Clutch SUZUKI GRAND VITARA 1999 2.G Owners Manual

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND
DIFFERENTIAL0A7A1
General Information0A
0B7B1
Maintenance and Lubrication0B
Manual Transmission7A1
7C1
HEATING AND AIR CONDITIONING
Automatic Transmission7B1
1A7D
Heater and Ventilation1A
Clutch7C1
1B7E
Air Conditioning1B
Transfer7D7F
STEERING, SUSPENSION, WHEELS
AND TIRESDifferential (Front)7E
3
Differential (Rear)7F
3A8
Steering, Suspension, Wheels and Tires3 ELECTRICAL SYSTEM3B18A
Front End Alignment3A
Electrical System8
3C18B
Power Steering (P/S) System3B1
Wiring Diagram8A3D8C
Air Bag Steering Wheel and Column3C1
Lightening System8B3E8D
Front Suspension3D
Instrumentation / Driver Information8C
3F8E
Rear Suspension3E
Windows, Mirrors, Security and Lock8D
8G
Wheels and Tires3F
Cruise Control System8E
4A2
DRIVE SHAFT AND PROPELLER SHAFT
Immobilizer control system (if equipped)8G4B9
Front Drive Shaft / Shaft Bearing,
Oil Seal4A2BODY SERVICE
Body Service9
510
Propeller Shaft4B RESTRAINT SYSTEM
5A10A
BRAKE SYSTEM
Restraint System10
5B10B
Brakes5
Seat Belt10A
5C
Brake Pipe / Hose / Master Cylinder5A
Air Bag System10B
5E2
Front Brake5B
Parking and Rear Brake5C
6-1
Antilock Brake System (ABS)5E2
6A2
ENGINE
6B
General Information and
Diagnosis (H27 Engine)6-1
6C
6E2
Engine Mechanical (H27 Engine)6A2
6F2
Engine Cooling6B
6G
Engine Fuel6C
6H
Engine and Emission Control System
(SFI For H27 Engine)6E2
6K
Ignition System (H27 Engines)6F2
Cranking System6G
Charging System6H
Exhaust System6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.

MAINTENANCE AND LUBRICATION 0B-3
IntervalKm (× 1,000) 153045607590
Miles (× 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
CHASSIS AND BODY
6-1. Clutch (pedal and fluid level)–I–I–I
6-2.Brake discs and pads (thickness, wear, damage) IIIIII
Brake drums and shoes (wear, damage)–I–I–I
6-3. Brake hoses and pipes (leakage, damage, clamp)–I–I–I
6-4. Brake fluid–R–R–R
6-5. Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles)
only
6-6.Tires (wear, damage, rotation) IIIIII
6-7.Wheel discs (damage) IIIIII
6-8. Suspension system (tighteness, damage, rattle, breakage)–I–I–I
6-9. Propeller shafts and drive shafts––I––I
6-10. Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I–R––R
6-11. Automatic transmission Fluid level –I–I–I
Fluid change Replace every 165,000 km (99,000
miles)
Fluid hose–––R––
6-12. Transfer oil (leakage, level) I–I–I–
6-13. Differential oil (leakage, level) (R: 1st 15,000 km only) R or I–I–I–
6-14. Steering system (tighteness, damage, breakage, rattle)–I–I–I
6-15.Power steering (if equipped) IIIIII
6-16. All latches, hinges and locks–I–I–I
6-17. Air conditioning filter (if equipped)–IR–IR
NOTE:
 “R”: Replace or change
 “I”: Inspect and correct, replace or lubricate if necessary

1B-2 AIR CONDITIONING (OPTIONAL)
Charging .................................................... 1B-22
On-Vehicle Service ...................................... 1B-25
Precaution .................................................. 1B-25
Piping ..................................................... 1B-25
Handling refrigerant HFC-134a (R-134a) 1B-26
Refrigerant recovery............................... 1B-26
Refrigerant charge ................................. 1B-26
Replenishing compressor oil .................. 1B-27
Rear A/C Unit (Rear A/C Evaporator) ........ 1B-28
Rear Expansion Valve ............................... 1B-29
Rear A/C Evaporator Temperature
Controller ................................................... 1B-30
Refrigerant Pipes and Hoses ..................... 1B-31
Solenoid Valve ........................................... 1B-32
Rear Blower Motor Assembly .................... 1B-33Rear Blower Motor Relay and Solenoid
Valve Relay................................................ 1B-34
Rear A/C Main Switch................................ 1B-34
Rear Blower Motor Resistor....................... 1B-35
Rear Blower Motor Switch ......................... 1B-36
Rear A/C No.1 and No.2 Duct ................... 1B-37
Rear A/C No.1 duct ................................ 1B-37
Rear A/C No.2 duct ................................ 1B-37
Compressor Assembly............................... 1B-38
Magnet Clutch............................................ 1B-41
Required Service Materials ......................... 1B-44
Tightening Torque Specification................ 1B-44
Special Tools ............................................... 1B-44

AIR CONDITIONING (OPTIONAL) 1B-3
General Description
Refrigerant Type
Whether the A/C in the vehicle being serviced uses HFC-134a
(R-134a) or CFC-12 (R-12) is indicated on LABEL on the com-
pressor. Also, it can be checked by the shape of the service
(charge) valve.
Refrigerant Flow of Air Conditioning System
[A] : HFC-134a (R-134a)
[B] : CFC-12 (R-12)
1. Compressor label
2. Service valve
NOTE:
For single A/C model, refer to the same section of the Service Manual mentioned in FOREWORD of
this manual.
[A] : Dual A/C model 3. Condenser assembly 6. Expansion valve 9. Rear expansion valve
1. Compressor 4. Receiver/dryer 7. A/C evaporator 10. Rear A/C evaporator
2. Magnet clutch 5. Dual pressure switch 8. Solenoid valve
[A]10
8
9
5
7
6
3
2
14 : Liquid
: Vapor
: Superheated Vapor

1B-6 AIR CONDITIONING (OPTIONAL)
Diagnosis
General
Main A/C system (front A/C system)
Condition Possible Cause Correction
Cool air does not
come out (A/C system
does not operative)No refrigerant Perform recover, evacuation and
charging.
Fuse blown Check “IG METER”, “REAR DEFG”
and “A/C” fuses, and check for
short circuit to ground.
A/C switch faulty Check A/C switch.
Blower motor switch faulty Check blower motor switch.
A/C evaporator temperature sensor (A/C evap-
orator thermistor) faultyCheck A/C evaporator tempera-
ture sensor (A/C evaporator ther-
mistor).
Refrigerant (dual) pressure switch faulty Check refrigerant (dual) pressure
switch.
Wiring or grounding faulty Repair as necessary.
A/C ON permission signal in ECM faulty Check A/C ON permission signal.
A/C controller and its circuit faulty Check A/C controller and its circuit.
Cool air does not
come out (A/C com-
pressor does not
operative (won’t rota-
tive))Magnet clutch faulty Check magnet clutch.
Compressor relay faulty Check compressor thermal switch.
Compressor relay faulty Check compressor relay.
Drive belt loose or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
A/C ON permission signal in ECM faulty Check A/C ON permission signal.
A/C controller faulty Check A/C controller.
Cool air does not
come out (A/C con-
denser cooling fan
motor does not opera-
tive)Condenser cooling fan motor relay faulty Check condenser cooling fan motor
relay.
Wiring or grounding faulty Repair as necessary.
A/C condenser fan motor relay signal in ECM
faultyCheck A/C condenser cooling fan
motor relay signal.
Condenser cooling fan motor faulty Check condenser cooling fan
motor.
Cool air does not
come out (Blower
motor does not opera-
tive)Fuse blown Check “FRONT BLOW” and
“REAR DEFG” fuses, and check for
short circuit to ground.
Blower motor relay faulty Check blower motor relay.
Blower motor resistor faulty Check blower motor resistor.
Blower motor switch faulty Check blower motor switch.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor.

AIR CONDITIONING (OPTIONAL) 1B-7
Cool air does not
come out or insuffi-
cient cooling (A/C sys-
tem normal operative)Insufficient or excessive charge of refrigerant Check charge of refrigerant.
Refrigerant leak in system Check system for leaks.
Condenser clogged Check condenser.
A/C evaporator clogged or frosted Check A/C evaporator.
A/C evaporator temperature sensor (A/C evap-
orator thermistor) faultyCheck A/C evaporator tempera-
ture sensor (A/C evaporator ther-
mistor).
A/C controller faulty Check A/C controller.
Expansion valve faulty Check expansion valve.
Drive belt slipping Check or replace drive belt.
Magnetic clutch faulty Check magnetic clutch.
Cool air does not
come out or insuffi-
cient cooling (A/C sys-
tem normal operative)Compressor faulty Check compressor.
Air in A/C system Replace condenser dryer, and then
perform evacuation and charging.
Air leaking from cooling unit or air duct Repair as necessary.
Heater and ventilation system faulty Check air inlet box assembly.
Check heater control lever assem-
bly.
Check heater assembly.
Blower motor faulty Check blower motor.
Excessive compressor oil existing in A/C sys-
temPull out compressor oil in A/C sys-
tem circuit, and replace compres-
sor.
Cool air does not
comes out only inter-
mittentlyWiring connection faulty Repair as necessary.
Expansion valve faulty Check expansion valve.
Excessive moisture in A/C system Replace condenser dryer, and then
perform evacuation and charging.
A/C controller faulty Check A/C controller.
Magnetic clutch faulty Check magnetic clutch.
Excessive charge of refrigerant Check charge of refrigerant.
Cool air comes out
only at high speedsCondenser clogged Check condenser.
Insufficient charge of refrigerant Check charge of refrigerant.
Air in A/C system Replace condenser dryer, and then
perform evacuation and charging.
Drive belt slipping Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air does not
comes out only at high
speedsExcessive charge of refrigerant Check charge refrigerant.
A/C evaporator frosted Check A/C evaporator.
Check A/C thermistor.
Insufficient velocity of
cooled airA/C evaporator clogged or frosted Check A/C evaporator.
Air leaking from cooling unit or air duct Repair as necessary.
Blower motor faulty Check blower motor.
Wiring or grounding faulty Repair as necessary. Condition Possible Cause Correction

AIR CONDITIONING (OPTIONAL) 1B-17
A/C CONTROLLER VOLTAGE VALUES TABLE
Terminal Wire CircuitMeasurement
groundNormal value Condition
AC-A-1BLK/
WHTController main
power supplyGround to
engine (Fig B)10 – 14 VIgnition switch ON with engine
stopped
AC-A-2BLK/
YELController main
groundGround to body
(Fig A)–0.4 – 0 V Engine running
AC-A-4 ORNRefrigerant
(dual) pressure
switch inputGround to
engine (Fig B)0 – 1 VRefrigerant pressure within 225
kpa (2.3 kg/cm
2, 32.7 psi) to
2548 kpa (26 kg/cm
2, 370 psi)
with engine running
10 – 14 VRefrigerant pressure below 196
kpa (2.0 kg/cm
2, 28 psi) or above
3140 kpa (32 kg/cm
2, 455 psi)
with engine running
AC-A-7GRN/
BLKA/C switch and/
or defroster
switch inputGround to
engine (Fig B)8 – 14 VBlower fan motor switch or A/C or
defroster switch OFF with engine
running
0 – 1.5 VBlower fan motor switch and A/C
or defroster switch ON with
engine running
AC-A-9GRY/
WHTSignal input from
ECM (A/C ON
permission sig-
nal)Ground to
engine (Fig B)10 – 14 V Approve of A/C ON
0 – 1 V A/C ON forbid
AC-A-13YEL/
BLKSignal output to
ECM (A/C ON
request signal)Ground to
engine (Fig B)0 – 1.5 VBlower fan motor switch and A/C
or defroster switch ON with
engine running at A/C evaporator
temperature sensor temperature
input more than approx. 2.5 °C
(less than 2.5 V (5840 Ω)) and
refrigerant pressure switch is ON
10 – 14 VExcept the above-mentioned with
engine running
AC-A-16 PNKCompressor
magnet clutch
relay outputGround to
engine (Fig B)0 – 1 VBlower fan motor switch and A/C
or defroster switch ON with
engine running at A/C evaporator
temperature sensor temperature
input more than approx. 2.5 °C
(less than 2.5 V (5840 Ω)), refrig-
erant pressure switch ON and
signal input from ECM ON
10 – 14 VExcept the above-mentioned with
engine running
AC-B-1BLU/
YELSensor groundGround to body
(Fig A)–0.4 – 0 V Engine running

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

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.