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

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VITARA
1. Electric leak detector
AIR CONDITIONING (OPTIONAL) 1B-29
REMOVING MANIFOLD GAUGE SET
When A / C system has been charged with a specified amount of re-
frigerant, remove manifold gauge set as follows:
1) Close low pressure-side valve of manifold gauge set, (The high
pressure-side valve is closed continuously during the process
of charging.).
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves.
This operation must be performed rapidly.
WARNING:
High pressure-side is naturally under high pressure.
So, care must be used to protect your eyes and skin.
5) Put caps on service valves.
LEAK-TESTING REFRIGERANT SYSTEM
Whenever a refrigerant leak is suspected in the system or any ser-
vice operation has been performed which may result in disturbing
lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general, de-
pend upon the nature of a complaint and the type of a service per-
formed on the system.
LIQUID LEAK DETECTORS
There are a number of fittings and places throughout the air condi-
tioning system where a liquid leak detector solution may be used
to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a swab,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (gas) leak detector is more practical for deter-
mining leaks.
WARNING:

To prevent explosions or fires, make sure that there are no
flammables in the vicinity.

When exposed to fire, the refrigerant turns into a poison-
ous gas (phosgene). Do not inhale this gas.

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1. Suction hose
2. Discharge hose
3. Liquid pipe
4. Condenser outlet pipe
5. Expansion valve
6. Dual pressure switch
7. Suction pipe
: Apply compressor oil
(refrigerant oil) to O-ring.
1B-30 AIR CONDITIONING (OPTIONAL)
ON-VEHICLE SERVICE
WARNING:
Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately.

DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S).
Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its
temperature above the freezing point.

Obtain proper treatment as soon as possible from a doctor or eye specialist.
Should liquid refrigerant HFC-134a (R-134a) get on your skin, such affected part should be treated
in the same manner as when skin is frostbitten or frozen.
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 one will result in leakage of refrigerant, damage in parts or other faulty condition.
PRECAUTION
When servicing air conditioning system, the following rules must be observed.
PIPING

When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling nuts
and O-ring.

Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.

Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system,
install a blind plug or cap to the fitting immediately.

When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.

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3B1
POWER STEERING (P / S) SYSTEM 3B1-1
GENERAL DESCRIPTION3B1- 2 . . . . . . . . . . . . . .
Power Steering System 3B1- 2. . . . . . . . . . . . . . . . .
Steering Gear Box 3B1- 3. . . . . . . . . . . . . . . . . . . . . .
Power Steering (P / S) Pump 3B1- 4. . . . . . . . . . . . . .
DIAGNOSIS3B1- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Table 3B1- 5. . . . . . . . . . . . . . . .
Steering Wheel 3B1- 7. . . . . . . . . . . . . . . . . . . . . . . .
Steering Wheel Play Check 3B1- 7. . . . . . . . . . . .
Steering Force Check 3B1- 7. . . . . . . . . . . . . . . . .
Power Steering Fluid 3B1- 7. . . . . . . . . . . . . . . . . . . .
Power Steering Fluid Level Check 3B1- 7. . . . . .
Power Steering Pump Drive Belt 3B1- 8. . . . . . . . .
Belt Tension Check 3B1- 8. . . . . . . . . . . . . . . . . . .
Belt Tension Adjustment 3B1- 8. . . . . . . . . . . . . . .
Idle Up System 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . .
Idle Up System Check 3B1- 9. . . . . . . . . . . . . . . .
Fluid 3B1- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Leakage Check 3B1- 9. . . . . . . . . . . . . . . . . Hydraulic Pressure in P / S Circuit 3B1-10. . . . . . . . .
Hydraulic Pressure Check 3B1-10. . . . . . . . . . . . .
Boot 3B1-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Rack Boot Check 3B1-11. . . . . . . . . . . . .
Tie-Rod End Boot Check 3B1-12. . . . . . . . . . . . . .
Air Bleeding Procedure 3B1-12. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3B1-13 . . . . . . . . . . . . . . . .
Tie-Rod End 3B1-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Gear Box Assembly 3B1-14. . . . . .
Rack Boot and Tie-Rod (Except Canvas
Top LH Model) 3B1-16. . . . . . . . . . . . . . . . . . . . . . . .
Rack Boot and Tie-Rod (For Canvas
Top LH Model) 3B1-17. . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump 3B1-19. . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATION3B1-26 . . .
REQUIRED SERVICE MATERIAL3B1-26 . . . . . . . .
SPECIAL TOOL3B1-26 . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3B1
POWER STEERING (P/S) SYSTEM
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:

Some parts in the Power Steering Gear Box cannot be disassembled or adjusted. For detailed informa-
tion, refer to the description of ªPOWER STEERING GEAR BOX ASSEMBLYº.

All steering gear fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and / or could result in major repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacement becomes necessary. Do not use a replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of these parts.

Although the figures in this section show only the left-hand steering vehicle, the same work procedure
and data apply to the right-hand steering vehicle.
CONTENTS

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3C1
AIR BAG STEERING WHEEL AND COLUMN 3C1-1
GENERAL DESCRIPTION3C1- 2 . . . . . . . . . . . . .
DIAGNOSIS3C1- 3 . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection and Repair Required after
Accident 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE3C1- 3 . . . . . . . . . . . . . . .
Service Precautions 3C1- 3. . . . . . . . . . . . . . . . .
Diagnosis and Servicing 3C1- 3. . . . . . . . . . . .
Disabling Air Bag System 3C1- 3. . . . . . . . . . .
Enabling Air Bag System 3C1- 3. . . . . . . . . . .
Handling and Storage 3C1- 3. . . . . . . . . . . . . .
Disposal 3C1- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Driver Air Bag (Inflator) Module 3C1- 4. . . . . . . .
Steering Wheel 3C1- 6. . . . . . . . . . . . . . . . . . . . . . Centering Contact Coil 3C1- 6. . . . . . . . . . . . .
Contact Coil and Combination Switch
Assembly 3C1- 7. . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column 3C1- 9. . . . . . . . . . . . . . . . . . . .
Steering Lock Assembly (Ignition
Switch) 3C1-14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Lower Shaft Assembly 3C1-15. . . . . . .
Checking Steering Column for Accident
Damage 3C1-17. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustable Steering Column Release
Lever 3C1-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS3C1-18 . . . . . . . . . . . . . . . . . . .
SPECIAL TOOL3C1-18 . . . . . . . . . . . . . . . . . . . . . .
SECTION 3C1
AIR BAG STEERING WHEEL AND COLUMN
WARNING:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Please observe all WARNINGS and ªService Precautionsº under ªOn-Vehicle
Serviceº in air bag system section before performing service on or around the air bag system compo-
nents or wiring. Failure to follow WARNINGS could result in unintentional activation of the system
or could render the system inoperative. Either of these two conditions may result in severe injury.

The procedures in this section must be followed in the order listed to disable the air bag system tem-
porarily and prevent false diagnostic trouble codes from setting. Failure to follow procedures could
result in possible activation of the air bag system, personal injury or otherwise unneeded air bag sys-
tem repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were re-
moved. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound, will be called
out. The correct torque value must be used when installing fasteners that require it. If the above proce-
dures are not followed, parts or system damage could result.
CONTENTS

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14
15
1. Driver air bag (inflator) module
2. Steering wheel
3. Steering wheel nut
4. Contact coil and combination switch assembly
5. Steering column upper cover
6. Steering column lower cover
7. Steering column assembly
8. Steering lock assembly
9. Steering column hole cover
10. Steering shaft joint
11. Steering lower shaft assembly
12. Adjustable steering column release lever
(if equipped)
13. Steering column lower seal
14. With adjustable steering column release lever type
15. Without adjustable steering column release lever type
3C1-2 AIR BAG STEERING WHEEL AND COLUMN
GENERAL DESCRIPTION
This double tube type steering column has the following three important features in addition to the steering function:

The column is energy absorbing, designed to compress in a front-end collision.

The ignition switch and lock are mounted conveniently on this column.

With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehicle.
To insure the energy absorbing action, it is important that only the specified screws, bolts, and nuts be used as
designated and that they are tightened to the specified torque. When the column assembly is removed from the
vehicle, special care must be taken in handling it. Use of a steering wheel puller other than the one recommended
in this manual or a sharp blow on the end of the steering shaft, leaning on the assembly, or dropping the assembly
could shear the plastic shear pins which maintain column length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver's and passenger's seat belts by deploying the air bags. The air bag (inflator) module should
be handled with care to prevent accidental deployment. When servicing, be sure to observe all WARNINGS in this
section. Refer to ªSERVICE PRECAUTIONSº in Section 10B.

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1 11
1. Mounting bolt
1. Driver air bag (inflator) module connector
2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel
3C1-4 AIR BAG STEERING WHEEL AND COLUMN
DRIVE AIR BAG (INFLATOR) MODULE
WARNING:
When handling an air bag (inflator) module, be sure to read
ªSERVICE PRECAUTIONSº under ªON-VEHICLE SERVICEº
in Section 10B and observe each instruction. Failure to fol-
low them could cause a damage to the air bag (inflator) mod-
ule or result in personal injury.
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to ªDISABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
3) Loosen 2 bolts mounting driver air bag (inflator) module till it
turns freely, pull them out and fix them to bolt clamps.
4) Remove air bag (inflator) module from steering wheel.
5) Remove driver air bag (inflator) module (yellow) connector and
horn connector from steering wheel.
6) Disconnect driver air bag (inflator) module (yellow) connector of
driver air bag (inflator) module and horn connector as shown in
the figure.
ii) Release locking of lever.
ii) After unlocked, disconnect connector.
WARNING:
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) module. Observe
ªSERVICE PRECAUTIONSº under ªON-VEHICLE SER-
VICEº in Section 10B. Otherwise, personal injury may re-
sult.

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6, (a)
1. Trim cover (pad surface)
2. Inflator case
3. Wire harness
1. Driver air bag (inflator) module connector
2. Horn connector
3. Driver air bag (inflator) module
4. Steering wheel
5. Mounting bolt (left side)
6. Mounting bolt (right side)
AIR BAG STEERING WHEEL AND COLUMN 3C1-5
INSPECTION
WARNING:
Never disassemble air bag (inflator) module or measure its
resistance. Otherwise, personal injury may result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.
Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.

Air bag being deployed.

Trim cover (pad surface) being cracked.

Wire harness or connector being damaged.

Air bag (inflator) module being damaged or having been exposed
to strong impact (dropped).
INSTALLATION
1) Connect horn connector securely.
2) Connect yellow connector of driver air bag (inflator) module con-
nector as shown in the figure securely.
ii) Connect connector.
ii) Lock connector with lock lever.
3) Install horn connector and driver air bag (inflator) module con-
nector.
4) Install driver air bag (inflator) module to steering wheel, taking
care so that no part of wire harness is caught between them.
5) Make sure that clearance between module and steering wheel
is uniform all the way.
6) Tighten driver air bag (inflator) module mounting bolt (left side)
to specified torque first and then driver air bag (inflator) module
mounting bolt (right side) to specified torque.
Tightening Torque
(a): 9 N
.m (0.9 kg-m, 6.5 lb-ft)
7) Connect negative battery cable.
8) Enable air bag system. Refer to ªENABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.

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1. Steering column assembly
2. Steering shaft joint
3. Marks
1. Steering column assembly
2. Steering shaft joint
3. Steering lower shaft assembly
4. Bolt (column side)
5. Bolt (lower shaft assembly side)1. Steering column hole cover
1
3C1-10 AIR BAG STEERING WHEEL AND COLUMN
REMOVAL
WARNING:
Never rest a steering column assembly on the steering
wheel with air bag (inflator) module face down and column
vertical. Otherwise personal injury may result.
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to ªDISABLING AIR BAG SYS-
TEMº under ªSERVICE PRECAUTIONSº in Section 10B.
3) Remove steering wheel and contact coil and combination switch
assembly, if necessary. Refer to ªSTEERING WHEELº and
ªCONTACT COIL AND COMBINATION SWITCH ASSEMBLYº
in this section.
Perform the following procedure if not removing steering wheel
and/or combination switch.
ii) Turn steering wheel so that vehicle's front tires are at straight-
ahead position.
ii) Turn ignition switch to ªLOCKº position and remove key.
4) Remove steering column hole cover.
5) Disconnect all connectors for the following parts.

Contact coil and combination switch

Ignition switch
6) Make alignment marks on shaft joint and shaft (column side) for
a guide during reinstallation.
7) After removing bolt on column side of shaft joint and loosening
bolt on its lower shaft assembly side, move shaft joint to lower
shaft assembly side (in arrow direction in the figure).

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ªAº: Drill hole with approximately
3 mm (0.12 in.) diameter.
REAR SUSPENSION 3E-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to SECTION 3.
SHOCK ABSORBER CHECK

Inspect for deformation or damage.

Inspect bushings for wear or damage.

Inspect for evidence of oil leakage.
Replace any defective part.
WARNING:
When handling rear shock absorber in which high-pressure
gas is sealed, make sure to observe the following precau-
tions.
1) Don't disassemble it.
2) Don't put it into the fire.
3) Don't store it where it gets hot.
4) Before disposing it, be sure to drill a hole in it where
shown by an arrow in the figure and let gas and oil out.
Lay it down sideways for this work.
5) The gas itself is harmless but it may issue out of the hole
together with chips generated by the drill. Therefore, be
sure to wear goggle.
LOWER ROD, UPPER ROD, LATERAL ROD
CHECK
Inspect for cracks, deformation or damage.
Replace any defective part.
Inspect each bush for wear and breakage. If found defective, re-
place.
AXLE HOUSING AND COIL SPRING CHECK
Inspect for cracks, deformation or damage.
Inspect for evidence of oil leakage at axle housing.
If any, replace defective part.

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[A]: Before correction
[B]: Corrective weights
1. Heavy spot wheel tramp
2. Balance weights addition point
3. C / L of spindle
[C]: Before correction
[D]: Corrective weights
1. Heavy spot wheel shimmy
2. Balance weights addition point
3. C / L of spindle
WHEELS AND TIRES 3F-3
DIAGNOSIS
DIAGNOSIS TABLE
Refer to SECTION 3.
BALANCING WHEELS
There are two types of wheel and tire balance: static and dynamic.
Static balance, as shown in left figure, is equal distribution of weight
around wheel. Wheels that are statically unbalanced cause bounc-
ing action called tramp. This condition will eventually cause uneven
tire wear.
Dynamic balance, as shown in left figure, is equal distribution of
weight on each side of wheel centerline so that when the tire spins
there is no tendency for the assembly to move from side to side.
Wheels that are dynamically unbalanced may cause shimmy.
GENERAL BALANCE PROCEDURE
Deposits of mud, etc. must be cleaned from inside of rim.
WARNING:
Stones should be removed from tread in order to avoid operator injury during spin balancing and to
obtain good balance.
Tire should be inspected for any damage, then balanced according to equipment manufacturer's recommendation.
OFF-VEHICLE BALANCING
Most electronic off-vehicle balancers are more accurate than on-vehicle spin balancers. They are easy to use and
give a dynamic (two plane) balance. Although they do not correct for drum or disc unbalance as does on-vehicle
spin balancing, this is overcome by their accuracy, usually to within 1 / 8 ounce.
ON-VEHICLE BALANCING
ON-vehicle balancing methods vary with equipment and tool manufacturers. Be sure to follow each manufacturer's
instructions during balancing operation.