Mount SUZUKI GRAND VITARA 1999 2.G Service Owner's Manual

YH4
GRAND
VITARA
1. New compressor
2. Removed compressor
3. Excess oil (A ± B)
1B-32 AIR CONDITIONING (OPTIONAL)
REPLENISHING COMPRESSOR OIL
When replacing air conditioning parts with new ones, it is necessary
to replenish oil by the amount supposedly remaining in each part.
When changing gas only
When it is unavoidable to change gas without replacing any compo-
nent part for engine removal and installation or for some other rea-
son, replenish 20 cc oil. When replenishing gas only, oil replenish-
ment it not necessary.
When replacing compressor
Compressor oil is sealed in each new compressor by the amount
required for air conditioner cycle. Therefore, when using a new
compressor for replacement, drain oil from it by the amount calcu-
lated as follows.
ªCº = ªAº ± ªBº
ªCº: Amount of oil to be drained
ªAº: Amount of oil sealed in a new compressor
ªBº: Amount of oil remaining in removed compressor
When replacing other part
Replaced partAmount of compressor oil
to be replenished
Evaporator25 cc
Condenser15 cc
Receiver / dryer20 cc
Hoses10 cc each
Pipes10 cc each

YH4
GRAND
VITARA
2. Bolt
For CAMI production vehicle
For IWATA production vehicle
AIR CONDITIONING (OPTIONAL) 1B-33
A / C CONDENSER ASSEMBLY
INSPECTION
Check
a) condenser fins for blockage
b) condenser fittings for leakage
c) condenser fins for damage
Clogged condenser fins should be washed with water, and should
be dried with compressed air.
CAUTION:
Be careful not to damage condenser fins. If condenser fin is
bent, straighten it by using a screwdriver or pair of pliers. If
any leakage is found from fitting or tube, repair or replace
condenser.
REMOVAL
1) Disconnect negative (±) cable at battery.
2) 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 added to the system.
3) Remove front bumper assembly and remove lower stay (1) if
equipped (Refer to Section 9 ªBODY SERVICEº).
4) Disconnect compressor discharge hose (1) from condenser in-
let fittings.
CAUTION:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust do not enter
condenser.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-39
COOLING UNIT (EVAPORATOR)
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº in
Section 10B.
3) 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 added to the system.
4) For G16 and J20 engine
Disconnect suction pipe (1), and liquid pipe (2) from evaporator
(cooling unit).
CAUTION:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust may not enter
cooling unit.
5) Remove blower motor unit. Refer to Section 1A ªHEATER AND
VENTILATIONº.
6) Disconnect thermistor wire coupler.
7) Remove cooling unit (evaporator).
DISASSEMBLY (FOR CAMI PRODUCTION VEHICLE)
1) Remove filter (2) from cooling unit (3) assembly by removing fil-
ter cover (1).
2) Remove screws (1) to separate evaporator upper and lower
cases from each other.

YH4
GRAND
VITARA
3. Pipe clamp
1B-42 AIR CONDITIONING (OPTIONAL)
EXPANSION VALVE
INSPECTION
Refer to ªTroubleshooting Procedure Using Manifold Gauge Setº in
this section.
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 added to the system.
2) Remove front grill.
3) Disconnect suction pipe (1), and liquid pipe (2) from evaporator
(Cooling unit).
CAUTION:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust may not enter
cooling unit.
4) Disconnect suction pipe, and liquid pipe from suction hose (1)
and condenser outlet pipe (2).
5) Remove pipe clamp then remove suction pipe and liquid pipe.
6) Remove expansion valve (1).
INSTALLATION
1) Reverse removal sequence to install expansion valve.
2) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.

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.

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GRAND
VITARA
1B-50 AIR CONDITIONING (OPTIONAL)
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.
NOTE:
The amount of compressor oil at removed must be mea-
sured and the same amount must be poured when installing
the compressor.
4) Disconnect thermal protector lead wire.
5) Disconnect suction and discharge hoses from compressor as-
sembly.
NOTE:
Cap open fitting immediately to keep moisture out of sys-
tem.
6)For G16 engine:
Remove compressor drive belt by loosening compressor as-
sembly mounting bolts.
For J20 engine:
Remove generator belt. Refer to Section 6H.
For H25 engine:
Remove compressor drive belt by loosening tension pulley bolt.
7) Remove compressor with magnet clutch assembly from its
mount.
8) If compressor assembly is replaced. Drain oil from compressor
assembly, and measure its amount.

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GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-51
G16 engine
J20 engine
H25 engine
3. Compressor pulley
4. Crankshaft pulley
INSTALLATION
FOR IWATA PRODUCTION VEHICLE
1) Pour new compressor oil. The amount must be the same with
the amount measured in REMOVAL.
NOTE:
Compressor assembly supplied from factory is filled up
with following amount of oil.
Amount of oil in compressor: 120 cm
3 (120 cc, 7.5 in3)
2)For G16 engine:
Install compressor assembly temporarily to bracket, then install
compressor drive belt (2).
For J20 and H25 engines:
Install compressor assembly to its bracket.
Tighten bolts (a) first, then (b).
Tightening Torque
(a), (b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Connect suction and discharge hoses to compressor assembly.
4)For G16 engine:
Tension compressor drive belt (2) by tightening compressor as-
sembly mounting bolts. Refer to Section 3B1 for drive belt ten-
sion.
Tighten bolt (a) first, then (b).
Tightening Torque
(a), (b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
For J20 engine:
Install generator belt (1). Refer to Section 6H for details.
For H25 engine:
Install compressor drive belt (2). Refer to Section 3B1 for instal-
lation and belt tension.
5) Connect thermal protector lead wire.
6) Evacuate and charge system according to previously described
procedure.
CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.

YH4
GRAND
VITARA
1B-52 AIR CONDITIONING (OPTIONAL)
G16 engine
J20 engine
3. Compressor pulley
4. Crankshaft pulley
FOR CAMI PRODUCTION VEHICLE
1) Pour new compressor oil. The amount must be the same with
the amount measured in REMOVAL.
NOTE:
Compressor assembly supplied from factory is filled up
with the following amount of oil.
Amount of oil in compressor: 120 cm
3 (120 cc, 7.5 in3)
2)For G16 engine:
Install compressor assembly temporarily to bracket, then install
compressor drive belt (2).
For J20 engine:
Install compressor assembly to its bracket.
Tighten bolts (a).
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Connect suction and discharge hoses to compressor assembly.
4)For G16 engine:
Tension compressor drive belt (2) by tightening compressor as-
sembly mounting bolts. Refer to Section 3B1 for drive belt ten-
sion.
Tighten bolt (a) first, then (b).
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
For J20 engine:
Install generator belt (1). Refer to Section 6H for details.
5) Connect thermal protector lead wire.
6) Evacuate and charge system according to previously described
procedure.
CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-59
PUSH
3. Cylinder
4. Case
5. O-ring
2. Bearing puller
LIP TYPE SEAL (FOR SEIKO SEIKI)
REMOVAL
1) Remove magnet clutch assembly, referring to ªMAGNET
CLUTCH ASSEMBLYº in this section.
2) Remove compressor front head (1) mounting bolt (10 pcs.).
3) Remove compressor front head (1) by pushing cylinder shaft
(2).
NOTE:
Be careful not to remove cylinder from case.
4) Remove O-ring.
5) Remove lip seal from compressor front head (1).
INSTALLATION
1) Press-fit lip seal (1) into compressor front head (2) using special
tool (E).
Special Tool
(E): 09991-06050
CAUTION:
Do not reuse mechanical seal once removed from com-
pressor.

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.