Oil pan SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

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GRAND
VITARA
2
1. Oil filter
2. Oil filter wrench
MAINTENANCE AND LUBRICATION 0B-9
3) Loosen oil filter by using oil filter wrench (special tool).
Special Tool
(A): 09915-47310 (H25 engine)
09915-47330 (G16 and J20 engines)
NOTE:
Before fitting new oil filter, be sure to oil its O-ring. Use engine
oil for this purpose.
4) Screw new filter on oil filter stand by hand until the filter O-ring
contacts the mounting surface.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which at filter O-ring first contacts
the mounting surface.
5) Tighten the filter 3 / 4 turn from the point of contact with the
mounting surface using an oil filter wrench.
Tightening Torque (Reference)
(b): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
6) Replenish oil until oil level is brought to FULL level mark on dip-
stick. (oil pan and oil filter capacity). The filler inlet is at the top
of the cylinder head cover.
It is recommended to use engine oil of SG, SH or SJ grade.
NOTE:
For temperature between ±20
C (±4
F) and 30
C (86
F), it
is highly recommended to use SAE 10W ± 30 oil.
G16 EngineJ20 EngineH25 Engine
Oil pan capacityAbout 4.0 liters
(10.6 / 8.8 US / Imp pt.)About 5.0 liters
(10.6 / 8.8 US / Imp pt.)

Oil filter capacityAbout 0.2 liters
(0.4 / 0.3 US / Imp pt.)
About 0.5 liters
(1.1 / 0.9 US / Imp pt.)
OthersAbout 0.3 liters
(0.6 / 0.5 US / Imp pt.)About 0.4 liters
(1.1 / 0.9 US / Imp pt.)About 0.7 liters
(1.5 / 1.2 US / Imp pt.)
TotalAbout 4.5 liters
(9.5 / 7.9 US / Imp pt.)About 5.6 liters
(11.8 / 9.8 US / Imp pt.)About 6.2 liters
(13.1 / 10.9 US / Imp pt.)

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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.

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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.

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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.

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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.

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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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VITARA
AIR CONDITIONING (OPTIONAL) 1B-41
INSPECTION
1) Check evaporator fins for blockage. If found clogged, use com-
pressed air to clean the fins.
CAUTION:
Do not use water for cleaning of evaporator.
Be careful not to damage evaporator fins. If evaporator
fin is bent, straighten it by using a screwdriver or pair of
pliers. If any leakage is found from fitting or tube, repair
or replace evaporator.
2) Check inlet and outlet fittings for crack or scratch. Repair them
as required.
REASSEMBLY and INSTALLATION
1) Reverse removal and disassembly sequence to install cooling
unit, noting the following points.

Install uniformly the evaporator packing to dash panel hole for
expansion valve.

Adjust fresh air control cable, refer to ªHEATER CONTROL
LEVER ASSEMBLYº in Section 1A.
2) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.
3) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
NOTE:
When the thermistor removed, it should be reinstalled in
original position.
If cooling unit or evaporator is replaced, pour 25 cc of refrig-
erating oil to compressor suction-side.

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VITARA
3. Pipe clamp
1B-42 AIR CONDITIONING (OPTIONAL)
EXPANSION VALVE
INSPECTION
Refer to ªTroubleshooting Procedure Using Manifold Gauge Setº in
this section.
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 added to the system.
2) Remove front grill.
3) 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.
4) Disconnect suction pipe, and liquid pipe from suction hose (1)
and condenser outlet pipe (2).
5) Remove pipe clamp then remove suction pipe and liquid pipe.
6) Remove expansion valve (1).
INSTALLATION
1) Reverse removal sequence to install expansion valve.
2) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.

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VITARA
AIR CONDITIONING (OPTIONAL) 1B-61
09900-06107
Snap ring pliers
(Opening type)09991-06010
Magnet clutch pulley installer09991-06020
Armature plate spanner09991-06030
Armature plate remover
09991-06040
Lip type seal protector09991-06050
Lip type seal installer
REQUIRED SERVICE MATERIAL
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Compressor oil for DENSO
compressor (Refrigerant oil)COMPRESSOR OIL (ND-OIL 8, 250 cc)
99000-27080
O-ring

Each component
Compressor oil for
SEIKO SEIKI compressor
(Refrigerant oil)COMPRESSOR OIL RS20 (150 cc)
99000-99088-00D
O-ring

Each component
RefrigerantREFRIGERANT DRUM (200 g)
95794-50G00
Refrigerant charge
SPECIAL TOOLS

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VITARA
1
1. Steering column hole cover 1. Steering column cover screw
2. Steering column upper cover
3. Steering column lower cover: Standard screw
: Tapping screw
*
* *
AIR BAG STEERING WHEEL AND COLUMN 3C1-9
3) Connect all connectors that have been removed in removal.
4) Install steering column upper and lower cover, and then tighten
steering column cover screws.
CAUTION:
When installing lower cover and upper cover, be careful
so that contact coil and combination switch lead wire is
not caught between covers.
5) Install steering column hole cover.
6) Install steering wheel to steering column. Refer to ªSTEERING
WHEELº in this section.
STEERING COLUMN
CAUTION:
Once the steering column is removed from the vehicle, the
column is extremely susceptible to damage.
Dropping the column assembly on its end could collapse
the steering shaft or loosen the plastic shear pins which
maintain column length leaning on the column assembly
could cause it to bend or deform.
Any of the above damage could impair the column's col-
lapsible design.
When loosening steering column mounting bolts, make
sure that steering column assembly and steering shaft low-
er assembly have been separated. Loosening them with
steering column assembly and steering shaft lower assem-
bly assembled could cause damage to bearing in steering
shaft lower assembly.
NOTE:
When servicing steering column or any column-mounted
component, remove steering wheel. But when removing steer-
ing column simply to gain access to instrument panel compo-
nents, leave steering wheel installed on steering column.