Shaft SUZUKI GRAND VITARA 2002 2.G Service User Guide

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-19
11) Check coil spring, upper rod, lower rod and lateral rod for de-
formation and damage.
12) Check upper rod, lower rod and lateral rod bushings and bump
stopper for wear, damage and deterioration.
13) Check other suspension parts for damage, loose or missing
parts; also for parts showing signs of wear or lack of lubrication.
Replace any parts found defective in steps 1) to 13).
ITEM 6-9
Propeller Shafts and Drive Shafts Inspection
1) Check universal joint and spline of propeller shaft for rattle. If
rattle is found, replace defective part with a new one.
2) Check propeller shaft (front & rear) flange yoke bolts for tight-
ness, and retighten them as necessary.
Refer to Section 4B for tightening torque.
3) Check drive axle boots (wheel side and differential side) for
leaks, detachment, tear or other damage.
Replace boot as necessary.

YH4
GRAND
VITARA
1. Drain plug (Apply sealant)
2. Reverse idle gear shaft bolt (DO NOT LOOSEN IT)
3. Filler / level plug (Apply sealant)
1. Drain plug
2. Filler / level plug
Type 1
Type 2
1. Level gauge
2. FULL HOT mark
3. LOW HOT mark
4. FULL COLD mark
5. LOW COLD mark
0B-20 MAINTENANCE AND LUBRICATION
ITEM 6-10
Manual Transmission Oil Inspection and Change
Inspection
1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transmission.
4) Check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found up
to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified oil.
5) Tighten level plug to specified torque.
Refer to Section 7A or 7A1 for installation and tightening torque.
Change
Change transmission oil with new specified oil referring to Section
7A or 7A1.
ITEM 6-11
Automatic Transmission Fluid Inspection and Change
Inspection
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Check fluid level.
For fluid level checking procedure, refer to On-vehicle service in
Section 7B1 and be sure to perform it under specified conditions.
If fluid level is low, replenish specified fluid.

YH4
GRAND
VITARA
The figure shows right-hand steering vehicle
The figure shows right-hand steering vehicle
0B-22 MAINTENANCE AND LUBRICATION
ITEM 6-14
Steering System Inspection
1) Check steering wheel for play and rattle, holding vehicle in
straight forward condition on the ground.
Steering wheel play ªaº: 0 ± 30 mm (0 ± 1.2 in.)
2) Check universal joints of steering shaft for rattle and damage. If
rattle or damage is found, replace defective part with a new one.
3) Check steering linkage for looseness and damage. Repair or re-
place defective part, if any.
4) Check bolts and nuts for tightness and retighten them as neces-
sary. Repair or replace defective parts, if any.
Refer to table of Tightening Torque Specification in Section 3B
(or 3B1) and 3C (or 3C1) for particular check points.
5) Check boots of steering linkage for damage (leaks, detachment,
tear, dent, etc.). If damage is found, replace it with new one.
If any dent is found on steering rack boots, correct it to original
shape by turning steering wheel to the right or left as far as it
stops and holding it for a few seconds.
6) Check wheel alignment.
NOTE:
For details of wheel alignment, refer to Wheel Alignment in
Section 3A.
ITEM 6-15
Power Steering (P / S) System Inspection (if equipped)
1) Visually check power steering system for fluid leakage and hose
for damage and deterioration.
Repair or replace defective parts, if any.
2) With engine stopped, check fluid level indicated on fluid tank,
which should be between MAX and MIN marks. If it is lower than
MIN, fill fluid up to MAX mark.
NOTE:

Be sure to use an equivalent of DEXRON

-II or DEX-
RON

-III for P / S fluid.

Fluid level should be checked when fluid is cool.

YH4
GRAND
VITARA
1B-8 AIR CONDITIONING (OPTIONAL)
DIAGNOSIS OF ABNORMAL NOISE
There are various types of noise, ranging from those produced in the engine compartment to those from the pas-
senger compartment, also from rumbling noises to whistling noises.
ABNORMAL NOISE FROM COMPRESSOR
ConditionPossible CauseCorrection

During compressor operation, a
rumbling noise is heard
proportional to engine
revolutions.
Inadequate clearance in piston
area (piston or swash-plate).
Repair or replace compressor as
necessary.

A loud noise is heard at a certain
rpm, disproportionately to engine
revolution.
Loose or faulty V-belt.

Loose mounting bolts.
Adjust V-belt tension, or
replace belt.

Retighten mounting bolts.

A loud rattle is heard at low
engine rpm.
Loose compressor center bolt.
Retighten center bolt.

Replace compressor if it was
operated in this condition for a
long time.
ABNORMAL NOISE FROM MAGNETIC CLUTCH
ConditionPossible CauseCorrection

A rumbling noise is heard when
compressor is not operating.
Worn or damaged bearings.
Replace bearings.

A chattering noise is heard when
compressor is engaged.
Faulty clutch gap (excessive).

Worn clutch friction surface.

Compressor oil leaked from shaft
seal, contaminating the friction
surface.
Adjust clutch gap.

Replace clutch.

Replace compressor shaft oil
seal.
ABNORMAL NOISE FROM TUBING
ConditionPossible CauseCorrection

A droning noise is heard inside
vehicle, but not particularly
noticeable in engine
compartment.
Faulty tubing clamps.

Resonance caused by pulsation
from variations in refrigerant
pressure.
Reposition clamps or increase
the number of clamps.

Attach a silencer to tubing, or
modify its position and length.
ABNORMAL NOISE FROM CONDENSER
ConditionPossible CauseCorrection

Considerable vibration in
condenser.
Resonance from condenser
mounting stay and body.
Firmly insert a silencer between
condenser mounting stay and
body.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-9
ABNORMAL NOISE FROM CRANKSHAFT PULLEY
ConditionPossible CauseCorrection

A large rattling noise is heard at
idle or sudden acceleration.
Loosen pulley mounting bolt.

Worn or broken bearings.
Retighten bolt.

Replace bearings.
ABNORMAL NOISE FROM TENSION PULLEY
ConditionPossible CauseCorrection

Clattering noise is heard from
pulley.

Pulley cranks upon contact.
Worn or damaged bearings.

Cracked or loose bracket.
Replace bearings.

Replace or retighten bracket.
ABNORMAL NOISE FROM EVAPORATOR
ConditionPossible CauseCorrection

Whistling sound is heard from
evaporator.
Depending on the combination of
the interior / exterior
temperatures, engine rpm and
refrigerant pressure, the
refrigerant flowing out of the
expansion valve may, under
certain conditions, make a
whistling sound.
At times, slightly decreasing
refrigerant volume may stop this
noise.

Inspect expansion valve and
replace if faulty.
ABNORMAL NOISE FROM BLOWER MOTOR
ConditionPossible CauseCorrection

Blower motor emits a chirping
sound in proportion to its speed of
rotation.

Fluttering noise or large droning
noise is heard from blower motor.
Worn or damaged motor brushes
or commutator.

Leaves or other debris
introduced from fresh air inlet to
blower motor.
Repair or replace blower motor.

Remove debris and make sure
that the screen at fresh air inlet is
intact.

YH4
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.

YH4
GRAND
VITARA
J20 engine
H25 engine G16 engine
1. Generator belt
2. Compressor drive belt3. Compressor pulley
4. Crankshaft pulley
1B-22 AIR CONDITIONING (OPTIONAL)
DRIVE BELT
INSPECTION
For G16 and H25 engines
Refer to Section 3B1 for details.
For J20 engine
Refer to Section 6H for details.

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
2. High pressure side (Delivery side hose)
3. Lower pressure side (Suction side pipe)
AIR CONDITIONING (OPTIONAL) 1B-49
COMPRESSOR ASSEMBLY
CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of A / C:
one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
For identification between these two types, refer to page 1B-2.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A / C installed in the vehicle being serviced.
Use of incorrect refrigerant or compressor oil will result in leakage of refrigerant, damage in parts or
other faulty condition.
PRECAUTION
When servicing the compressor, keep dirt or foreign material away from getting on or into the compressor parts
and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any ªOn-vehicleº repair
or before removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled
should be cleaned with Trichloroethane, naphtha, kerosene or equivalent solvent and dried with dry air. Use only
lint free cloths to wipe parts.
The operations described are based on bench overhaul with compressor removed from the vehicle, except as
noted. They have been prepared in order of accessibility of the components.
When compressor is removed from the vehicle for servicing, the oil remaining in the compressor should be dis-
carded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair procedures re-
quire that the system be discharged of refrigerant.
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.
2) Close Hi (4) and Lo (5) hand valves.
3) Run engine at fast idle.
4) Check compressor assembly for following items.
If any of the above checks indicated a defect, repair compressor
assembly.

High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.

Metallic sound.

Leakage from shaft seal.

YH4
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.