valve cover SUZUKI GRAND VITARA 1999 2.G Service Workshop Manual

YH4
GRAND
VITARA
0B-8 MAINTENANCE AND LUBRICATION
ITEM 1-2
Camshaft Timing Belt Replacement (G16 engine only)
Replace timing belt referring to Section 6A1.
ITEM 1-3
Valve Lash Inspection (G16 engine only)
1) Remove cylinder head cover.
2) Inspect intake and exhaust valve lash and adjust as necessary.
Refer to Section 6A1 for valve lash inspection and adjustment
procedure.
Valve
lash
(ªº)
When cold
(Coolant tempera-
ture is 15 ± 25
C
or 59 ± 77
F)When hot
(Coolant tempera-
ture is 60 ± 68
C
or 140 ± 154
F)
(gap ªaº)
specifica-
tion
Intake0.13 ± 0.17 mm
(0.005 ± 0.007 in.)0.17 ± 0.21 mm
(0.007 ± 0.008 in.)
tion
Exhaust0.23 ± 0.27 mm
(0.009 ± 0.011 in.)0.28 ± 0.32 mm
(0.011 ± 0.013 in.)
3) Install cylinder head cover and tighten bolts to specification.
ITEM 1-4
Engine Oil and Filter Change
WARNING:
New and used engine oil can be hazardous.
Be sure to read ªWARNINGº in General Precaution in Sec-
tion 0A and observe what in written there.
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part be-
fore proceeding to the following work.
1) Drain engine oil by removing drain plug.
2) After draining oil, wipe drain plug clean. Reinstall drain plug, and
tighten it securely as specified below.
Tightening Torque
(a): 35 N
.m (3.5 kg-m, 25.5 lb-ft)

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VITARA
1B-6 AIR CONDITIONING (OPTIONAL)
DIAGNOSIS
GENERAL
ConditionPossible CauseCorrection
Cool air won't come out
(A / C system won't
operative)
No refrigerant

Fuse blown

A / C switch faulty

Blower motor switch faulty

A / C thermistor faulty

Dual pressure switch faulty

Wiring or grounding faulty

A / C ON permission signal in ECM
faulty

A / C controller and its circuit faultyRecover, evacuation and charging.
Check ªIG METERº fuse, ªREAR DEFGº
fuse, and ªA / C FUSEº and check for
short circuit to ground.
Check A / C switch.
Check blower motor switch.
Check A / C evaporator thermistor.
Check dual pressure switch.
Repair as necessary.
Check ON permission signal.
Check A / C controller and its circuit.
Cool air won't come out
(A / C compressor won't
operative)
Magnet clutch faulty

Compressor relay faulty

Compressor thermal switch faulty
(if equipped)

Drive belt loose or broken

Compressor faulty

A / C ON permission signal in ECM
faulty

A / C controller faultyCheck magnet clutch.
Check compressor thermal switch.
Check compressor relay.
Adjust or replace drive belt.
Check compressor.
Check ON permission signal.
Check A / C controller.
Cool air won't come out
(A / C condenser cooling
fan motor won't
operative)
Condenser cooling fan relay faulty

Wiring or grounding faulty

ªA / C condenser cooling fan relayº
signal in ECM faulty

Condenser cooling fan motor faultyCheck condenser cooling fan relay.
Repair as necessary.
Check A / C condenser cooling fan relay
signal.
Check condenser cooling fan motor.
Cool air won't come out
(Blower motor won't
operative)
Fuse blown

Blower motor relay faulty

Blower motor resistor faulty

Blower motor switch faulty

Wiring or grounding faulty

Blower motor faultyCheck ªHEATER FUSEº, ªREAR DEFGº
fuse and check for short circuit to
ground.
Check blower motor relay.
Check blower motor resistor.
Check blower motor switch.
Repair as necessary.
Check blower motor.
Cool air won't come out
or insufficient cooling
(A / C system normal
operative)
Insufficient or excessive charge of
refrigerant

Refrigerant leak in system

Condenser clogged

A / C evaporator clogged or frosted

A / C thermistor faulty

A / C controller faulty

Expansion valve faulty

Drive belt slipping

Magnetic clutch faultyCheck charge of refrigerant.
Check system for leaks.
Check condenser.
Check A / C evaporator.
Check A / C thermistor.
Check A / C controller.
Check expansion valve.
Check or replace drive belt.
Check magnetic clutch.

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GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-11
COMPRESSION SYSTEM DIAGNOSIS
Compressor troubles are mainly following three types: gas leakage, noise and insufficient pressure.
Compressor gas leakages in most cases develop from the shaft seal. When detecting gas leakage, always use
a leak tester. If a small amount of oil seeps out from the shaft seal, there is no necessity of replacing the seal. The
shaft seal has been designed to allow a small amount of oil to leak out for lubricating purpose. Thus, the shaft seal
should be replaced only when a large amount of compressor oil is leaking out or when gas leakage is discovered
by using gas tester.
In regard to noise and insufficient pressure, repairs should be made only after diagnosing the trouble properly.
CONDITION
POSSIBLE CAUSESCORRECTION
Noise from compressor
Defective bearing

Defective cylinder and / or shaftReplace.
Replace.
Noise from magnetic clutch
Defective bearing

Defective clutch faceReplace.
Replace.
Insufficient cooling
Defective gasketReplace.

Defective reed valveReplace.
Not rotating
Locked compressor

Seized magnetic clutch

Rotating parts seized by insufficient oil
amountReplace.
Replace.
Replace.
Oil and / or gas leakage
Defective seal

Defective O-ringReplace.
Replace.

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VITARA
For CAMI production vehicle
For IWATA production vehicle
AIR CONDITIONING (OPTIONAL) 1B-25
EVACUATING
EVACUATING PROCEDURE
CAUTION:
Do not evacuate before recovering refrigerant in system.
NOTE:
Whenever opened (exposed to atmospheric air), air condition-
ing system must be evacuated by using a vacuum pump. The
A / C system should be attached with a manifold gauge set, and
should be evacuated for approx. 15 minutes.
1) Connect high charging hose (1) and low charging hose (2) of
manifold gauge set (3) respectively as follows:
High Charging Hose (1)
High pressure charging valve (4)
on Discharge Hose
Low Charging Hose (2)i
Low pressure charging valve (5)
on Suction Pipe
2) Attach center charging hose (6) of manifold gauge set (3) to vac-
uum pump (7).
3) Operate vacuum pump (7), and then open discharge-side valve
(9) (Hi) of manifold gauge set (3).
If there is no blockage in the system, there will be an indication
on high pressure gauge (10).
When this occurs, open the other-side valve (8) (Lo) of the set.
4) Approx. 10 minutes later, low pressure gauge (11) should show
a vacuum lower than ± 760 mmHg providing no leakage exists.
NOTE:

If the system does not show a vacuum below ± 760 mmHg,
close both valves, stop vacuum pump and watch move-
ment of low pressure gauge.

Increase in the gauge reading suggests existence of leak-
age. In this case, repair the system before continuing its
evacuation.

If the gauge shows a stable reading (suggesting no leak-
age), continue evacuation.
5) Evacuation should be carried out for a total of at least 15 minutes.
6) Continue evacuation until low pressure gauge indicates a vacu-
um less than ± 760 mmHg, and then close both valves (8), (9).
7) Stop vacuum pump (7). Disconnect center charging hose (6) from
pump inlet. Now, the system is ready for charging refrigerant.
CHECKING SYSTEM FOR PRESSURE LEAKS
After completing the evacuation, close manifold gauge high pres-
sure valve (HI) and low-pressure valve (LO) and wait 10 minutes.
Verify that low-pressure gauge reading has not changed.
CAUTION:
If the gauge reading moves closer to ª0º, there is a leak
somewhere. Inspect the tubing connections, make neces-
sary corrections, and evacuate system once again, making
sure that there are no leaks.

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
1
1B-40 AIR CONDITIONING (OPTIONAL)
3) Remove upper case (1) and remove evaporator (2) from lower
case (3).
4) Remove following components from evaporator.

Expansion valve (5)

Thermistor (evaporator temperature sensor) (4)
DISASSEMBLY (FOR IWATA PRODUCTION VEHICLE)
1) Remove filter (2) from cooling unit (3) assembly by removing fil-
ter cover (1).
2) Detach clamps (1) to separate evaporator upper and lower
cases from each other.
3) Remove upper case (1) and remove evaporator (2) from lower
case (3).
4) Remove following components from evaporator.

Expansion valve (5)

Thermistor (evaporator temperature sensor) (4)

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
1. Suction connector
2. O-ring
3. Pressure switch
4. Flow control valve
(Relief valve)
5. Spring
6. Plug
7. Pump cover
8. Cam ring
9. Vane
10. Rotor
11. Snap ring
12. Side plate
13. Pulley (pump shaft)
14. Oil seal
15. Pump body
16. Flow control valve Assembly
3B1-4 POWER STEERING (P / S) SYSTEM
POWER STEERING (P / S) PUMP
The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft.
ModelVane type
Hydraulic
pressure
controlRelieved
pressure
6500 kPa (65 kg / cm2, 924 psi)
G16 Type engine . . . . . . . . . . . . . . . . . . . . . .
7000 kPa (70 kg / cm
2, 995 psi)
J20 Type engine . . . . . . . . . . . . . . . . . . . . . . .
7350 kPa (73.5 kg / cm
2, 1045 psi)
H25 Type engine . . . . . . . . . . . . . . . . . . . . . .
ControlFlow control valve
deviceRelief valve
Power steering
pressure switch
Switch turns on (closes) when the
pressure is higher than 2500 ± 3500 kPa
(25 ± 35 kg / cm
2, 356 ± 498 psi).
ECM uses this signal for idle speed control.
Capacity0.70 ± 0.75

(1.48 / 1.23 ± 1.58 / 1.32 US / Imp. pt)
Specified fluidDEXRON
II, DEXRON
III A / T fluid
or equivalent
FLOW CONTROL VALVE
As the discharge rate of the P/S pump increases in proportion to the
pump revolution speed, a flow control valve is added to control it so
that the optimum amount of fluid for steering operation is supplied
according to the engine speed (driving condition).
Described below is its operation at different engine speed.

YH4
GRAND
VITARA
3B1-20 POWER STEERING (P / S) SYSTEM
1. P/S fluid
reservoir
2. Suction hose
1. P / S pulley
2. Mounting bolt
9. Vane
10. Rotor
11. Snap ring
12. Side plate
13. Pulley (pump shaft)
14. Oil seal
15. Pump body
16. Flow control
valve Assembly 1. Suction connector
2. O-ring
3. Pressure switch
4. Flow control valve
(Relief valve)
5. Spring
6. Plug
7. Pump cover
8. Cam ring
REMOVAL
NOTE:
Be sure to clean each joint of suction and discharge sides
thoroughly before removal.
1) Remove suction hose from pump, then disconnect battery nega-
tive cable.
2) Remove P / S fluid reservoir with suction hose.
3) Remove union bolt. Then disconnect high pressure pipe from
pump.
NOTE:
As fluid flows out of disconnected joints, put a receptacle
under joints or a plug to pipe.
4) Disconnect pressure switch lead wire at switch terminal.
5) Loosen related bolts and remove power steering drive belt.
6) Remove P / S pump mounting bolt (s).
7) Remove P / S pump.
NOTE:
Plug each port of removed pump to prevent dust or any oth-
er foreign matter from entering.
DISASSEMBLY
1) Clean its exterior thoroughly.
2) With aluminum plates placed on vise first, grip pump body with
it.
3) Remove suction connector bolt, suction connector and O-ring
from pump body.
4) Remove power steering pressure switch (terminal set) from
pump body.
5) Remove plug, flow control spring and relief valve (flow control
valve) from pump body.
6) Remove cover bolts, pump cover and O-ring from pump body.
7) Remove snap ring from pump shaft.
8) Remove vanes from rotor.
9) Remove cam ring, rotor, side plate and O-rings from pump
body.
10) Pull out pulley from pump body.
11) Remove oil seal from pump body.

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VITARA
POWER STEERING (P / S) SYSTEM 3B1-21
1. Thickness gauge
INSPECTION
Pump Body, Cover, Side Plate and Shaft
Check sliding surfaces of each part for wear and damage.
If any defect is found, replace pump assembly.
Cam Ring
Check vane sliding surface of cam ring for wear and damage.
If any defect is found, replace pump assembly.
Rotor and Vane

Check sliding surfaces of rotor and vane for wear and damage.

Check clearance between rotor and vane.
Clearance: Standard 0.015 mm (0.0006 in.)
Limit 0.027 mm (0.0011 in.)
Replace pump assembly if any defect is found in above checks.
Relief Valve (Flow Control Valve) and Its Spring

Check fluid passage of relief valve and orifice of connector for ob-
struction (clogged).

Check sliding surface of relief valve for wear and damage.