVERY,
EVACUATION AND CHARGING1B-23 . . . . . . . .
Operation Procedure for Charging A / C
with Refrigerant 1B-23. . . . . . . . . . . . . . . . . . . . .
Recovery 1B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuating 1B-25. . . . . . . . . . . . . . . . . . . . . . . . . .
Charging 1B-26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Manifold Gauge Set 1B-29. . . . . . . . .
Leak-Testing Refrigerant System 1B-29. . . . . . .
Liquid Leak Detectors 1B-29. . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE1B-30 . . . . . . . . . . . . . . . .
Precaution 1B-30. . . . . . . . . . . . . . . . . . . . . . . . . . .
A / C Condenser Assembly 1B-33. . . . . . . . . . . . .
Condenser Cooling Fan Assembly 1B-35. . . . . .
SECTION 1B
AIR CONDITIONING (OPTIONAL)
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 autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº 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
ªLOCKº 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).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of A / C:
one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to the description in page 1B-2.
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.
For basic servicing method of the air conditioning system that is not described in this section, refer to AIR CONDI-
TIONING BASIC MANUAL (99520-02130).
CONTENTS

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-7
ConditionPossible CauseCorrection
Cool air does not come
out or insufficient
cooling (A / C system
normal operative)
Compressor faulty

Air in A / C system

Air leaking from cooling unit or air
duct

Heater and ventilation system faulty

Blower motor faulty

Excessive compressor oil existing in
A / C systemCheck compressor.
Replace condenser dryer, and
evacuation and charging.
Repair as necessary.
Check blower unit.
Check heater control lever assembly.
Check heater assembly.
Check blower motor.
Pull out compressor oil in A / C system
circuit, and replace compressor.
Cool air does not comes
out only intermittently
Wiring connection faulty

Expansion valve faulty

Excessive moisture in A / C system

A / C controller faulty

Magnetic clutch faulty

Excessive charge of refrigerantRepair as necessary.
Check expansion valve.
Replace condenser dryer, and
evacuation and charging.
Check A / C controller.
Check magnetic clutch.
Check charge of refrigerant.
Cool air comes out only
at high speeds
Condenser clogged

Insufficient charge of refrigerant

Air in A / C system

Drive belt slipping

Compressor faultyCheck condenser.
Check charge of refrigerant.
Replace condenser dryer, and
evacuation and charging.
Adjust or replace drive belt.
Check compressor.
Cool air does not comes
out only at high speeds
Excessive charge of refrigerant

A / C evaporator frostedCheck charge refrigerant.
Check A / C evaporator.
Check A / C thermistor.
Insufficient velocity of
cooled air
A / C evaporator clogged or frosted

Air leaking from cooling unit or air
duct

Blower motor faulty

Wiring or grounding faultyCheck A / C evaporator.
Repair as necessary.
Check blower motor.
Repair as necessary.

YH4
GRAND
VITARA
1B-8 AIR CONDITIONING (OPTIONAL)
DIAGNOSIS OF ABNORMAL NOISE
There are various types of noise, ranging from those produced in the engine compartment to those from the pas-
senger compartment, also from rumbling noises to whistling noises.
ABNORMAL NOISE FROM COMPRESSOR
ConditionPossible CauseCorrection

During compressor operation, a
rumbling noise is heard
proportional to engine
revolutions.
Inadequate clearance in piston
area (piston or swash-plate).
Repair or replace compressor as
necessary.

A loud noise is heard at a certain
rpm, disproportionately to engine
revolution.
Loose or faulty V-belt.

Loose mounting bolts.
Adjust V-belt tension, or
replace belt.

Retighten mounting bolts.

A loud rattle is heard at low
engine rpm.
Loose compressor center bolt.
Retighten center bolt.

Replace compressor if it was
operated in this condition for a
long time.
ABNORMAL NOISE FROM MAGNETIC CLUTCH
ConditionPossible CauseCorrection

A rumbling noise is heard when
compressor is not operating.
Worn or damaged bearings.
Replace bearings.

A chattering noise is heard when
compressor is engaged.
Faulty clutch gap (excessive).

Worn clutch friction surface.

Compressor oil leaked from shaft
seal, contaminating the friction
surface.
Adjust clutch gap.

Replace clutch.

Replace compressor shaft oil
seal.
ABNORMAL NOISE FROM TUBING
ConditionPossible CauseCorrection

A droning noise is heard inside
vehicle, but not particularly
noticeable in engine
compartment.
Faulty tubing clamps.

Resonance caused by pulsation
from variations in refrigerant
pressure.
Reposition clamps or increase
the number of clamps.

Attach a silencer to tubing, or
modify its position and length.
ABNORMAL NOISE FROM CONDENSER
ConditionPossible CauseCorrection

Considerable vibration in
condenser.
Resonance from condenser
mounting stay and body.
Firmly insert a silencer between
condenser mounting stay and
body.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-9
ABNORMAL NOISE FROM CRANKSHAFT PULLEY
ConditionPossible CauseCorrection

A large rattling noise is heard at
idle or sudden acceleration.
Loosen pulley mounting bolt.

Worn or broken bearings.
Retighten bolt.

Replace bearings.
ABNORMAL NOISE FROM TENSION PULLEY
ConditionPossible CauseCorrection

Clattering noise is heard from
pulley.

Pulley cranks upon contact.
Worn or damaged bearings.

Cracked or loose bracket.
Replace bearings.

Replace or retighten bracket.
ABNORMAL NOISE FROM EVAPORATOR
ConditionPossible CauseCorrection

Whistling sound is heard from
evaporator.
Depending on the combination of
the interior / exterior
temperatures, engine rpm and
refrigerant pressure, the
refrigerant flowing out of the
expansion valve may, under
certain conditions, make a
whistling sound.
At times, slightly decreasing
refrigerant volume may stop this
noise.

Inspect expansion valve and
replace if faulty.
ABNORMAL NOISE FROM BLOWER MOTOR
ConditionPossible CauseCorrection

Blower motor emits a chirping
sound in proportion to its speed of
rotation.

Fluttering noise or large droning
noise is heard from blower motor.
Worn or damaged motor brushes
or commutator.

Leaves or other debris
introduced from fresh air inlet to
blower motor.
Repair or replace blower motor.

Remove debris and make sure
that the screen at fresh air inlet is
intact.

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
1B-12 AIR CONDITIONING (OPTIONAL)
PERFORMANCE DIAGNOSIS
1) Confirm that vehicle and environmental conditions are as fol-
lows.

Vehicle is not exposed to direct sun.

Ambient temperature is within 15C ± 35C (59F ± 95F).
2) Make sure that high pressure valve (1) and low pressure valve
(2) of manifold gauge are firmly closed.
3) Connect high pressure charging hose (3) to high pressure ser-
vice valve (5) on vehicle, and connect low pressure charging
hose (4) to low pressure service valve (6) on vehicle.
4) Bleed the air in charging hoses (3), (4) by loosening their respec-
tive nuts on manifold gauge, utilizing the refrigerant pressure.
When a hiss is heard, immediately tighten nut.
CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.
5) Warm up engine to normal operating temperature (engine cool-
ant temperature at 80 ± 90C (176 ± 194F)) and keep it at spe-
cified idle speed. (Radiator cooling fan should not be working
when checking pressure and temperature.)
6) Turn A / C switch ON, and set blower switch at ªHIº (4th position),
temperature control knob at ªCOOLº, air outlet control knob at
ªFACEº, fresh / circulation control knob at ªCIRCULATIONº.
(Confirm that A / C compressor and condenser fan are working.)
7) Keep all windows, doors and engine food open.
Ambient temperature
15 ± 35C (59F ± 95F)
Engine rpmKeep to 1,500 rpm.
Blower motor switchMax. (4th position)
Temperature controlMax. cool
Air outlet controlFace
Vehicle doorsAll open
Air inlet door positionRecirculation
8) With about 20 mm (0.8 in.) of dry bulb thermometer (1) inserted
into center duct air outlet and another one set near evaporator
air inlet, read temperature indicated on each thermometer.

YH4
GRAND
VITARA
1B-20 AIR CONDITIONING (OPTIONAL)
A / C CONTROLLER VOLTAGE VALUES TABLE
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC1-1B/WController main
power supplyGround to
engine (Fig. B)10 ± 14 voltsIgnition switch ON with engine
stopped
AC1-2B/YController main
groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
AC1 4Or
Refrigerant
p
ressure switchGround to
0 ± 1 volt
Refrigerant pressure within 225 kPa
(2.3 kg / cm
2, 32.7 psi) to 2548 kPa
(26 kg / cm
2, 370 psi) with engine
running
AC1-4Orpressure switch
inputengine (Fig. B)
10 ± 14 volts
Refrigerant pressure below
196 kPa (2.0 kg / cm
2, 28 psi) or
above 3140 kPa (32 kg / cm
2, 455 psi)
with engine running
AC1 7G/B
A / C switch input
and / or defroster
Ground to
8 ± 14 volts
Blower fan motor switch and A / C or
defroster position switch (see NOTE)
ON with engine running
AC1-7G/Bposition switch
input (see NOTE)engine (Fig. B)
0 ± 1.5 volts
Blower fan motor switch or A / C or
defroster position switch (see NOTE)
OFF with engine running
AC1 9Gr/W
Signal input from
ECM (A / C ON
Ground to10 ± 14 voltsApprove of A / C ON
AC1-9Gr/W(
permission
signal)engine (Fig. B)0 ± 1 voltA / C ON forbid
AC1-13Y/B
Signal output to
ECM (A / C ON
request signal)Ground to engine
(Fig. B)0 ± 1.5 volts
Blower fan motor switch and A / C or
defroster position switch (see NOTE)
ON with engine running at evaporator
thermistor temperature input more
than approx. 2.5
C (less than 2.5 V
(5840
)) and refrigerant pressure
switch is ON
10 ± 14 voltsExcept the above-mentioned with
engine running
AC1-16P
Compressor
magnet clutch
relay outputGround to engine
(Fig. B)0 ± 1 volt
Blower fan motor switch and A / C or
defroster position switch ON with
engine running at evaporator
thermistor temperature input more
than approx. 2.5
C (less than 2.5 V
(5840
)), refrigerant pressure
switch ON and signal input from ECM
ON
10 ± 14 voltsExcept the above-mentioned with
engine running

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-21
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC2-1L/YSensor groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
1.5 volts
(3150
)Evaporator thermistor temperature at
approx. 15C (59F) with engine
running
AC2-2W/B
Evaporator
thermistor
temperature
(evaporator temp.
sensor) input
Ground to engine
(Fig. B)
2.62 volts
(6.311
)
Evaporator thermistor temperature at
approx. 1C (34F) with engine
running
* If the temperature is less than
approx. 1C, in this case
compressor and condenser fan
should be stop (come back at more
than approx. 2.5C (less than
5840
, 2.5 V))
H25
engine
E61-27 /
G16 J20Gr/W
Signal output to
A / C controller
(A / C ON
Ground to engine
(Fig C)
10 ± 14 volts
Required A / C ON (terminal AC-A13)
at engine running with normal
condition (refer to ªINSPECTION OF
ECM AND ITS CIRCUITº in Section
6E)
G16, J20
engines
E61-8
(
permission
signal)(Fig. C)
0 ± 1 volt
Except the above-mentioned with
engine running
In this case compressor should be
stop
H25
engine
E61-28 /
Y/B
Signal input from
A / C controller
Ground to engine
0 ± 1.5 voltsRequire A / C ON
G16, J20
engines
E61-17Y/B(A / C ON request
signal)
g
(Fig. C)
10 ± 14 voltsTurn off the A / C
H25
engine
E61-5 /
G16, J20
engines
E61-22
Y/L
A / C condenser
cooling fan relay
outputGround to engine
(Fig. C)0 ± 1 volt

Blower fan motor switch and A / C or
defroster position switch (see
NOTE) ON with engine running at
evaporator thermistor temperature
input more than approx. 2.5C (less
than 2.5 V (5840
)), refrigerant
pressure switch ON and signal
input from ECM ON

Engine coolant temperature sensor
more than 113C (236F) with
engine running
10 ± 14 voltsExcept the above-mentioned with
engine running
NOTE:
Defroster position switch circuit is equipped with LH vehicle only.