Washer SUZUKI GRAND VITARA 2000 2.G Service Workshop Manual

YH4
GRAND
VITARA
ªAº
0A-8 GENERAL INFORMATION

When removing the battery, be sure to disconnect the nega-
tive cable first and then the positive cable. When reconnect-
ing the battery, connect the positive cable first and then the
negative cable, and replace the terminal cover.

When removing parts that are to be reused, be sure to keep
them arranged in an orderly manner so that they may be rein-
stalled in the proper order and position.

Whenever you use oil seals, gaskets, packing, O-rings, lock-
ing washers, split pins, self-locking nuts, and certain other
parts as specified, be sure to use new ones. Also, before
installing new gaskets, packing, etc., be sure to remove any
residual material from the mating surfaces.

Make sure that all parts used in reassembly are perfectly
clean.

When use of a certain type of lubricant, bond or sealant is
specified, be sure to use the specified type.
ªAº: Sealant 99000-31150

Be sure to use special tools when instructed.
Special Tool
(A): 09917-98221
(B): 09916-58210

YH4
GRAND
VITARA
1B-56 AIR CONDITIONING (OPTIONAL)
1. Clutch plate bolt
2. Clutch plate
3. Circlip
4. Clutch pulley
5. Washer
6. Shim
7. Oil felt ring
8. Clutch coil
9. Lip type seal
10. Compressor front head
11. Compressor body component
12. O-ring
13. Compressor thermal switch
3. Washer
(if equipped)1. Thermal switch
2. Ohmmeter
MAGNET CLUTCH ASSEMBLY (FOR SEIKO SEIKI)
INSPECTION
MAGNET CLUTCH

Inspect clutch plate and clutch pulley for signs of oil.

Check clutch pulley bearings for noise and grease leakage.

Using and ohmmeter, measure resistance of clutch coil between
clutch coil lead wire (1) and compressor body.
If measured resistance is not within tolerance, replace coil.
Standard resistance: 2.5 ± 4.5
at 20C, 68F
COMPRESSOR THERMAL SWITCH
Use an ohmmeter to check thermal switch for continuity. If there is
no continuity, replace it.
REMOVAL
1) Remove compressor assembly from vehicle. Refer to COM-
PRESSOR ASSEMBLY in this section.
2) Fix clutch plate (1) with special tool (A) and remove clutch plate
bolt (2).
Special Tool
(A): 09991-06020
NOTE:
Do not reuse armature plate nut.

YH4
GRAND
VITARA
3. Washer
(if equipped)
1B-58 AIR CONDITIONING (OPTIONAL)
4) Install clutch pulley (1).
(1) Set clutch pulley squarely over clutch pulley installation boss.
(2) Place special tool (D) onto clutch pulley bearing.
Ensure that edge rests only on inner race of bearing.
(3) Install snap ring.
Special Tool
(D): 09991-06010
CAUTION:
Be careful not to scratch bearing seal.
5) Adjust clearance, between clutch plate and clutch pulley (2) by
putting shim on compressor shaft.
Standard clearance ªaº: 0.3 ± 0.6 mm (0.012 ± 0.024 in.)
6) Tighten new clutch plate (1) bolt (2) as specified below.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
Special Tool
(A): 09991-06020

YH4
GRAND
VITARA
1B-60 AIR CONDITIONING (OPTIONAL)
1. Front head
2) Coat special tool (F) surface with oil and place it on the shaft.
Special Tool
(F): 09991-06040
3) Install O-ring (2) to case.
4) Apply compressor (refringent) oil to lip seal and O-ring.
5) Install compressor front head (1).
6) Tighten compressor front head bolt.
Tightening Torque
(a): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
NOTE:

Be sure to use new front head bolt washer.

Tighten bolt (a) first, and next (b).

YH4
GRAND
VITARA
POWER STEERING (P / S) SYSTEM 3B1-17
1. Tie-rod
2. Steering rack
3. Boot
4. Mark
1. Tie-rod lock washer
2. Tie-rod
3. Steering rack
4. Aluminium plate
5. Vise
1. Tie-rod
2. Mark
3. Lock nut
4. Tie-rod end
5. Knuckle
6. Nut
2) Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock
nut to the mark made in removal.
3) Install steering gear box assembly by referring ªPOWER
STEERING GEAR BOX ASSEMBLY INSTALLATIONº in this
section.
After installation, fill specified P / S fluid and bleed air from sys-
tem. Then check toe setting and adjust as required.
RACK BOOT AND TIE-ROD
(FOR CANVAS TOP LH MODEL)
REMOVAL
1) Remove steering gear case, refer to ªPOWER STEERING
GEAR BOX ASSEMBLY REMOVALº in this section.
2) For ease of adjustment after installation, make marking of tie-rod
end lock nut position of tie-rod thread.
3) Loosen tie-rod end lock nut and remove tie-rod end.
4) Remove boot band and clip.
5) Remove boot from tie-rod.
6) Unbend washer (2 places), and remove tie-rod from rack.

YH4
GRAND
VITARA
3B1-18 POWER STEERING (P / S) SYSTEM
ªAº
1
1
1. Mark
1. Tie-rod lock washer
(A)
INSTALLATION
1) Install new tie-rod lock washer and tie-rod to rack.
2) Tighten tie-rod ball nut to specified torque.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
3) Bend lock washer 2 place at the flat part of tie-rod ball nut.
4) Apply grease to ªAº indicated in figure.
5) Position boot properly in grooves of gear case and tie-rod.
Check to ensure that boot is free from twist and dent.
6) Fasten boot with new clamp and clip securely.
Special Tool
(A): 09943-55010
7) Install tie-rod end lock nut and tie-rod end to tie-rod.
Position lock nut to marking made in removal.
NOTE:
When tie-rod was replaced, measure length ªAº on re-
moved tie-rod and use it on new replacement tie-rod so as
to position lock nut properly.
8) Install steering gear case. Refer to ªPOWER STEERING GEAR
BOX ASSEMBLY INSTALLATIONº in this section.

YH4
GRAND
VITARA
FRONT SUSPENSION 3D-5
1. Suspension control arm
2. Stabilizer bar
3. Stabilizer ball joint
4. Ball joint bushings
5. Ball joint washers
6. Ball joint nuts
7. Bracket bolts
1. Painted
2. Mount bush bracket
3. Mount bush
ON-VEHICLE SERVICE
STABILIZER BAR / BUSHINGS
REMOVAL
1) Hoist vehicle.
2) Remove stabilizer bar mount bush bracket bolts.
3) Remove stabilizer ball joint nuts, washers and bushings.
4) Remove stabilizer bar with its ball joints.
5) Disconnect stabilizer ball joints from stabilizer bar.
INSTALLATION
NOTE:
For correct installation of stabilizer bar, side-to-side, be sure
that color paint on stabilizer bar aligns with mount bush, both
right and left, as shown.
1) Connect stabilizer ball joints and stabilizer bar.
2) Install stabilizer ball joints to control arms.
NOTE:
Do not tighten stabilizer ball joint nuts completely.
3) Install stabilizer bar mount bush brackets.
4) When installing stabilizer, loosely assemble all components
while insuring that stabilizer is centered, side-to-side.
Check that ball joint is set at neutral position seeing from body
upper side.
5) Tighten stabilizer bracket bolts and stabilizer ball joint nuts to
specified torque.
Tightening Torque
(a): 29 N
.m (2.9 kg-m, 21.0 lb-ft)
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(c): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
3D-8 FRONT SUSPENSION
1. Circlip
2. Washer
1. Wire
1. Front wheel
speed sensor
2. Harness clamp bolt
COIL SPRING
REMOVAL
1) Hoist vehicle, allowing front suspension to hang free.
2) Remove wheels.
3) Remove axle shaft drive flange (For 4WD vehicle).
4) Remove front drive shaft circlip and washer (For 4WD vehicle).
5) Remove caliper bolts and suspend caliper with a wire hook.
CAUTION:
Hang removed caliper with a wire hook so as to prevent
brake hose from bending and twisting excessively or be-
ing pulled.
Don't operate brake pedal with pads removed.
6) If equipped with ABS, remove harness clamp bolt and remove
front wheel speed sensor from knuckle.
CAUTION:

Do not pull wire harness when removing front wheel
speed sensor.

Do not cause damage to surface of front wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.
7) Remove brake disc.
NOTE:
If brake disc can not be removed by hand, use 8 mm bolts
as shown.

YH4
GRAND
VITARA
3D-10 FRONT SUSPENSION
ªaº < ªbº
1. Circlip
2. Large diameter
1. Axle shaft drive flange
2. Bolt 1. Spring seat
Bottom
INSTALLATION
Reverse removal procedure to install coil spring.
NOTE:
Upper and lower diameters of coil spring are different.
Bring larger diameter end at bottom and set its open end in
place on spring seat.

Be sure to use specified torque for tightening each fastener.

Refer to torque specification chart at the end of this section.

As for ball stud nut, be sure to insert split pin and bend it after tight-
ening it.

Tighten tie-rod end nut with pushing ball stud to upper side so as
not ball stud to be rotated.

For 4WD vehicle
Apply lithium grease to front drive shaft washer and front wheel
spindle outer.
ªAº: Grease 99000-25010

For 4WD vehicle
When installing circlip to drive shaft, utilize screw hole in drive
shaft to pull it out and bring large diameter of circlip at right as
shown.

For 4WD vehicle
When installing axle shaft drive flange to wheel hub, apply sealant
to mating surface of axle shaft drive flange and tighten flange bolt
to specified torque.
ªAº: Sealant 99000-31090
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)

YH4
GRAND
VITARA
3D-12 FRONT SUSPENSION
1. Lock washer
2. Screws 1. Axle shaft drive flange
WHEEL HUB (INCLUDED WHEEL BEARING)
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove axle shaft drive flange (4WD vehicle) or hub cap (2WD
vehicle).
3) If equipped with ABS, remove wheel speed sensor from knuckle
and harness clamp from strut.
4) Remove caliper bolt and suspend caliper.
CAUTION:
Hang removed caliper with a wire hook or the like so as to
prevent brake hose from bending and twisting excessively
or being pulled.
Don't operate brake pedal with pads removed.
5) Remove brake disc.
NOTE:
If brake disc can not be removed by hand, use 8 mm bolts as
shown.
6) Remove front wheel bearing lock washer by loosening 4 screws.
7) Remove front wheel bearing lock nut by using special tool.
Special Tool
(A): 09951-16050
8) Remove front wheel bearing washer.
9) Remove wheel hub component by hand.