check oil SUZUKI GRAND VITARA 1999 2.G Owners Manual

GENERAL INFORMATION 0A-5
CAUTION:
 Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys-
tem parts and other related parts according to instructions under “REPAIR AND INSPECTION
REQUIRED AFTER AN ACCIDENT” in SECTION 10B.
 When servicing parts other than air bag system, if shocks may be applied to air bag system compo-
nent parts, remove those parts beforehand.
 When handling the air bag (inflator) modules (driver and passenger), forward sensors or SDM, be
careful not to drop it or apply an impact to it. If an excessive impact was applied (e.g., dropped from
a height of 91.4 cm (3 feet) or more), never attempt disassembly or repair but replace it with a new
one.
 When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and pas-
senger), wipe off immediately with a dry cloth.
 Air bag wire harness can be identified easily as it is covered with a yellow protection tube. Be very
careful when handling it.
 When an open in air bag wire harness, damaged wire harness, connector or terminal is found,
replace wire harness, connectors and terminals as an assembly.
 Do not apply power to the air bag system unless all components are connected or a diagnostic
chart requests it, as this will set a diagnostic trouble code.
 Never use air bag system component parts from another vehicle.
 When using electric welding, be sure to temporarily disable air bag system referring to “DIS-
ABLING AIR BAG SYSTEM” in SECTION 10B.
 Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
 WARNING/CAUTION labels are attached on each part of air bag system components. Be sure to fol-
low the instructions.
 After vehicle is completely repaired, perform “AIR BAG DIAGNOSTIC SYSTEM CHECK” in SEC-
TION 10B.

0B-6 MAINTENANCE AND LUBRICATION
POWER STEERING PUMP AND/OR A/C COMPRESSOR
DRIVE BELTS (IF EQUIPPED) INSPECTION
1) Disconnect negative (–) cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace.
Check belt for tension.
If belt tension is out of above specification, adjust it referring
to Section 1B or 3B1.
Power steering pump and/or A/C compressor
drive belt tension
“a” : 4 - 7 mm (0.16 - 0.28 in.) deflection under
100 N (10 kg, 22 lb) pressure
3) Connect negative (–) cable to battery.
POWER STEERING PUMP AND/OR A/C COMPRESSOR
DRIVE BELTS (IF EQUIPPED) REPLACEMENT
Replace belt referring to Section 1B or 3B1 for replacement pro-
cedure of belt.
ITEM 1-4
Engine oil and filter replacement
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.
[A]: H27 engine with P/S system
[B]: H27 engine with P/S and A/C system
1. Crankshaft pulley
2. P/S pump pulley
3. A/C compressor pulley (if equipped)
4. Tension pulley
5. Tension pulley bolts
WARNING:
 New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
 Step 1) - 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

0B-8 MAINTENANCE AND LUBRICATION
6) Replenish oil until oil level is brought to FULL level mark on
dipstick. (oil pan and oil filter capacity). The filler inlet is at
the top of the cylinder head cover.
It is recommended to use engine oil of SE, SF, SG, SH or SJ
grade.
NOTE:
Select the appropriate oil viscosity according to the proper
engine oil viscosity chart [A].
Engine oil specification :
7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait 5 min-
utes before checking oil level. Add oil, as necessary, to bring
oil level to FULL level mark on dipstick.
[A]: Proper engine oil viscosity chart
H27 engine
Oil pan capacity liters (US/lmp pt.) About 5.0 (10.6/8.8)
Oil filter capacity liters (US/lmp pt.) About 0.5 (1.1/0.9)
Others liters (US/lmp pt.) About 0.7 (1.5/1.2)
Total liters (US/lmp pt.) About 6.2 (13.1/10.9)
NOTE:
Engine oil capacity is specified. However, note that the
amount of oil required when actually changing oil may
somewhat differ from the data in the table depending on
various conditions (temperature, viscosity, etc.)
1. Full level mark (hole)
2. Low level mark (hole)

AIR CONDITIONING (OPTIONAL) 1B-1
1B
SECTION 1B
AIR CONDITIONING (OPTIONAL)
CONTENTS
General Description ....................................... 1B-3
Refrigerant Type .......................................... 1B-3
Refrigerant Flow of Air Conditioning System 1B-3
Major Components And Location ................. 1B-4
Diagnosis ........................................................ 1B-6
General ........................................................ 1B-6
Main A/C system (front A/C system) ........ 1B-6
Rear A/C system ...................................... 1B-8
Quickly Checking of Refrigerant Charge
(If Equipped with Sight Glass) ...................... 1B-9
Performance Diagnosis .............................. 1B-10
Performance diagnosis table .................. 1B-12
Detail diagnosis table (at ambient temperature within 30 - 35 °C
(85 - 95 °F)) ............................................ 1B-13
Wiring Circuit.............................................. 1B-14
Inspection of A/C Controller and Its
Circuits ....................................................... 1B-15
Voltage check......................................... 1B-15
Refrigerant Recovery, Evacuation and
Charging ....................................................... 1B-19
Operation Procedure for Charging A/C with
Refrigerant ................................................. 1B-19
Recovery .................................................... 1B-20
Evacuating ................................................. 1B-21
Evacuating procedure ............................ 1B-21
Checking system for pressure leaks ...... 1B-22 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to “REFRIGERANT TYPE” in this section.
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.
NOTE:
 For the descriptions (items) not found in this section, refer to the same section of the Service Man-
ual mentioned in FOREWORD of this manual.
 For basic servicing method of the air conditioning system that is not described in this section, refer
to “AIR CONDITIONING BASIC MANUAL (99520-02130)”.

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

1B-12 AIR CONDITIONING (OPTIONAL)
Performance diagnosis table
HIGH PRESSURE GAUGE
LOW PRESSURE GAUGE
THERMOMETER AT CENTER DUCT
Condition Possible Cause Correction
Pressure high
(“A” area of high side
graph)Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high side Clean or replace.
Condenser cooling fan malfunction (Insufficient cooling
of condenser)Check condenser cooling fan.
Dirty or bent condenser fins (Insufficient cooling of con-
denser)Clean or repair.
Compressor malfunction (Insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system.
Pressure low
(“B” area of high side
graph)Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.
Condition Possible Cause Correction
Pressure high
(“C” area of low side
graph)Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.
Pressure low
(“D” area of low side
graph)Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too narrow) Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.
Condition Possible Cause Correction
Outlet air temperature at
center duct is high
(Crossing point is in area
“E”)Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of damper in cool-
ing (heater) unitRepair or replace.
Compressor malfunction Check compressor.
Outlet air temperature at
center duct is low
(Crossing point is in area
“F”)Insufficient air volume from center duct (Heater blower
malfunction)Check blower motor and fan.
Compressor malfunction Check compressor.
NOTE:
If ambient temperature is within 30 - 35 °C (85 - 95 °F), it is possible to do using “DETAIL DIAGNOSIS
TABLE” in this section for detail diagnosis.

AIR CONDITIONING (OPTIONAL) 1B-13
Detail diagnosis table (at ambient temperature within 30 - 35 °C (85 - 95 °F))
Condition Possible Cause Correction
MANIFOLD
GAUGEMPa
(kg/cm
2)
(psi)Detail
Lo Hi
0.23 - 0.35
(2.3 - 3.5)
(33 - 50)1.4 - 1.75
(14 - 17.5)
(200 - 249)Normal condition––
Negative
pressure0.5 - 0.6
(5 - 6)
(71.2 - 85.3)The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.
Presence of frost around
tubing to and from receiver/
dryer and expansion valve.Dust particles or water drop-
lets are either stuck or frozen
inside expansion valve, pre-
venting the refrigerant from
flowing.Clean expansion valve.
Replace it if it cannot be
cleaned.
Replace condenser/dryer.
Evacuate the A/C system and
recharge with fresh refriger-
ant.
Normal :
0.23 - 0.35
(2.3 - 3.5)
(33 - 50)
↑ ↓
↑ ↓↑ ↓ ↑ ↓
Abnormal :
Negative
pressureNormal :
1.4 - 1.75
(14 - 17.5)
(200 - 249)
↑ ↓
↑ ↓↑ ↓ ↑ ↓
Abnormal :
0.7 - 1.0
(7 - 10)
(100 - 142)During A/C operation, the
low pressure side some-
times indicates negative
pressure, and sometimes
normal pressure. Also high
pressure side reading fluc-
tuates between the abnor-
mal and normal pressure.Expansion valve is frozen due
to moisture in the system, and
temporarily shuts off the
refrigeration cycle.Replace expansion valve.
Replace condenser/dryer.
Evacuate A/C system and
recharge with fresh refriger-
ant.
0.05 - 0.15
(0.5 - 1.5)
(4.2 - 21.3)0.7 - 1.0
(7 - 10)
(100 - 142)Both low and high pressure
sides indicate low readings.
Continuous air bubbles are
visible through sight glass.
Output air is slightly cold.Insufficient refrigerant in sys-
tem. (Refrigerant leaking)Using a gas leak detector,
check for leaks and repair as
necessary.
Recharge refrigerant to a
specified amount.
If the pressure reading is
almost 0 when the manifold
gauges are attached, check
for any leaks, repair them,
and evacuate the system.
0.4 - 0.6
(4 - 6)
(56.9 - 85.3)Pressure on low pressure
side is high.
Pressure on high pressure
side is low.
Both pressure becoming
equal right after A/C is
turned OFF.Internal leak in compressor Inspect compressor and
repair or replace as neces-
sary.
0.35 - 0.45
(3.5 - 4.5)
(50 - 64)2.0 - 2.5
(20 - 25)
(285 - 355)High pressure reading on
both low and high pressure
sides.
Air bubbles are not visible
even when engine rpm is
lowered.Overcharged A/C system.
Faulty condenser cooling
operation.
Faulty condenser fan opera-
tion.Adjust refrigerant to specified
amount.
Clean condenser.
Inspect and repair condenser
fan.
High pressure reading on
both low and high pressure
sides.
Low pressure side tubing is
not cold when touched.
Air bubbles are visible
through sight glass.Presence of air in A/C sys-
tem. (Improperly evacuated)Replace condenser dryer.
Inspect quantity of compres-
sor oil and presence of con-
taminants in oil.
Evacuate system and
recharge with fresh refriger-
ant.
0.45 - 0.55
(4.5 - 5.5)
(64 - 78)High pressure reading on
both low and high pressure
sides.
Large amount of frost or
dew on the low pressure
side tubing.Faulty expansion valve.
Refrigerant flow is not regu-
lated properly.Replace expansion valve.

AIR CONDITIONING (OPTIONAL) 1B-29
4) Loosen floor suction pipe and floor liquid pipe mounting bolt
(1).
5) Remove rear A/C No.1 duct (1).
6) Disconnect rear A/C unit wire couplers (2).
7) Remove rear A/C unit mounting bolts (3), and then remove
rear A/C unit (4).
INSPECTION
Check the following.
Clog of rear A/C evaporator fins.
If any clogs are found, rear A/C evaporator fins should be
washed with water, and should be dried with compressed air.
Rear A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace rear A/C evapora-
tor.
INSTALLATION
Reverse removal procedure to install rear A/C unit noting the fol-
lowing points.
Evacuate and charge system. Refer to “RECOVERY” and
“EVACUATING” in this section.
When the rear A/C evaporator thermistor (temperature sen-
sor) removed, it should be reinstalled in original position.
If rear A/C unit or rear A/C evaporator is replaced, pour 25
cm
3 (25 cc) of refrigerating oil to compressor suction-side.
Rear Expansion Valve
INSPECTION
Refer to “PERFORMANCE DIAGNOSIS” in this section.
2. Muffler
1
2
NOTE:
Cap open fitting immediately to keep moisture out of sys-
tem.
23
1
4

AIR CONDITIONING (OPTIONAL) 1B-31
INSPECTION
1) Connect battery positive (+) cable to terminal “b” and battery
negative (–) cable to terminal “c” as shown.
2) Using ohmmeter, check continuity between terminal “a” and
terminal “b” at specified temperature as shown.
Rear A/C evaporator temperature controller specification :
“A” : Approximately 3.5 °C (38.3 °F)
“B” : Approximately 5.0 °C (41 °F)
INSTALLATION
Reverse removal procedure to install rear A/C evaporator temper-
ature controller noting the following instruction.
When the rear A/C evaporator thermistor (temperature sen-
sor) removed, it should be reinstalled in original position.
Refrigerant Pipes and Hoses
INSPECTION
Use a leak tester to check hoses and pipes for any gas leakage.
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 sys-
tem when reinstalling.
2) Replace defective hose or pipe.
INSTALLATION
Reverse removal procedure to install refrigerant line noting the following instruction.
Evacuate and charge system. Refer to “EVACUATING” and “CHARGING” in this section.
CAUTION:
As soon as the above hose or pipe is disconnected, cap its opened fitting to prevent moisture and
dust from entering.
NOTE:
Remove EVAP canister and fuel tank cover, if necessary

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