actuator SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
VITARA
GENERAL INFORMATION 0A-21
A
ABS : Anti-lock Brake System
ATDC : After Top Dead Center
API : American Petroleum Institute
ATF : Automatic Transmission Fluid
ALR : Automatic Locking Retractor
AC : Alternating Current
A / T : Automatic Transmission
A / C : Air Conditioning
ABDC : After Bottom Dead Center
A / F : Air Fuel Mixture Ratio
A-ELR : Automatic-Emergency
Locking Retractor
B
B+ : Battery Positive Voltage
BTDC : Before Top Dead Center
BBDC : Before Bottom Dead Center
C
CKT : Circuit
CMP Sensor : Camshaft Position Sensor
(Crank Angle Sensor, CAS)
CO : Carbon Monoxide
CPP Switch : Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
CPU : Central Processing Unit
CRS : Child Restraint System
D
DC : Direct Current
DLC : Data Link Connector
(Assembly Line Diag. Link,
ALDL, Serial Data Link, SDL)
DOHC : Double Over Head Camshaft
DOJ : Double Offset Joint
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
(Diagnostic Code)
E
EBCM : Electronic Brake Control
Module, ABS Control
Module
EBD : Electric Brake force Distribution
ECM : Engine Control Module
ECT Sensor : Engine Coolant Temperature
Sensor (Water Temp.
Sensor, WTS)
EGR : Exhaust Gas Recirculation
EGRT Sensor : EGR Temperature Sensor
(Recirculated Exhaust Gas
Temp. Sensor, REGTS)
EFE Heater : Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
ELR : Emergency Locking Retractor
EPS : Electronic Power Steering
EVAP : Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Charcoal Canister)
F
4WD : 4 Wheel Drive
G
GEN : Generator
GND : Ground
H
HC : Hydrocarbons
HO2S : Heated Oxygen Sensor
I
IAC Valve : Idle Air Control Valve (Idle
Speed Control Solenoid
Valve, ISC Solenoid Valve)
IAT Sensor : Intake Air Temperature
Sensor (Air temperature
Sensor, ATS)
ICM : Immobilizer Control Module
IG : Ignition
ISC Actuator : Idle Speed Control Actuator
(Motor)
ABBREVIATIONS MAY BE USED IN THIS MANUAL

YH4
GRAND
VITARA
1A
HEATER AND VENTILATION 1A-1
SECTION 1A
HEATER AND VENTILATION
WARNING:
For vehicles equipped with Supplement 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 or 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:
The link mechanism of the heater varies depending on the specifications.
CONTENTS
GENERAL DESCRIPTION1A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Body Ventilation1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table1A- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Circuit1A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE1A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Unit1A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor1A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Relay1A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Motor Resistor1A- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Switch1A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Mode Control Actuator1A-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Lever Assembly 1A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Control Cables1A-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Unit1A-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Duct1A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-3
BODY VENTILATION
The body ventilation system of this vehicle has a fresh air intake located at the cowl top panel. When fresh air intake
control lever is at FRESH AIR position, ventilating air is drawn into the interior from the cowl center garnish and
drawn out from the ventilator outlet provided at each side body outer panel (both right and left side).
DIAGNOSIS
DIAGNOSIS TABLE
TroublePossible causeRemedy
Heater blower won't
work even when its
switch is ON.Blower fuse blown
Blower resistor faulty
Blower motor faulty
Wiring or grounding faultyReplace fuse to check for short.
Check resistor.
Replace motor.
Repair as necessary.
Incorrect temperature
output.Control cables broken or binding
Air damper broken
Air ducts clogged
Heater radiator leaking or clogged
Heater hoses leaking or cloggedCheck cables.
Repair damper.
Repair air ducts.
Replace radiator.
Replace hoses.
When mode control
switch is changed,
air outlet port is not
changed.Mode control switch faulty
Mode actuator faulty
Fuse blown
Wiring or grounding faulty
Air damper broken
Air ducts cloggedCheck and replace as necessary.
Check and replace as necessary.
Replace fuse to check for short.
Repair as necessary.
Repair damper.
Repair air ducts.

YH4
GRAND
VITARA
1A-4 HEATER AND VENTILATION
FOR LH VEHICLE
FOR RH VEHICLE
1. From ignition switch 1
2. From ignition switch 2
3. From blower fuse
4. Head light relay
5. To A / C controller6. Blower motor relay
7. Blower motor switch
8. Blower resistor
9. Blower motor
10. To ECM11. To illumination controller
(if equipped) or body ground
12. Mode control actuator
13. Mode control switch
14. From main fuse15. TAIL fuse 15 A
16. IG METER fuse 20 A
17. HEATER fuse 30 A
18. REAR DEFG fuse 15 A
19. Drive circuit
WIRING CIRCUIT

YH4
GRAND
VITARA
1A-12 HEATER AND VENTILATION
1. Temperature control lever
2. Fresh air control lever
1. Fresh air control cable 1. Heater unit
2. Control cable1
2
INSTALLATION
1) Install in reverse order of removal procedure.
2) Adjust cables as follows.
(1) Move control lever fully in arrow direction.
(2) Push heater lever fully in arrow direction and fix cable with
clamp in position as shown in left figure.
(3) Push blower lever fully in arrow direction and fix cable with
clamp in position as shown in left figure.
NOTE:
After installing control cables, be sure that control levers
move smoothly and stop at proper position.
3) If equipped with air bag, enable air bag system. Refer to ªENAB-
LING AIR BAG SYSTEMº in Section 10B.
HEATER MODE CONTROL ACTUATOR
REMOVAL
1) Disconnect negative (±) cable at battery.
2) If equipped with air bag system, disable air bag system.
Refer to DISABLING AIR BAG SYSTEM in Section 10B.
3) Remove column hole cover.

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-13
1. Lever
FOR LEFT HAND STEERING VEHICLE
FOR RIGHT HAND STEERING VEHICLE
4) Disconnect heater mode control actuator coupler (1).
5) Disconnect heater mode control actuator rod (2) from heater
unit.
6) Remove heater mode control actuator from heater unit by re-
moving its mounting screw (3).
INSPECTION
1) Connect battery voltage (+) to terminal ªb'º and (±) to terminal
ªaº.
2) Connect each terminal listed below to terminal ªa'º (negative (±)
terminal of battery) and check if lever rotation angle is as speci-
fied in figure.
MODE
TERMINAL
VENTc
BI-LEVELd
HEATe
DEF / HEATf
DEFg
INSTALLATION
1) Install in reverse order of removal procedure.
2) If equipped with air bag system, enable air bag system.
Refer to ENABLING AIR BAG SYSTEM in Section 10B.

YH4
GRAND
VITARA
1A-16 HEATER AND VENTILATION
1. Heater unit
2. Heater core
3. Damper
4. Heater mode control actuator
5. Heater mode control switch
6. Heater control lever assembly
HEATER UNIT

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
[FOR VEHICLE WITHOUT ABS]
[FOR VEHICLE WITH ABS]
1. Master cylinder
2-1. 4-way joint
2-2. 2-way joint
3. LSPV (Load Sensing Proportioning Valve)
4. Rear axle housing
5. ABS actuator (H.U.)
F.R.:Front side
5-2 BRAKES
GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons
(two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make
two independent circuits. One connects front brakes (right and left) and the other connects rear brakes (right and
left).
The load sensing proportioning valve (LSPV) is included in these circuits between the master cylinder and the rear
brake for the vehicle without ABS.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading / trailing
shoes) for the rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and me-
chanical linkage system. The same brake shoes are used for both parking and foot brakes.

YH4
GRAND
VITARA
1. 4-way joint / 2-way joint
2. Master cylinder
3. LSPV
4. Right brake caliper
5. Left brake caliper
6. Right wheel cylinder
7. Left wheel cylinder
8. ABS actuator

: Air bleeding point [A]: Without ABS
[B]: With ABS
1. Plug cap2. Vinyl tube (See-through tube)
3. Container
[A]
[B]
BRAKES 5-7
CHECK AND ADJUSTMENT
BLEEDING BRAKES
CAUTION:
Brake fluid is extremely damaging to paint. If fluid should
accidentally touch painted surface, immediately wipe
fluid from paint and clean painted surface.
NOTE:
For vehicle equipped with ABS, make sure that ignition switch
turns off.
Be sure to bleed air of brake system according to following proce-
dure when its oil hydraulic circuit has been disconnected.
Hydraulic lines of brake system consists of two separate lines, one
for front wheel brakes and the other for rear wheel brakes.
Air bleeding is necessary at right and left front wheel brakes, left
rear wheel brake and LSPV (if equipped without ABS), i.e. 4 places
(3 places for vehicle with ABS) in all.
1) Fill master cylinder reservoir with brake fluid and keep at least
one-half full of fluid during bleeding operation.
2) Remove bleeder plug cap.
Attach a vinyl tube to bleeder plug of wheel cylinder, and insert
the other end into container.
3) Depress brake pedal several times, and then while holding it de-
pressed, loosen bleeder plug about one-third to one half turn.