check engine SUZUKI GRAND VITARA 2002 2.G Service User Guide

YH4
GRAND
VITARA
0B-24 MAINTENANCE AND LUBRICATION
FINAL INSPECTION
Seats
Check that seat slides smoothly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
If ªREPLACE BELTº label on front seat belt is visible,
replace belt.
Check that seat belt is securely locked.
Battery Electrolyte Level Check
Check that the electrolyte level of all battery cells is
between the upper and lower level lines on the case.
If battery is equipped with built-in indicator, check bat-
tery condition by the indicator.
Accelerator Pedal Operation
Check that pedal operates smoothly without getting
caught or interfered by and other part.
Engine Start
Check engine start for readiness.
On automatic transmission vehicles, try to start the
engine in each select lever position. The starting mo-
tor should crank only in ªPº (Park) or ªNº (Neutral).
On manual transmission vehicles, place the shift le-
ver in ªNeutral,º depress clutch pedal fully and try to
start.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (For Manual transmission)
Check for the following:

Clutch is completely released when depressing
clutch pedal.

No slipping clutch occurs when releasing pedal and
accelerating.

Clutch itself is free from any abnormal condition.
Gearshift or Select Lever (Transmission)
Check gear shift or select lever for smooth shifting to
all positions and for good performance of transmis-
sion in any position.
With automatic transmission equipped vehicle, also
check that shift indicator indicates properly according
to which position select lever is shifted to.
With automatic transmission equipped vehicle, make
sure that vehicle is at complete stop when shifting se-
lect lever to ªPº range position and release all brakes.
Brake
[Foot brake]
Check the following:

that brake pedal has proper travel,

that brake works properly,

that it is free from noise,

that braking force is applied equally on all wheels,

and that brake do not drag.
[Parking brake]
Check that lever has proper travel.
WARNING:
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property damage.
Be prepared to apply regular brake quickly
even if vehicle should start to move.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and
brake lever is pulled all the way.
WARNING:
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.
WARNING:
Before performing the following check, be
sure to have enough room around the vehicle.
Then, firmly apply both the parking brake and
the regular brakes. Do not use the accelerator
pedal. If the engine starts, be ready to turn off
the ignition promptly. Take these precautions
because the vehicle could move without warn-
ing and possibly cause personal injury or
property damage.

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-25
Steering

Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.

Check that the vehicle does not wander or pull to
one side.
Engine

Check that engine responds readily at all speeds.

Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to ªHIº position for this check.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSG, SH or SJ (Refer to engine oil viscosity chart in item 1-4)
Engine coolant (Ethylene glycol
base coolant)ªAntifreeze / Anticorrosion coolantº
Brake fluidDOT 3
Manual transmission oilRefer to Section 7A or 7A1Transfer oilRefer to Section 7A or 7A1.
Differential oil (front & rear)Refer to Section 7E or 7F.
Automatic transmission fluid and
Power steering fluidRefer to Section 3B1 or 7B1.
Door hingesEngine oil or water resistance chassis greaseHood latch assemblyEngine oil or water resistance chassis grease
Key lock cylinderSpray lubricant

YH4
GRAND
VITARA
3. Bubbles
1B-10 AIR CONDITIONING (OPTIONAL)
QUICKLY CHECKING OF REFRIGERANT
CHARGE (IF EQUIPPED WITH SIGHT GLASS)
CHARGE OF REFRIGERANT
The following procedure can be used for quickly checking whether
the A / C system has a proper charge of refrigerant or not.
Run engine at fast idle, and operate A / C at its max. cooling capacity
for a few minutes. Then, look at the sight glass (1) on receiver / dryer
(2) and compare what is observed with the symptoms listed in
ªCHECKING REFRIGERANT CHARGEº table given below.
CHECKING REFRIGERANT CHARGE
CONDITIONPOSSIBLE CAUSESCORRECTION
Bubbles observed in sight glassInsufficient charge of refrigerant in
systemCheck system for leaks with a leak
tester.
No bubbles observed in sight glassNo charge or proper or too much
charge of refrigerant in systemRefer to the following item.
No temperature difference
between compressor inlet and
outletEmpty or nearly empty systemRecovery, evacuate and charge
system and then check it for leaks
with a leak tester.
Noticeable temperature difference
between compressor inlet and
outletProper or too much charge of
refrigerant in systemRefer to the following item.
When A / C is turned OFF,
refrigerant in sight glass clears
immediately and remains clearToo much charge of refrigerant in
systemDischarge excess charge of
refrigerant to adjust it to a specified
charge.
When A / C is turned OFF,
refrigerant in sight glass once
produces bubbles and then clearsProper charge of refrigerant in
systemNo correction needed because
charge of refrigerant is normal.

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
1B-12 AIR CONDITIONING (OPTIONAL)
PERFORMANCE DIAGNOSIS
1) Confirm that vehicle and environmental conditions are as fol-
lows.

Vehicle is not exposed to direct sun.

Ambient temperature is within 15C ± 35C (59F ± 95F).
2) Make sure that high pressure valve (1) and low pressure valve
(2) of manifold gauge are firmly closed.
3) Connect high pressure charging hose (3) to high pressure ser-
vice valve (5) on vehicle, and connect low pressure charging
hose (4) to low pressure service valve (6) on vehicle.
4) Bleed the air in charging hoses (3), (4) by loosening their respec-
tive nuts on manifold gauge, utilizing the refrigerant pressure.
When a hiss is heard, immediately tighten nut.
CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.
5) Warm up engine to normal operating temperature (engine cool-
ant temperature at 80 ± 90C (176 ± 194F)) and keep it at spe-
cified idle speed. (Radiator cooling fan should not be working
when checking pressure and temperature.)
6) Turn A / C switch ON, and set blower switch at ªHIº (4th position),
temperature control knob at ªCOOLº, air outlet control knob at
ªFACEº, fresh / circulation control knob at ªCIRCULATIONº.
(Confirm that A / C compressor and condenser fan are working.)
7) Keep all windows, doors and engine food open.
Ambient temperature
15 ± 35C (59F ± 95F)
Engine rpmKeep to 1,500 rpm.
Blower motor switchMax. (4th position)
Temperature controlMax. cool
Air outlet controlFace
Vehicle doorsAll open
Air inlet door positionRecirculation
8) With about 20 mm (0.8 in.) of dry bulb thermometer (1) inserted
into center duct air outlet and another one set near evaporator
air inlet, read temperature indicated on each thermometer.

YH4
GRAND
VITARA
1B-14 AIR CONDITIONING (OPTIONAL)
HIGH PRESSURE CAUGE LOW PRESSURE GAUGE THERMOMETER AT
CENTER DUCT
Insufficient
cooling of
condenser
PERFORMANCE DIAGNOSIS TABLE
TESTING RESULTSPOSSIBLE CAUSEREMEDY
Pressure high
(ªAº area of high side
graph)
Refrigerant overcharged

Expansion valve frozen or clogged

Clogged refrigerant passage of high side

Condenser fan malfunction

Dirty or bent condenser fins

Compressor malfunction (Insufficient oil etc.)

Engine overheat
Recharge

Check expansion valve

Clean or replace

Check condenser fan

Clean or repair

Check compressor

Check engine cooling
system
Pressure low
(ªBº area of high side
graph)
Insufficient refrigerant (Insufficient charge or
leakage)

Expansion valve malfunction (Valve opens too
wide)

Compressor malfunction (Insufficient
compression)
Check for leakage, repair if
necessary and recharge

Check expansion valve

Check compressor
Pressure high
(ªAº area of low side
graph)
Expansion valve malfunction (Valve opens too
wide)

Compressor malfunction (Insufficient
compression)
Check expansion valve

Check compressor
Pressure low
(ªBº area of low side
graph)
Insufficient refrigerant (Insufficient charge or
leakage)

Expansion valve malfunction (Valve opens too
narrow)

Clogged refrigerant passage (Crashed pipe)
Check for leakage, repair if
necessary and recharge

Check expansion valve

Repair or replace
Outlet air temperature
at center duct is high
(Crossing point is in
area ªAº)
Insufficient or excessive charge of refrigerant

Dirty or bent evaporator fins

Air leakage from cooling (heater) unit or air
duct

Malfunctioning, switchover function of damper
in cooling (heater) unit

Compressor malfunction
Check refrigerant
pressure

Clean or repair

Repair or replace

Repair or replace

Check compressor
Outlet air temperature
at center duct is low
(Crossing point is in
area ªBº)
Insufficient air volume from center duct
(Heater blower malfunction)

Compressor malfunction
Check blower motor and
fan

Check compressor
NOTE:
If ambient temperature is within 30 ± 35C (85 ± 95F), it is possible to do using next page table for more
detail diagnosis.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-15
AMBIENT TEMPERATURE WITHIN 30 ± 35C (85 ± 95F)
CONDITION
MANIFOLD
GAUGEMPa
(kg/cm2)
(psi)DETAILCAUSECORRECTION
LoHi
0.23 ± 0.35
(2.3 ± 3.5)
(33 ± 50)1.4 ± 1.75
(14 ± 17.5)
(200 ± 249)
Normal condition.ÐÐÐÐ
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
droplets are either stuck or
frozen inside expansion
valve, preventing the
refrigerant from flowing.
Clean expansion valve.
Replace it if it cannot be
cleaned.

Replace receiver / dryer.

Evacuate the A / C
system and recharge
with fresh refrigerant.
Normal:
0.23 ± 0.35
(2.3 ± 3.5)
(33 ± 50)

Abnormal:
Negative
pressureNormal:
1.4 ± 1.75
(14 ± 17.5)
(200 ± 249)

Abnormal:
0.69 ± 0.98
(7 ± 10)
(100 ± 142)
During A / C operation, the
low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.
Expansion valve is frozen
due to moisture in the
system, and temporarily
shuts off the refrigeration
cycle.
Replace expansion
valve.

Replace receiver / dryer.

Evacuate A / C system
and recharge with fresh
refrigerant.
0.05 ± 0.15
(0.5 ± 1.5)
(4.2 ± 21.3)
0.69 ± 0.98
(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
system. (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
necessary.
035 045

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
operation.
Adjust refrigerant to
specified amount.

Clean condenser.

Inspect and repair
condenser fan.
0.35 ± 0.45(3.5 ± 4.5)
(50 ± 64)
1.96 ± 2.45
(20 ± 25)
(285 ± 355)

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
system. (Improperly
evacuated)
Replace receiver / dryer.

Inspect quantity of
compressor oil and
presence of
contaminants in oil.

Evacuate system and
recharge with fresh
refrigerant.
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
regulated properly.
Replace expansion
valve.

YH4
GRAND
VITARA
Fig. A
Fig. B
Fig. C
C51-3-6 For G16
and J20 engines
C51-3-25 For
H25 engine
1B-18 AIR CONDITIONING (OPTIONAL)
INSPECTION OF A / C CONTROLLER AND ITS
CIRCUITS
CAUTION:
A / C controller and ECM cannot be checked by itself.
It is strictly prohibited to connect voltmeter or ohmmeter to
A / C controller and ECM with couplers disconnected from it.
A / C controller (1) and its circuits can be checked at A / C controller
wiring couplers by measuring voltage.
Voltage Check
1) Remove A / C controller (1) from vehicle (refer to ªA / C CON-
TROLLER REMOVALº in this section).
2) Remove ECM (2) from vehicle.
3) Connect A / C controller couplers to A / C controller and connect
ECM couplers to ECM.
4) Check each terminal voltage with couplers connected by refer-
ing to the A / C CONTROLLER VOLTAGE VALUES TABLE the
later.

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
1B-44 AIR CONDITIONING (OPTIONAL)
REFRIGERANT PIPES AND HOSES
INSPECTION
1) Use a leak tester to check hoses and pipes for any gas leakage.
2) Check each hose or pipe clamp for tightness.
Retighten or replace loose clamp as required, if any.
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 must be added to the system when reinstal-
ling.
2) Replace defective hose or pipe.
CAUTION:
As soon as the above hose or pipe is disconnected, cap
its opened fitting to prevent moisture and dust from en-
tering.
INSTALLATION
1) Reverse removal procedure to install refrigerant line.
2) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
INSPECTION OF IDLE SPEED WITH A / C ON
For G16 and J20 engines model, refer to Section 6E1.
For H25 engine model, refer to Section 6E2.

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.