2004 SUZUKI GRAND VITARA check engine

YH4
GRAND
VITARA
Fig. A
Fig. B
Fig. C
C51-3-6 For G16
and J20 engines
C51-3-25 For
H25 engine
1B-18 AIR CONDITIONING (OPTIONAL)
INSPECTION OF A / C CONTROLLER AND ITS
CIRCUITS
CAUTION:
A / C controller and ECM cannot be checked by itself.
It is strictly prohibited to connect voltmeter or ohmmeter to
A / C controller and ECM with couplers disconnected from it.
A / C controller (1) and its circuits can be checked at A / C controller
wiring couplers by measuring voltage.
Voltage Check
1) Remove A / C controller (1) from vehicle (refer to ªA / C CON-
TROLLER REMOVALº in this section).
2) Remove ECM (2) from vehicle.
3) Connect A / C controller couplers to A / C controller and connect
ECM couplers to ECM.
4) Check each terminal voltage with couplers connected by refer-
ing to the A / C CONTROLLER VOLTAGE VALUES TABLE the
later.

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
1B-26 AIR CONDITIONING (OPTIONAL)
CHARGING
CAUTION:

ALWAYS CHARGE THROUGH LOW PRESSURE-SIDE of A / C system at after the initial charging is per-
formed from the high-pressure side with the engine stopped.

NEVER CHARGE TO HIGH PRESSURE-SIDE of A / C system with engine running.

Do not charge while compressor is hot.

When installing tap valve to refrigerant container to make a hole there through, carefully follow direc-
tions given by manufacturer.

A pressure gauge should always be used before and during charging.

The refrigerant container should be emptied of refrigerant when discarding it.

The refrigerant container should not be heated up to 40C (104F) or over.

Refrigerant container should not be reversed in direction during charging. Reversing in direction
causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid refrig-
erant and the like.
NOTE:
The air conditioning system contains HFC-134a (R-134a).
Described here is a method to charge the air conditioning system with refrigerant from the refrigerant ser-
vice container.
When charging refrigerant recovered by using the refrigerant and recycling equipment (when recycling
refrigerant), follow the procedure described in the equipment manufacturer's instruction manual.
The initial charging of the A / C system is performed from the high-
pressure side with the engine stopped.
And next, this method must be followed by charging from the low-
pressure side with the engine running.
1) Check to make sure that hoses are routed properly after eva-
cuating the system.
2) Connect Low-side hose (1) and High side hose (2) of the man-
ifold gauge set (3) in position. Thus open refrigerant container
valve (4) to purge the charging line.
3) Open the high-pressure side valve (6) and charge refrigerant to
system.
4) After a while, open the low-pressure side valve (5) and close the
high-pressure side valve (6).
WARNING:
Make sure that high pressure-side valve is closed se-
curely.
5) Start engine and keep engine speed at 1500 r / min. Then, oper-
ate air conditioning.
6) Charge A / C system with refrigerant in vapor state. At this time,
refrigerant container should be held upright.

YH4
GRAND
VITARA
1B-44 AIR CONDITIONING (OPTIONAL)
REFRIGERANT PIPES AND HOSES
INSPECTION
1) Use a leak tester to check hoses and pipes for any gas leakage.
2) Check each hose or pipe clamp for tightness.
Retighten or replace loose clamp as required, if any.
REMOVAL
1) Recover refrigerant by using recovery and recycling equipment.
Be sure to follow the instruction manual for the equipment.
The amount of compressor oil removed must be measured and
the same amount must be added to the system when reinstal-
ling.
2) Replace defective hose or pipe.
CAUTION:
As soon as the above hose or pipe is disconnected, cap
its opened fitting to prevent moisture and dust from en-
tering.
INSTALLATION
1) Reverse removal procedure to install refrigerant line.
2) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
INSPECTION OF IDLE SPEED WITH A / C ON
For G16 and J20 engines model, refer to Section 6E1.
For H25 engine model, refer to Section 6E2.

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
2. High pressure side (Delivery side hose)
3. Lower pressure side (Suction side pipe)
AIR CONDITIONING (OPTIONAL) 1B-49
COMPRESSOR ASSEMBLY
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 refrigerant or compressor oil will result in leakage of refrigerant, damage in parts or
other faulty condition.
PRECAUTION
When servicing the compressor, keep dirt or foreign material away from getting on or into the compressor parts
and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any ªOn-vehicleº repair
or before removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled
should be cleaned with Trichloroethane, naphtha, kerosene or equivalent solvent and dried with dry air. Use only
lint free cloths to wipe parts.
The operations described are based on bench overhaul with compressor removed from the vehicle, except as
noted. They have been prepared in order of accessibility of the components.
When compressor is removed from the vehicle for servicing, the oil remaining in the compressor should be dis-
carded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair procedures re-
quire that the system be discharged of refrigerant.
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.
2) Close Hi (4) and Lo (5) hand valves.
3) Run engine at fast idle.
4) Check compressor assembly for following items.
If any of the above checks indicated a defect, repair compressor
assembly.

High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.

Metallic sound.

Leakage from shaft seal.

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-7
STEERING WHEEL
STEERING WHEEL PLAY CHECK
Check steering wheel for looseness or rattle by trying to move it in
its shaft direction and lateral direction.
If found defective, repair or replace.
Check steering wheel for play, holding car in straight forward condi-
tion on the ground and with engine stopped.
Steering wheel play ªaº: 0 ± 30 mm (0 ± 1.2 in.)
If steering wheel play is not within specification, inspect as follows
and replace if found defective.

Tie-rod end ball stud for wear

Lower ball joint for wear

Steering shaft joint for wear

Steering pinion or rack gear for wear or breakage

Each part for looseness
STEERING FORCE CHECK
1) Place vehicle on level road and set steering wheel at straight-
ahead position.
2) Check that tire inflation pressure is as specified. (Refer to tire
placard.)
3) Start engine and keep it running till power steering fluid is
warmed to 50 to 60C (122 to 140F).
4) With engine idling, measure steering force by pulling spring ba-
lancer hooked on steering wheel in tangential direction.
Steering force: Less than 50 N (5.0 kg, 11.0 lb)
POWER STEERING FLUID
POWER STEERING FLUID LEVEL CHECK
With engine stopped, check fluid level indicated on P / S fluid reser-
voir, which should be between ªMAXº and ªMINº marks. If it is lower
than ªMINº mark, fill fluid up to ªMAXº mark.
NOTE:

Be sure to use an specified power steering fluid.

Fluid level should be checked when fluid is cool.

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
POWER STEERING (P / S) SYSTEM 3B1-9
IDLE UP SYSTEM
IDLE UP SYSTEM CHECK
1) Warm up engine to normal operating temperature.
2) Turn A / C switch OFF, if equipped.
3) Turn steering wheel fully and check idle speed.
Engine idle speed drops a little momentarily when steering
wheel is turned fully but returns to its specified level immediately.
If power steering pressure switch connector is connected, check
the same with that connector disconnected. Momentary drop of
engine idle speed should be less when it is connected than when
disconnected.
FLUID
FLUID LEAKAGE CHECK
Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is provided. Then
visually check gear box, P / S pump and P / S fluid reservoir themselves and each joint of their connecting pipes for
leakage.
CAUTION:
Never keep steering wheel turned fully for longer than 10 seconds.

YH4
GRAND
VITARA
1. P / S fluid reservoir
2. Attachment
3. Gasket4. Union bolt
5. High pressure side
6. Low pressure side
1. P / S fluid reservoir
2. Gauge valve (open)
3. P / S pump4. P / S gear box
5. High pressure side
6. Low pressure side
3B1-10 POWER STEERING (P / S) SYSTEM
HYDRAULIC PRESSURE IN P / S CIRCUIT
HYDRAULIC PRESSURE CHECK
1) After cleaning joint of high pressure hose and P / S pump thor-
oughly, disconnect hose from pump and install special tool (oil
pressure gauge, attachment and hose).
Tighten each flare nut to specified torque.
CAUTION:
Take care not to cause damage to A / C condenser during
service operation, if equipped.
Special Tool
(A): 09915-77410 (Oil pressure gauge)
(B): 09915-77420
2) Check each connection for fluid leakage and bleed air.
Refer to ªAIR BLEEDING PROCEDUREº in this section.
3) With engine idling, turn steering wheel and warm up engine till
temperature of fluid in P/S fluid reservoir rises to 50 ± 60
C (122
± 140
F).
4) Check back pressure by measuring hydraulic pressure with en-
gine idling and hands off steering wheel.
Back pressure: Lower than 1000 kPa (10 kg / cm
2, 142 psi)
When back pressure is higher than specified values, check con-
trol valve and piping for clogging.