Ventilation SUZUKI GRAND VITARA 2002 2.G Service Owner's Manual

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
1A-18 HEATER AND VENTILATION
11) Remove heater core pipe clamps (1) and grommet (2).
12) Pull out heater core (1) from unit (2).
INSTALLATION
1) Install heater unit by reversing removal procedure, noting the
following items.

When installing each part, be careful not to catch any cable or
wiring harness.

When installing steering column assembly, refer to STEER-
ING COLUMN INSTALLATION in Section 3C or 3C1.
2) Install control cables. (Refer to HEATER CONTROL CABLES in
this section.)
3) Fill engine coolant to radiator.
4) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.
5) Evacuate and charge system. Refer to items EVACUATING
SYSTEM and PROCEDURE OF CHARGING in Section 1B.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-19
1. Heater unit
2. Rear duct
3. SDM
REAR DUCT
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Remove front seat.
3) Remove console box.
4) Take off carpet till rear duct is totally exposed.
5) Remove rear duct.
INSTALLATION
Reverse removal sequence to install rear duct.

YH4
GRAND
VITARA
1. Cooling unit
2. Compressor
3. Condenser assembly
4. Receiver / dryer
5. Discharge hose
6. Suction hose
7. Condenser outlet pipe
8. Liquid pipe9. Expansion valve
10. Ventilation air
11. Foot air
12. Defroster air
13. Demister air
14. Fresh air
15. Recirculation air
16. Heater unit17. Air inlet box
18. Dual pressure switch
19. Low pressure charge valve
20. High pressure charge valve
21. Suction pipe
22. Sight glass
CAMI PRODUCTION VEHICLE IWATA PRODUCTION VEHICLE
AIR CONDITIONING (OPTIONAL) 1B-5
MAJOR COMPONENTS AND LOCATION

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-7
ConditionPossible CauseCorrection
Cool air does not come
out or insufficient
cooling (A / C system
normal operative)
Compressor faulty

Air in A / C system

Air leaking from cooling unit or air
duct

Heater and ventilation system faulty

Blower motor faulty

Excessive compressor oil existing in
A / C systemCheck compressor.
Replace condenser dryer, and
evacuation and charging.
Repair as necessary.
Check blower unit.
Check heater control lever assembly.
Check heater assembly.
Check blower motor.
Pull out compressor oil in A / C system
circuit, and replace compressor.
Cool air does not comes
out only intermittently
Wiring connection faulty

Expansion valve faulty

Excessive moisture in A / C system

A / C controller faulty

Magnetic clutch faulty

Excessive charge of refrigerantRepair as necessary.
Check expansion valve.
Replace condenser dryer, and
evacuation and charging.
Check A / C controller.
Check magnetic clutch.
Check charge of refrigerant.
Cool air comes out only
at high speeds
Condenser clogged

Insufficient charge of refrigerant

Air in A / C system

Drive belt slipping

Compressor faultyCheck condenser.
Check charge of refrigerant.
Replace condenser dryer, and
evacuation and charging.
Adjust or replace drive belt.
Check compressor.
Cool air does not comes
out only at high speeds
Excessive charge of refrigerant

A / C evaporator frostedCheck charge refrigerant.
Check A / C evaporator.
Check A / C thermistor.
Insufficient velocity of
cooled air
A / C evaporator clogged or frosted

Air leaking from cooling unit or air
duct

Blower motor faulty

Wiring or grounding faultyCheck A / C evaporator.
Repair as necessary.
Check blower motor.
Repair as necessary.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-39
COOLING UNIT (EVAPORATOR)
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº in
Section 10B.
3) 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 added to the system.
4) For G16 and J20 engine
Disconnect suction pipe (1), and liquid pipe (2) from evaporator
(cooling unit).
CAUTION:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust may not enter
cooling unit.
5) Remove blower motor unit. Refer to Section 1A ªHEATER AND
VENTILATIONº.
6) Disconnect thermistor wire coupler.
7) Remove cooling unit (evaporator).
DISASSEMBLY (FOR CAMI PRODUCTION VEHICLE)
1) Remove filter (2) from cooling unit (3) assembly by removing fil-
ter cover (1).
2) Remove screws (1) to separate evaporator upper and lower
cases from each other.

YH4
GRAND
VITARA
AIR BAG SYSTEM 10B-73
1. Driver air bag (inflator) module
2. Trim cover must face up
3. 185 cm (6 ft) of clearance
1. Trim cover must face up
2. 185 cm (6 ft) of clearance
3. Mounting attachment
4. Bag opening side
5. M8 bolt and nut
6. Hold-down bolt and nut
(B)
6) [In case of Driver Air Bag (Inflator) Module]
ii) Clear a space on the ground about 185 cm (6 ft) in diameter
where the driver air bag (inflator) module is to be deployed.
A paved, outdoor location where there is no activity is pre-
ferred. If an outdoor location is not available, a space on the
shop floor where there is no activity and sufficient ventilation
is recommended.
Ensure no loose or flammable objects are within the deploy-
ment area.
ii) Place the driver air bag (inflator) module, with its vinyl trim
cover facing up, on the ground in the space just cleared.
[In case of Passenger Air Bag (Inflator) Module]
iii) Clear a space on the ground about 185 cm (6 ft) in diameter
where the fixture (special tool) with attached air bag (inflator)
module is to be placed for deployment. A paved outdoor loca-
tion where there is no activity is preferred. If an outdoor loca-
tion is not available, a space on the shop floor where there is
no activity and sufficient ventilation is recommended. Ensure
that no loose or flammable objects are within the deployment
area.
iii) Place special tool (passenger air bag (inflator) module de-
ployment fixture) on the ground in the space cleared in step
i), if it has not already been placed there.
Special Tool
(B): 09932-75040
iii) Fill plastic reservoir in fixture (special tool) with water or sand.
This is necessary to provide sufficient stabilization of the fix-
ture during deployment.
iv) Securely attach the passenger air bag (inflator) module in the
fixture (special tool) using mounting attachment, hold-down
bolts and nuts and M8 bolts and nuts.
CAUTION:
Be sure to use the following bolt and nut for fixing pas-
senger air bag (inflator) module to mounting attach-
ment. Size: M8, Strength: 7T
Passenger air bag (inflator) module must be mounted so that
the bag will deploy upward. Securely tighten all fastener prior
to deployment.

YH4
GRAND
VITARA
1. Seat belt pretensioner (retractor assembly)
2. Webbing
3. 185 cm (6 ft) of clearance
4. Exhaust hole
1. Stretch deployment harness to full length 10 m (33 ft).
2. Connect connectors.
3. Power source (12V vehicle battery)
4. Short the two deployment harness leads.
5. Seat belt pretensioner harness
4
AIR BAG SYSTEM 10B-85
6) Pull out the webbing fully as shown at the left and cut it at the
root of the pretensioner (retractor assembly) as shown in the
figure.
WARNING:
As the drum of the retractor assembly turns very quick-
ly as soon as the webbing is cut, fix the retractor assem-
bly with a vise on the workbench and keep your hands
and fingers away from it when cutting the webbing.
7) Clear a space on the ground about 185 cm (6 ft) in diameter
where the seat belt pretensioner is to be activated. A paved,
outdoor location where there is no activity is preferred. If an out-
door location is not available, a space on the shop floor where
there is no activity and sufficient ventilation is recommended.
Ensure no loose or flammable objects are within the activation
area.
8) Place the seat belt pretensioner as shown in the figure on the
ground in the space just cleared.
9) Stretch the deployment harness from the seat belt pretension-
er to its full length 10 m (33 ft).
10) Place a power source near the shorted end of the deployment
harness. Recommended application: 12 Volts minimum, 2
amps minimum. A vehicle battery is suggested.
11) Verify that the area around the seat belt pretensioner is clear
of all people and loose or flammable objects.
12) Verify that the seat belt pretensioner is placed as shown in the
figure on the ground in the space just cleared.
13) Connect the seat belt pretensioner harness to the deployment
harness connector and lock the connector with lock lever.
Special Tool
(A): 09932-75030