2004 SUZUKI GRAND VITARA Pin

YH4
GRAND
VITARA
1. Electric leak detector
AIR CONDITIONING (OPTIONAL) 1B-29
REMOVING MANIFOLD GAUGE SET
When A / C system has been charged with a specified amount of re-
frigerant, remove manifold gauge set as follows:
1) Close low pressure-side valve of manifold gauge set, (The high
pressure-side valve is closed continuously during the process
of charging.).
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves.
This operation must be performed rapidly.
WARNING:
High pressure-side is naturally under high pressure.
So, care must be used to protect your eyes and skin.
5) Put caps on service valves.
LEAK-TESTING REFRIGERANT SYSTEM
Whenever a refrigerant leak is suspected in the system or any ser-
vice operation has been performed which may result in disturbing
lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general, de-
pend upon the nature of a complaint and the type of a service per-
formed on the system.
LIQUID LEAK DETECTORS
There are a number of fittings and places throughout the air condi-
tioning system where a liquid leak detector solution may be used
to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a swab,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (gas) leak detector is more practical for deter-
mining leaks.
WARNING:

To prevent explosions or fires, make sure that there are no
flammables in the vicinity.

When exposed to fire, the refrigerant turns into a poison-
ous gas (phosgene). Do not inhale this gas.

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.

YH4
GRAND
VITARA
1B-54 AIR CONDITIONING (OPTIONAL)
2
4) Remove shims from shaft.
5) Using special tool (C), remove circlip.
Special Tool
(C): 09900-06107
6) Remove clutch coil lead wire clamp screw, and remove clutch
coil read wire ground terminal.
7) Remove clutch pulley with puller (1) from compressor (2).
NOTE:
Be careful not to damage pulley when tapping magnet
clutch assembly.
8) Remove clutch coil.
Special tool
(C): 09900-06107
INSTALLATION
1) Install clutch coil (2).
Protrusion on under side of coil ring 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) Install clamp portion and ground terminal of lead wire.

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
STEERING, SUSPENSION, WHEELS AND TIRES 3-1
GENERAL DIAGNOSIS3-1 . . . . . . . . . . . . . . . . .
Diagnosis Table 3-1. . . . . . . . . . . . . . . . . . . . . .
TIRE DIAGNOSIS3-6 . . . . . . . . . . . . . . . . . . . . . .
Irregular and / or Premature Wear 3-6. . . . . . .
Wear Indicator 3-6. . . . . . . . . . . . . . . . . . . . . . . Radial Tire Waddle 3-6. . . . . . . . . . . . . . . . . . .
Radial Tire Lead 3-8. . . . . . . . . . . . . . . . . . . . . .
VIBRATION DIAGNOSIS3-8 . . . . . . . . . . . . . . .
SECTION 3
STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT END ALIGNMENT3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING SYSTEM3B1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG STEERING WHEEL AND COLUMN3C1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION3D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION3E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEELS AND TIRES3F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS
GENERAL DIAGNOSIS
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered
when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged parts.
3) Spin front wheel. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and / or rough wheel bear-
ings.
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Vehicle Pulls (Leads)
Mismatched or uneven tires.

Tires not adequately inflated.

Broken or sagging springs.

Radial tire lateral force.

Disturbed front end alignment.

Disturbed rear axle alignment.

Brake dragging in one road wheel.

Loose, bent or broken front or rear
suspension parts.Replace tire.
Adjust tire pressure.
Replace spring.
Replace tire.
Check front end alignment.
Check rear axle alignment.
Repair front brake.
Tighten or replace suspension part.

YH4
GRAND
VITARA
3-2 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Abnormal or
Excessive Tire Wear
Sagging or broken springs.

Tire out of balance.

Disturbed front end alignment.

Faulty shock absorber.

Hard driving.

Overloaded vehicle.

Tires not rotating.

Worn or loose road wheel bearings.

Wobbly wheel or tires.

Tires not adequately inflated.Replace spring.
Adjust balance or replace tire.
Check front end alignment.
Replace shock absorber.
Replace tire.
Replace tire.
Replace or rotate tire.
Replace wheel bearing.
Replace wheel or tire.
Adjust the pressure.
Wheel Tramp
Blister or bump on tire.

Improper shock absorber action.Replace tire.
Replace shock absorber.
Shimmy, Shake or
Vibration
Tire or wheel out of balance.

Loose wheel bearings.

Worn tie rod ends.

Worn lower ball joints.

Excessive wheel runout.

Blister or bump on tire.

Excessively loaded radial runout of
tire / wheel assembly.

Disturbed front end alignment.

Loose or worn tie-rod end.

Loose steering gear case bolts.Balance wheels or replace tire and /
or wheel.
Replace wheel bearing.
Replace tie rod end.
Replace front suspension control
arm.
Repair or replace wheel and / or tire.
Replace tire.
Replace tire or wheel.
Check front end alignment.
Tighten or replace tie-rod end.
Tighten case bolts.
Hard Steering
Bind in tie rod end ball studs or
lower ball joints.

Disturbed front end alignment.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)

Tire not adequately inflated.

Bind in steering column.

Low fluid level, loose drive belt or
malfunction of power steering system.
(if equipped with P / S)Replace tie rod end or front
suspension control arm.
Check front end alignment.
Check and adjust steering gear box.
Inflate tires to proper pressure.
Repair or replace.
Check and correct.

YH4
GRAND
VITARA
STEERING, SUSPENSION, WHEELS AND TIRES 3-3
ConditionPossible CauseCorrection
Too Much Play in
Steering
Wheel bearings worn.

Loose steering gear case bolts.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)

Worn steering shaft joints.

Worn tie rod ends or tie rod
inside ball joints.

Worn lower ball joints.Replace wheel bearing.
Tighten.
Check and adjust rack and pinion
torque.
Replace joint.
Replace tie rod end or steering
gear case.
Replace front suspension control
arm.
Poor Returnability
Bind in tie rod end ball studs.

Bind in ball joints.

Bind in steering column.

Poorly lubricated rack and pinion.
(if equipped with manual steering gear
case)

Disturbed front end alignment.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)

Tires not adequately inflated.Replace tie rod end.
Replace ball joint.
Repair or replace.
Check, repair or lubricate rack and
pinion.
Check and adjust front end
alignment.
Check and adjust rack and pinion
torque.
Adjust pressure.
Steering Noise
(Rattle or Chuckle)
Loose bolts and nuts.

Broken or otherwise damaged wheel
bearings.

Worn or sticky tie rod ends.

Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)Retighten.
Replace.
Replace.
Check and adjust rack and pinion
torque.
Abnormal Noise,
Front End
Worn, sticky or loose tie rod
ends, lower ball joints, tie rod
inside ball joints or drive shaft
joints.

Damaged shock absorbers, struts
or mountings.

Worn control arm bushings.

Loose stabilizer bar.

Loose wheel nuts.

Loose suspension bolts or nuts.

Broken or otherwise damaged
wheel bearings.

Broken suspension springs.

Poorly lubricated or worn strut
bearings.Replace tie rod end, control arm,
steering gear case or drive shaft
joint.
Replace or repair.
Replace.
Tighten bolts or replace bushes.
Tighten wheel nuts.
Tighten suspension bolts or nuts.
Replace wheel bearing.
Replace spring.
Lubricate or replace strut bearing.

YH4
GRAND
VITARA
3-4 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Wander or Poor
Steering Stability
Mismatched or uneven tires.

Loose ball joints and tie rod
ends.

Faulty shock absorbers / struts or
mounting.

Loose stabilizer bar.

Broken or sagging springs.

Rack and pinion not properly adjusted.
(if equipped with manual steering
gear case)

Disturbed front end alignment.Replace tire or inflate tires to
proper pressure.
Replace suspension control arm or
tie rod end.
Replace absorber / strut or repair
mounting.
Tighten or replace stabilizer bar or
bushes.
Replace spring.
Check or adjust rack and pinion
torque.
Check and adjust front end alignment.
Erratic Steering when
Braking
Worn wheel bearings.

Broken or sagging springs.

Leaking wheel cylinder or caliper.

Warped discs.

Badly worn brake linings.

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Defective wheel cylinders.

Disturbed front end alignment.Replace wheel bearing.
Replace spring.
Repair or replace wheel cylinder or
caliper.
Replace brake disc.
Replace brake shoe lining.
Replace brake drum.
Inflate tires to proper pressure.
Replace or repair wheel cylinder.
Check front end alignment.
Low or Uneven Trim
Height
Right-to-left trim height
(H) difference should be
within 15 mm (0.6 in.)
with curb weight.
*Same with rear side.
Broken or sagging springs.

Overloaded.

Incorrect springs.Replace spring.
Check loading.
Replace spring.
Ride Too Soft
Faulty shock absorber or struts.Replace shock absorber or strut.
Suspension Bottoms
Overloaded.

Faulty shocks or struts.

Incorrect broken or sagging springs.Check loading.
Replace shock absorber or strut.
Replace spring.