panel SUZUKI GRAND VITARA 2000 2.G Service Workshop Manual

YH4
GRAND
VITARA
G16 engine
J20 engine
H25 engine
M / T (Type1)
4-speed A / T M / T (Type2)
GENERAL INFORMATION 0A-17
IDENTIFICATION INFORMATION
BODY NUMBER
The vehicle body number is on the left side of instrument panel and
punched on the chassis inside the tire housing on the right front side.
It is possible to identify the country of origin (the production plant)
of the vehicle by the first three digits of the body number as shown
below.
JSAxxx Japan (Iwata) produced. . . . . . . . . . .
2S2xxx Canada (CAMI) produced. . . . . . . . . . .
ENGINE IDENTIFICATION NUMBER
The number is punched on the cylinder block.
TRANSMISSION IDENTIFICATION NUMBER
The number is located on the transmission case.

YH4
GRAND
VITARA
1. Side ventilator outlet
2. Side defroster outlet
3. Center ventilator outlet
4. Heater unit
5. Defroster duct6. Ventilator duct
7. Heater control lever assembly
8. Heater mode control switch
9. Blower unit
10. Rear duct
1A-2 HEATER AND VENTILATION
GENERAL DESCRIPTION
The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an
agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left)
of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air outlets
at places, right and left, along the windshield glass.
The heater and ventilation consist of following parts.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-3
BODY VENTILATION
The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake
control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and
drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
DIAGNOSIS
DIAGNOSIS TABLE
TroublePossible causeRemedy
Heater blower won't
work even when its
switch is ON.Blower fuse blown
Blower resistor faulty
Blower motor faulty
Wiring or grounding faultyReplace fuse to check for short.
Check resistor.
Replace motor.
Repair as necessary.
Incorrect temperature
output.Control cables broken or binding
Air damper broken
Air ducts clogged
Heater radiator leaking or clogged
Heater hoses leaking or cloggedCheck cables.
Repair damper.
Repair air ducts.
Replace radiator.
Replace hoses.
When mode control
switch is changed,
air outlet port is not
changed.Mode control switch faulty
Mode actuator faulty
Fuse blown
Wiring or grounding faulty
Air damper broken
Air ducts cloggedCheck and replace as necessary.
Check and replace as necessary.
Replace fuse to check for short.
Repair as necessary.
Repair damper.
Repair air ducts.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-7
1. Fastening nuts
1. Air flow
BLOWER MOTOR
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Remove ECM with bracket from blower motor unit.
4) Disconnect harness clamps from dash panel.
5) Loosen three nuts fastening blower unit.
6) Disconnect blower motor lead wire at coupler (2).
7) Remove blower motor (3) from blower unit (1).
INSPECTION

Check continuity between terminal to terminal as shown in left fig-
ure.
If check results are continuity, proceed to next operation check.
If not, replace.

Connect battery to blower motor as shown, then check that the
blower motor operates smoothly and specified current.
Specified current: Max. 25 A at 12 V
INSTALLATION
1) Reverse removal procedure for installation.
2) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-11
1
1. Mode control switch coupler
7) Disconnect heater blower motor switch connector (1).
8) Remove mode control switch with heater control lever assem-
bly from the removed hole in mentioned step (5).
9) Pull off heater control lever knob.
10) Remove heater mode control switch (2) with heater control
panel (3) from heater control lever assembly (1).
11) Remove heater control panel from mode control switch.
INSPECTION
Mode Control Switch

Check if continuity exists between each pair of terminals listed be-
low when mode control button is pressed.
Mode
Mode control switch terminals
VENTF ± M
BI-LEVELF ± N
HEATF ± E
DEF / HEATF ± B
DEFF ± C

With battery voltage (+) connected to terminal ªIº and (±) to termi-
nal ªFº, press each mode control button and check if indicator
lamp (3) lights.

With battery voltage (+) connected to terminal ªAº and (±) to termi-
nal ªHº, check if illumination lamp lights.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-17
1. Dash panel (engine room) 2. Nuts
REMOVAL
WARNING:
Failure to follow the following procedure and WARNING
may cause air bag deployment, personal injury, damage to
parts, or air bag being unable to deploy.

Never rest a steering column assembly on steering wheel
with air bag (inflator) module face down and column verti-
cal.

When handling the air bag (inflator) modules (driver and
passenger), 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 disas-
sembly 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 passenger), wipe off
immediately with a dry cloth.
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped. Refer to DISABLING AIR
BAG SYSTEM in Section 10B.
3) Drain engine coolant and disconnect heater hose (1) from
heater unit.
4) Remove instrument panel, refer to item INSTRUMENT PANEL
REMOVAL in Section 9.
5) Remove cooling unit (If equipped).
Refer to item EVAPORATOR (COOLING UNIT) REMOVAL in
Section 1B.
6) Disconnect rear duct (4) from heater unit.
7) Disconnect heater mode control actuator lead wire (1) at cou-
plers.
8) Remove A / C controller (2) (If equipped).
9) Remove SDM (3) (If equipped).
10) Remove heater unit.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-41
INSPECTION
1) Check evaporator fins for blockage. If found clogged, use com-
pressed air to clean the fins.
CAUTION:
Do not use water for cleaning of evaporator.
Be careful not to damage evaporator fins. If evaporator
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 evaporator.
2) Check inlet and outlet fittings for crack or scratch. Repair them
as required.
REASSEMBLY and INSTALLATION
1) Reverse removal and disassembly sequence to install cooling
unit, noting the following points.

Install uniformly the evaporator packing to dash panel hole for
expansion valve.

Adjust fresh air control cable, refer to ªHEATER CONTROL
LEVER ASSEMBLYº in Section 1A.
2) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.
3) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
NOTE:
When the thermistor removed, it should be reinstalled in
original position.
If cooling unit or evaporator is replaced, pour 25 cc of refrig-
erating oil to compressor suction-side.

YH4
GRAND
VITARA
1. Steering column hole cover
2. If equipped
1. Steering column cover screw
2. Steering column lower cover
3. Steering column upper cover: Tapping screw
: Standard screw
*
* *
STEERING WHEEL AND COLUMN 3C-5
3) Install steering column upper and lower cover.
4) Tighten steering column cover screws.
CAUTION:
When installing lower cover and upper cover, be careful
so that combination switch lead wire is not caught be-
tween covers.
5) Install steering column hole cover.
6) Install steering wheel to steering column. Refer to ªSTEERING
WHEELº in this section.
7) Connect battery negative cable.
STEERING COLUMN ASSEMBLY
CAUTION:
Once the steering column is removed from the vehicle, the
column is extremely susceptible to damage.
Dropping the column assembly on its end could collapse
the steering shaft or loosen the plastic shear pins which
maintain column length. Leaning on the column assembly
could cause it to bend or deform.
Any of the above damage could impair the column's col-
lapsible design.
When loosening steering column mounting bolts, make
sure that steering column assembly and steering shaft low-
er assembly have been separated. Loosening them with
steering column assembly and steering shaft lower assem-
bly assembled could cause damage to bearing in steering
shaft lower assembly.
NOTE:
When servicing steering column or any column-mounted
component, remove steering wheel. But when removing steer-
ing column simply to gain access to instrument panel compo-
nents, leave steering wheel installed on steering column.
REMOVAL
1) Disconnect negative battery cable at battery terminal.

YH4
GRAND
VITARA
1. Steering column
2. Mounting bolt
3. Steering column lower seal
4. Dash panel
1. Steering column lower seal
In engine room
In cabin
3C-8 STEERING WHEEL AND COLUMN
4) Check steering column lower seal for breakage or deformation.
If found defective, replace.
5) Check steering shaft joints and shaft for any damages such as
crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as steering lower shaft assem-
bly or steering column assembly.
6) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
7) Check steering shaft and column for bend, cracks or deforma-
tion.
If found defective, replace as column assembly.
INSTALLATION
CAUTION:

After tightening steering column mounting bolts, steering
shaft joint bolts should be tightened.

After tightening steering column lower bolts, steering col-
umn upper bolts should be tightened.
1) Be sure that front wheels and steering wheel are in straight-
ahead position.
2) If equipped with shift (key) interlock cable, install shift (key) inter-
lock cable to ignition switch.
3) Install steering column assembly to dash panel and upper
bracket so that boss of steering column lower seal and all around
it project out of hole in dash panel into engine room. Tighten
steering column lower bolts (4 pieces) first and then upper bolts
(2 pieces) to specified torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
1
1. Steering column hole cover 1. Steering column cover screw
2. Steering column upper cover
3. Steering column lower cover: Standard screw
: Tapping screw
*
* *
AIR BAG STEERING WHEEL AND COLUMN 3C1-9
3) Connect all connectors that have been removed in removal.
4) Install steering column upper and lower cover, and then tighten
steering column cover screws.
CAUTION:
When installing lower cover and upper cover, be careful
so that contact coil and combination switch lead wire is
not caught between covers.
5) Install steering column hole cover.
6) Install steering wheel to steering column. Refer to ªSTEERING
WHEELº in this section.
STEERING COLUMN
CAUTION:
Once the steering column is removed from the vehicle, the
column is extremely susceptible to damage.
Dropping the column assembly on its end could collapse
the steering shaft or loosen the plastic shear pins which
maintain column length leaning on the column assembly
could cause it to bend or deform.
Any of the above damage could impair the column's col-
lapsible design.
When loosening steering column mounting bolts, make
sure that steering column assembly and steering shaft low-
er assembly have been separated. Loosening them with
steering column assembly and steering shaft lower assem-
bly assembled could cause damage to bearing in steering
shaft lower assembly.
NOTE:
When servicing steering column or any column-mounted
component, remove steering wheel. But when removing steer-
ing column simply to gain access to instrument panel compo-
nents, leave steering wheel installed on steering column.