cooling SUZUKI GRAND VITARA 2001 2.G Owners Manual

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND
DIFFERENTIAL0A7A1
General Information0A
0B7B1
Maintenance and Lubrication0B
Manual Transmission7A1
7C1
HEATING AND AIR CONDITIONING
Automatic Transmission7B1
1A7D
Heater and Ventilation1A
Clutch7C1
1B7E
Air Conditioning1B
Transfer7D7F
STEERING, SUSPENSION, WHEELS
AND TIRESDifferential (Front)7E
3
Differential (Rear)7F
3A8
Steering, Suspension, Wheels and Tires3 ELECTRICAL SYSTEM3B18A
Front End Alignment3A
Electrical System8
3C18B
Power Steering (P/S) System3B1
Wiring Diagram8A3D8C
Air Bag Steering Wheel and Column3C1
Lightening System8B3E8D
Front Suspension3D
Instrumentation / Driver Information8C
3F8E
Rear Suspension3E
Windows, Mirrors, Security and Lock8D
8G
Wheels and Tires3F
Cruise Control System8E
4A2
DRIVE SHAFT AND PROPELLER SHAFT
Immobilizer control system (if equipped)8G4B9
Front Drive Shaft / Shaft Bearing,
Oil Seal4A2BODY SERVICE
Body Service9
510
Propeller Shaft4B RESTRAINT SYSTEM
5A10A
BRAKE SYSTEM
Restraint System10
5B10B
Brakes5
Seat Belt10A
5C
Brake Pipe / Hose / Master Cylinder5A
Air Bag System10B
5E2
Front Brake5B
Parking and Rear Brake5C
6-1
Antilock Brake System (ABS)5E2
6A2
ENGINE
6B
General Information and
Diagnosis (H27 Engine)6-1
6C
6E2
Engine Mechanical (H27 Engine)6A2
6F2
Engine Cooling6B
6G
Engine Fuel6C
6H
Engine and Emission Control System
(SFI For H27 Engine)6E2
6K
Ignition System (H27 Engines)6F2
Cranking System6G
Charging System6H
Exhaust System6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.

0A-8 GENERAL INFORMATION
Warning, Caution and Information Labels
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels.
If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.
1. Passenger seat belt label (if equipped) 5. Blank 9. Jacking instruction label
2. Radiator cap label 6. Air bag label on sun visor 10. Transfer label (if equipped)
3. Air bag label 7. Air bag label on sun visor (Back side)
Air bag label and utility vehicle label on sun visor (Face side)11. Armrest label on strap
4. Engine cooling fan label 8. Jacking instructions 12. Seat label (if equipped)
1. Air bag label on driver air bag (inflator) module 5. Air bag label on wire harness
2. Air bag label on combination switch and contact coil assembly 6. Air bag label on SDM
3. Air bag label on steering column cover 7. Pretensioner label on seat belt pretensioner
4. Air bag label on passenger air bag (inflator) module
3
7
7
56
4

1B-4 AIR CONDITIONING (OPTIONAL)
Major Components And Location
[A] : Dual A/C model 6. Receiver/dryer 13. Suction pipe 20. Ventilation air
[B] : Single A/C model 7. Front expansion valve 14. Discharge pipe 21. Rear A/C air
1. Front cooling unit 8. Heater unit 15. Recirculation air 22. Room air
2. Front A/C evaporator 9. Rear A/C unit 16. Fresh air 23. Solenoid valve
3. Front blower fan motor 10. Rear blower fan motor 17. Defroster air 24. Rear A/C evaporator
4. Compressor 11. Rear expansion valve 18. Demister air
5. Condenser assembly 12. Liquid pipe 19. Foot air
17 17
18 18
16 [A]
[B]15
21
2211
23
9
24
10 141320
21
19 19
4 12
6 312
78
17 17
18 18
16
15
20
19 19 1
2
8 5
7
12
6
513
4 14

AIR CONDITIONING (OPTIONAL) 1B-5
[A] : Dual A/C LH steering model 4. Condenser 11. Low pressure charge valve
[B] : Dual A/C RH steering model 5. Sight glass 12. Floor liquid pipe
[C] : Single A/C LH steering model 6. Refrigerant (dual) pressure sensor 13. Floor suction pipe
[D] : Single A/C RH steering model 7. Discharge pipe 14. Rear A/C unit
1. Front cooling unit 8. Liquid pipe 15. Rear A/C duct No.1
2. Heater unit 9. Suction pipe 16. Rear A/C duct No.2
3. Compressor 10. High pressure charge valve
[A]
[B]
[C][D]
10
7
9 3 4 6 5 1181
213
12 16
1514
1 2
13
12 16
1514
7
10
5
6
4
38
9 11
1 2
7
10
5
6
4
38
9 11
10
7
9 3 4 6 5 1181
2

1B-6 AIR CONDITIONING (OPTIONAL)
Diagnosis
General
Main A/C system (front A/C system)
Condition Possible Cause Correction
Cool air does not
come out (A/C system
does not operative)No refrigerant Perform recover, evacuation and
charging.
Fuse blown Check “IG METER”, “REAR DEFG”
and “A/C” fuses, and check for
short circuit to ground.
A/C switch faulty Check A/C switch.
Blower motor switch faulty Check blower motor switch.
A/C evaporator temperature sensor (A/C evap-
orator thermistor) faultyCheck A/C evaporator tempera-
ture sensor (A/C evaporator ther-
mistor).
Refrigerant (dual) pressure switch faulty Check refrigerant (dual) pressure
switch.
Wiring or grounding faulty Repair as necessary.
A/C ON permission signal in ECM faulty Check A/C ON permission signal.
A/C controller and its circuit faulty Check A/C controller and its circuit.
Cool air does not
come out (A/C com-
pressor does not
operative (won’t rota-
tive))Magnet clutch faulty Check magnet clutch.
Compressor relay faulty Check compressor thermal switch.
Compressor relay faulty Check compressor relay.
Drive belt loose or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
A/C ON permission signal in ECM faulty Check A/C ON permission signal.
A/C controller faulty Check A/C controller.
Cool air does not
come out (A/C con-
denser cooling fan
motor does not opera-
tive)Condenser cooling fan motor relay faulty Check condenser cooling fan motor
relay.
Wiring or grounding faulty Repair as necessary.
A/C condenser fan motor relay signal in ECM
faultyCheck A/C condenser cooling fan
motor relay signal.
Condenser cooling fan motor faulty Check condenser cooling fan
motor.
Cool air does not
come out (Blower
motor does not opera-
tive)Fuse blown Check “FRONT BLOW” and
“REAR DEFG” fuses, and check for
short circuit to ground.
Blower motor relay faulty Check blower motor relay.
Blower motor resistor faulty Check blower motor resistor.
Blower motor switch faulty Check blower motor switch.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor.

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.

1B-14 AIR CONDITIONING (OPTIONAL)
Wiring Circuit
ACG
LT GRN
PNK
PNK
BLKORN
BLK
YEL/GRNRED/BLKBLK/WHT
BLU/WHTPNK/BLK
PNK/GRN
RED/BLK
WHT/RED
YEL/GRN
YEL/BLU
A/C
RED/BLU
RED/BLU
RED/BLKBLK
BLU/ORN
BLU/WHT
BLU/WHT
PNK
PNK/BLU
BLK
PNK/WHT
YEL/BLK
GRY/WHT
GRN/BLK
BLK/WHT
RED/BLK
YEL/GRN
BLK
BLK
BLK
YEL/BLK
YEL/GRN
YEL/GRNBLU/GRN
BLU/YELBLUBLU/BLK
BLU/BLK
17
21
22 18
16
15
19
2026 25 24 23
14
12
29
3
4
7
33 30
31
32
28
27
1213
10
11
35 349
856
A
1. Front blower motor main relay 10. Compressor relay 19. Battery 28. Solenoid valve relay
2. Front blower motor 11. Compressor 20. Generator 29. Rear blower motor relay
3. Front blower motor resistor 12. Condenser cooling fan motor
relay21. Ignition main fuse 60 A 30. Rear blower motor resistor
4. Front blower motor switch 13. Condenser cooling fan motor 22. Heater/A/C main fuse 60 A 31. Rear blower motor
5. A/C controller 14. Fuse box 23.“IG METER” fuse 20 A 32. Rear blower motor switch
6. ECM (PCM) 15.“A/C” fuse 25 A 24.“REAR DEFG” fuse 25 A 33. Rear A/C main switch
7. Heater mode control switch 16. Ignition switch 25.“REAR BLOW” fuse 20A 34. Rear A/C evaporator temperature con-
troller
8. Dual (refrigerant) pressure switch 17. Main fuse box 26.“FRONT BLOW” fuse 30A 35. Rear A/C evaporator temperature sensor
9. A/C evaporator thermistor
(A/C evaporator temperature sensor)18. Battery main fuse 100 A 27. Solenoid valve [A] : Rear A/C wiring circuit (if equipped)

1B-16 AIR CONDITIONING (OPTIONAL)
SYSTEM CIRCUIT
Terminal arrangement of A/C controller
Terminal arrangement of ECM
A: To “FRONT BLOW” fuse 1. Front blower motor relay 6. Dual (refrigerant) pressure switch 11. Condenser cooling fan motor
B: To “REAR DEFG” fuse 2. Front blower motor 7. A/C thermistor (evaporator temperature sensor) 12. A/C controller
C: To “IG METER” fuse 3. Front blower motor resistor 8. Compressor relay 13. ECM
D: To “A/C” fuse 4. Front blower motor switch 9. Compressor
5. A/C switch 10. Condenser cooling fan motor relay
5V
12V12V
12V5V
12V
5V
AC-A-1
AC-A-7
AC-A-4
AC-B-2
AC-B-1
AC-A-16AC-A-9
AC-A-2 AC-A-13
E61-8
E61-17
E61-22
A
DBBC
1
2
3
4
7 865
1011912
13
12 12
3
45 6 7 8 9 101112131415 16 AC-B
AC-A
87
22 23
34
3565
16 17
25
262
1
8 9
20
212
1
8 9
21
22 1 2 3 4 5 6
9
24 25 26 27 28 29 30 31 32 3310 11
12 13 14 15 16 17 18 19 20 211 2 3 4
7 8 9
10 11 12 13 14 15
18 19 20 21 22 23 243 4 5 6 7
10 11 12 13 14 15 16 17 18 19
22 23 24 25 26
27 283 4 5 6 7
10 11 12 13 14 15 16 19 18 2017
23
24 25 26 27 29 28 30 E61 C51-3 C51-1 C51-2