SUZUKI GRAND VITARA 1999 2.G Repair Manual

1B-36 AIR CONDITIONING (OPTIONAL)
Rear Blower Motor Switch
INSPECTION
Check rear blower motor switch for each terminal-to-terminal
continuity.
If check results are not specified, replace rear blower motor
switch.
Check rear blower motor switch bulb come ON when con-
nect battery positive (+) cable to terminal “c” and battery
negative (–) cable to terminal “f”.
If A/C blower fan switch bulb does not come ON, replace it.
1. Rear blower motor switch 5. Rear A/C air louver holder
Install proper direction as shown in figure
2. Bulb 6. Rear A/C air louver
3. Bracket 7. Knob
4. Rear A/C air louver case
2
13
4
66
7
55
ab
f e
dc
TERMINAL
POSITION
Low
Middle
Highabde
OFF

AIR CONDITIONING (OPTIONAL) 1B-37
Rear A/C No.1 and No.2 Duct
Rear A/C No.1 duct
REMOVAL
1) Remove rear A/C unit referring to “REAR A/C UNIT” in this
section.
2) Remove rear A/C No.1 duct (1).
INSTALLATION
Reverse removal procedure to install rear A/C No.1 duct (1).
Rear A/C No.2 duct
CAUTION:
Never remove rear A/C No.2 duct (2) from head lining.
Performing this prohibited service will break head lining.
1
2

1B-38 AIR CONDITIONING (OPTIONAL)
Compressor Assembly
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.
2) Close Hi (4) and Lo (5) side valves.
3) Run engine at fast idle.
4) Check compressor for the following items.
If any of the above checks indicated a defect, repair com-
pressor.
High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.
Metallic sound.
Leakage from compressor. 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 66.
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.
When servicing the compressor, keep dirt or foreign material away from getting on or into the com-
pressor 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 “On-
vehicle” 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 Trichloromethane, 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 discarded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair pro-
cedures require that the system be discharged of refrigerant.
2. High pressure side (Delivery side hose)
3. Low pressure side (Suction side pipe)
1
4 5
2
3

AIR CONDITIONING (OPTIONAL) 1B-39
REMOVAL
1) Run engine at idle with A/C ON for 10 minutes.
2) Disconnect negative (–) cable at battery.
3) Recover refrigerant from refrigeration system using recovery
and recycling equipment.
4) Remove P/S pump referring to step 4) to 7) of “REMOVAL”
under “P/S PUMP” in Section 3B1.
5) Disconnect magnet clutch connector.
6) Disconnect suction hose (1) and discharge hose (2) from
compressor.
7) Remove compressor (1) from its mount (2).NOTE:
The amount of compressor oil at removed must be mea-
sured and the same amount must be poured when install-
ing the compressor.
NOTE:
It is not necessary to drain P/S fluid.
NOTE:
Cap open fitting immediately to keep moisture out of sys-
tem.
2
1
NOTE:
If compressor assembly is replaced. Drain oil from com-
pressor, and measure its amount.
1 2

1B-40 AIR CONDITIONING (OPTIONAL)
INSTALLATION
Reverse removal procedure to install compressor assembly not-
ing the following instructions.
If compressor was replaced, pour new compressor oil with
the same amount as that drained from compressor.
Refer to “REPLENISHING COMPRESSOR OIL” in this sec-
tion.
Install P/S pump referring to “P/S PUMP” in Section 3B1.
Evacuate and charge system. Refer to “EVACUATING” and
“CHARGING” in this section. CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.
1. New compressor
2. Removed compressor
3. Excess oil (A–B)

AIR CONDITIONING (OPTIONAL) 1B-41
Magnet Clutch
INSPECTION
Check the following items.
Check no sigh of compressor oil leakage
Check magnet clutch pulley bearing for noise and grease
leakage.
Check magnet clutch operation as follows :
a) Connect battery (1) and ammeter (2) to compressor (3) as
shown.
b) Check that steadily locks between armature plate (4) and
magnet clutch pulley (5).
c) Check that ammeter (2) indicates specified current.
Specified current of magnet clutch :
4A MAX at 12V
If any detects are found, repair or replace magnet clutch assem-
bly.
REMOVAL
1) Remove compressor from vehicle. Refer to “COMPRESSOR
ASSEMBLY” in this section.
2) Fix armature plate (1) with special tool and remove armature
plate bolt.
Special tool
(A) : 09920-53740
3) Remove armature plate (1).
4) Remove shims from shaft.
1. Armature plate bolt 3. Circlip 5. Shim (s) 7. Compressor body assembly
2. Armature plate 4. Magnet clutch 6. Magnet clutch coil 8. Magnet clutch assembly
1234367
5
8
3
2
1 5 4
NOTE:
Do not reuse armature plate bolt.
(A)1

1B-42 AIR CONDITIONING (OPTIONAL)
5) Using special tool, remove circlip.
Special tool
(A) : 09900-06107
6) Remove magnet clutch lead wire clamp screw, and remove
magnet clutch read wire ground terminal.
7) Remove magnet clutch with puller.
8) Remove circlip using special tool.
Special tool
(A) : 09900-06107
9) Remove magnet clutch coil (1).
INSTALLATION
1) Install magnet clutch coil (2).
2) Using special tool, install new circlip (1) as shown.
Special tool
(A) : 09990-06107
3) Install clamp portion and ground terminal of lead wire.
NOTE:
Be careful not to damage pulley when tapping magnet
clutch.
1. Puller
2. Compressor
NOTE:
Protrusion on under side of magnet clutch coil (2) must
match hole in compressor assembly (3) to prevent move-
ment and correctly locate lead wire.

AIR CONDITIONING (OPTIONAL) 1B-43
4) Install magnet clutch (1).
a) Set magnet clutch squarely over clutch installation boss.
b) Place special tool onto clutch bearing.
Ensure that edge rests only on inner race of bearing.
Special tool
(A) : 09991-06010
c) Install new circlip.
5) Adjust clearance between armature plate (1) and magnet
clutch (2) by putting shim(s) on compressor shaft.
Standard clearance between armature plate and magnet
clutch “a” :
0.35 - 0.6 mm (0.014 - 0.023 in.)
6) Tighten new armature plate nut (1) to specified torque.
Tightening torque
Armature plate nut (a) :18 N·m (1.8 kg-m, 13.0 lb-ft)
Special tool
(A) : 09920-53740
7) Install compressor to vehicle. Refer to “COMPRESSOR
ASSEMBLY” in this section. CAUTION:
Be careful not to scratch bearing seal.
“a”
1
2
2. Armature plate
1, (a)
2(A)

1B-44 AIR CONDITIONING (OPTIONAL)
Required Service Materials
Tightening Torque Specification
Special Tools
MaterialRecommended SUZUKI product
(Part Number)Use
Compressor oil (refrigerant oil) COMPRESSOR OIL (ND-OIL8, 250 cc)
(99000-27080)O-ring
Each component
Fastening partTightening torque
Nm kg-m lb-ft
Refrigerant pipe (8 mm (0.31 in.)) 13 1.3 9.5
Refrigerant pipe (12.7 mm (0.5 in.)) 22 2.2 16.0
Refrigerant pipe (16 mm (0.63 in.)) 33 3.3 24.0
Armature plate nut 18 1.8 13.0
09900-06107 09920-53740 09990-06010
Snap ring pliers
(Opening type)Armature plate holder Manifold gauge set
See NOTE below.
09990-86011 09991-06010
Gas leak detector Magnet clutch pulley
installer
NOTE:
This kit includes the following items.
1. Manifold gauge, 2. Changing hose, 3. Quick connector, 4. Refrigerant container tap valve,
5. Refrigerant container T joint, 6. Packing set

FRONT END ALIGNMENT 3A-1
3A
SECTION 3A
FRONT END ALIGNMENT
CONTENTS
General Information ........................................3A-1
Alignment Service Data (without Load) ......... 3A-1On-Vehicle Service ......................................... 3A-1
Reference Information .................................. 3A-1

General Information
Alignment Service Data (without Load)
Toe-in (Toe-in gauge measurement) “B” – “A” :
1 ± 2 mm (0.04 ± 0.08 in.)
Camber angle “C” :
0 ± 1° 30’
Caster :
2° 30’ ± 1°
On-Vehicle Service
Reference Information
SIDE SLIP
For inspecting front wheel side slip with side slip tester
Side slip limit :
IN 4 mm/m – OUT 2 mm/m
(IN 0.158 in/3.3 ft – OUT 0.078 in/3.3 ft)
If side slip exceeds above limit, toe-in or front wheel alignment
may out not be correct. NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.
[A] : Top view 1. Center line of wheel✱1. Forward
[B] : Front view✱2. Body center