2002 SUZUKI GRAND VITARA Low ac port

YH4
GRAND
VITARA
0A-12 GENERAL INFORMATION
1. Check for loose connectionSensor
ECM
Check contact tension by
Inserting and removing just for
once
1. Looseness of crimping
2. Open
3. Thin wire (Single strand of wire)
ELECTRICAL CIRCUIT INSPECTION
PROCEDURE
While there are various electrical circuit inspection methods, de-
scribed here is a general method to check its open and short circuit
by using an ohmmeter and a voltmeter.
OPEN CIRCUIT CHECK
Possible causes for the open circuit are as follows. As the cause is
in the connector or terminal in many cases, they need to be checked
particularly carefully.

Loose connection of connector

Poor contact of terminal (due to dirt, corrosion or rust on it, poor
contact tension, entry of foreign object etc.)

Wire harness being open
When checking system circuits including an electronic control unit
such as ECM, TCM, ABS control module, etc., it is important to per-
form careful check, starting with items which are easier to check.
1) Disconnect negative cable from battery.
2) Check each connector at both ends of the circuit being checked
for loose connection. Also check lock condition of connector if
equipped with connector lock.
3) Using a test male terminal, check both terminals of the circuit be-
ing checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly caused
by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.
4) Using continuity check or voltage check procedure described in
the following page, check the wire harness for open circuit and
poor connection with its terminals. Locate abnormality, if any.

YH4
GRAND
VITARA
L
LH : Left Hand
LSPV : Load Sensing Proportioning
Valve
M
MAF Sensor : Mass Air Flow Sensor
(Air Flow Sensor, AFS, Air
Flow Meter, AFM)
MAP Sensor : Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Max : Maximum
MFI : Multiport Fuel Injection
(Multipoint Fuel Injection)
Min : Minimum
MIL : Malfunction Indicator Lamp
(ªCHECK ENGINEº Light)
M / T : Manual Transmission
N
NOx : Nitrogen Oxides
O
OBD : On-Board Diagnostic System
(Self-Diagnosis Function)
O / D : Overdrive
OHC : Over Head Camshaft
P
PNP : Park / Neutral Position
P / S : Power Steering
PSP Switch : Power Steering Pressure
Switch (P / S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation
R
RH : Right Hand
S
SAE : Society of Automotive
Engineers
SDM : Sensing and Diagnostic
Module (Air bag controller,
Air bag control module)
SFI : Sequential Multiport Fuel
Injection
SOHC : Single Over Head Camshaft
T
TBI : Throttle Body Fuel Injection
(Single-Point Fuel Injection,
SPI)
TCC : Torque Converter Clutch
TCM : Transmission Control Module
(A / T Controller, A / T Control
Module)
TP Sensor : Throttle Position Sensor
TVV : Thermal Vacuum Valve
(Thermal Vacuum Switching
Valve, TVSV, Bimetal Vacuum
Switching Valve, BVSV)
TWC : Three Way Catalytic
Converter (Three Way
Catalyst)
2WD : 2 Wheel Drive
V
VIN : Vehicle Identification
Number
VSS : Vehicle Speed Sensor
W
WU-OC : Warm Up Oxidation
Catalytic Converter
WU-TWC : Warm Up Three Way
Catalytic Converter
0A-22 GENERAL INFORMATION

YH4
GRAND
VITARA
0B-24 MAINTENANCE AND LUBRICATION
FINAL INSPECTION
Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
If ªREPLACE BELTº label on front seat belt is visible,
replace belt.
Check that seat belt is securely locked.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat-
tery condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by and other part.
Engine Start
Check engine start for readiness.
On automatic transmission vehicles, try to start the
engine in each select lever position. The starting mo-
tor should crank only in ªPº (Park) or ªNº (Neutral).
On manual transmission vehicles, place the shift le-
ver in ªNeutral,º depress clutch pedal fully and try to
start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (For Manual transmission)
Check for the following:

Clutch is completely released when depressing
clutch pedal.

No slipping clutch occurs when releasing pedal and
accelerating.

Clutch itself is free from any abnormal condition.
Gearshift or Select Lever (Transmission)
Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis-
sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.
With automatic transmission equipped vehicle, make
sure that vehicle is at complete stop when shifting se-
lect lever to ªPº range position and release all brakes.
Brake
[Foot brake]
Check the following:

that brake pedal has proper travel,

that brake works properly,

that it is free from noise,

that braking force is applied equally on all wheels,

and that brake do not drag.
[Parking brake]
Check that lever has proper travel.
WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly
even if vehicle should start to move.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.
WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the vehicle could move without warn-
ing and possibly cause personal injury or
property damage.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-3
BODY VENTILATION
The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake
control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and
drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
DIAGNOSIS
DIAGNOSIS TABLE
TroublePossible causeRemedy
Heater blower won't
work even when its
switch is ON.Blower fuse blown
Blower resistor faulty
Blower motor faulty
Wiring or grounding faultyReplace fuse to check for short.
Check resistor.
Replace motor.
Repair as necessary.
Incorrect temperature
output.Control cables broken or binding
Air damper broken
Air ducts clogged
Heater radiator leaking or clogged
Heater hoses leaking or cloggedCheck cables.
Repair damper.
Repair air ducts.
Replace radiator.
Replace hoses.
When mode control
switch is changed,
air outlet port is not
changed.Mode control switch faulty
Mode actuator faulty
Fuse blown
Wiring or grounding faulty
Air damper broken
Air ducts cloggedCheck and replace as necessary.
Check and replace as necessary.
Replace fuse to check for short.
Repair as necessary.
Repair damper.
Repair air ducts.

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
AIR CONDITIONING (OPTIONAL) 1B-13
9) Check for each pressure of low side and high side if it is within
shaded range of graph.
If each gauge reading is out of specified pressure, correct de-
fective part referring to following Test Diagnosis table.
Example:
Gauges should read as follows when ambient
temperature is 30
C.
Pressure on high pressure
gauge (HI):1400 ± 1750 kPa
14.0 ± 17.5 kg / cm
2
Pressure on high pressure
gauge (LO):230 ± 350 kPa
2.3 ± 3.5 kg / cm
2
NOTE:
Pressure registered on gauge varies with ambient temper-
ature. Therefore, use left graphs when determining if pres-
sures are normal or not.
10) Check inlet port temperature-to-outlet port temperature rela-
tionship using graph.
For example, if evaporator inlet port temperature is 25
C
(77
F) and center duct air outlet temperature is 8
C (46.4
F),
their crossing point is within acceptable range as shown in
graph.
11) If crossing point is out of acceptable range, diagnose trouble
referring to following Performance Diagnosis table.

YH4
GRAND
VITARA
1. Suction hose
2. Discharge hose
3. Liquid pipe
4. Condenser outlet pipe
5. Expansion valve
6. Dual pressure switch
7. Suction pipe
: Apply compressor oil
(refrigerant oil) to O-ring.
1B-30 AIR CONDITIONING (OPTIONAL)
ON-VEHICLE SERVICE
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 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.
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.

Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.

Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system,
install a blind plug or cap to the fitting immediately.

When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.