Switch SUZUKI GRAND VITARA 2003 2.G Service User Guide

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-11
1
1. Mode control switch coupler
7) Disconnect heater blower motor switch connector (1).
8) Remove mode control switch with heater control lever assem-
bly from the removed hole in mentioned step (5).
9) Pull off heater control lever knob.
10) Remove heater mode control switch (2) with heater control
panel (3) from heater control lever assembly (1).
11) Remove heater control panel from mode control switch.
INSPECTION
Mode Control Switch

Check if continuity exists between each pair of terminals listed be-
low when mode control button is pressed.
Mode
Mode control switch terminals
VENTF ± M
BI-LEVELF ± N
HEATF ± E
DEF / HEATF ± B
DEFF ± C

With battery voltage (+) connected to terminal ªIº and (±) to termi-
nal ªFº, press each mode control button and check if indicator
lamp (3) lights.

With battery voltage (+) connected to terminal ªAº and (±) to termi-
nal ªHº, check if illumination lamp lights.

YH4
GRAND
VITARA
1. Blower motor switch connector
1
1A-14 HEATER AND VENTILATION
HEATER CONTROL LEVER ASSEMBLY
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 mode control switch. Refer to item HEATER MODE
CONTROL SWITCH in this section.
INSPECTION
Check heater blower motor switch for each terminal-to-terminal
continuity. For the detail refer to WIRING CIRCUIT earlier in this
section.
EFLMLMHH
LOW
M1
M2
HIGH

YH4
GRAND
VITARA
HEATER AND VENTILATION 1A-15
1. Heater unit
2. Blower unit
3. Fresh air control cable
4. Temperature control cable
5. Heater control lever assembly
HEATER CONTROL CABLES
REMOVAL
1) Remove heater control lever assembly.
Refer to HEATER CONTROL LEVER ASSEMBLY in this sec-
tion.
2) Remove control cables (2) from control lever assembly (1).
INSTALLATION
1) Install in reverse order of removal procedure.
Refer to HEATER MODE CONTROL SWITCH in this section.
2) If equipped with air bag, 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
1B
AIR CONDITIONING (OPTIONAL) 1B-1
GENERAL DESCRIPTION1B- 3 . . . . . . . . . . . . . .
Identification of Refrigerating System 1B- 3. . . .
Refrigerant Flow of Air Conditioning
System 1B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Components and Location 1B- 5. . . . . . .
DIAGNOSIS1B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 1B- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis of Abnormal Noise 1B- 8. . . . . . . . . .
Quickly Checking of Refrigerant Charge
(If Equipped with Sight Glass) 1B-10. . . . . . . . .
Compression System Diagnosis 1B-11. . . . . . . .
Performance Diagnosis 1B-12. . . . . . . . . . . . . . .
Wiring Circuit 1B-16. . . . . . . . . . . . . . . . . . . . . . . .
Inspection of A / C Controller and Its
Circuits 1B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . REFRIGERANT RECOVERY,
EVACUATION AND CHARGING1B-23 . . . . . . . .
Operation Procedure for Charging A / C
with Refrigerant 1B-23. . . . . . . . . . . . . . . . . . . . .
Recovery 1B-24. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evacuating 1B-25. . . . . . . . . . . . . . . . . . . . . . . . . .
Charging 1B-26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Manifold Gauge Set 1B-29. . . . . . . . .
Leak-Testing Refrigerant System 1B-29. . . . . . .
Liquid Leak Detectors 1B-29. . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE1B-30 . . . . . . . . . . . . . . . .
Precaution 1B-30. . . . . . . . . . . . . . . . . . . . . . . . . . .
A / C Condenser Assembly 1B-33. . . . . . . . . . . . .
Condenser Cooling Fan Assembly 1B-35. . . . . .
SECTION 1B
AIR CONDITIONING (OPTIONAL)
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).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of A / C:
one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to the description in 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.
For basic servicing method of the air conditioning system that is not described in this section, refer to AIR CONDI-
TIONING BASIC MANUAL (99520-02130).
CONTENTS

YH4
GRAND
VITARA
1B-2 AIR CONDITIONING (OPTIONAL)
Condenser Dryer (Receiver / Dryer) 1B-36. . . . . .
Air Filter Element 1B-37. . . . . . . . . . . . . . . . . . . . .
Cooling Unit (Evaporator) 1B-39. . . . . . . . . . . . . .
Expansion Valve 1B-42. . . . . . . . . . . . . . . . . . . . .
A / C Evaporator Thermistor (Evaporator
Temperature Sensor) 1B-43. . . . . . . . . . . . . . . .
Refrigerant Pipes and Hoses 1B-44. . . . . . . . . . .
A / C Switch 1B-45. . . . . . . . . . . . . . . . . . . . . . . . . .
A / C Controller 1B-46. . . . . . . . . . . . . . . . . . . . . . . .
Dual Pressure Switch 1B-47. . . . . . . . . . . . . . . . . A / C Compressor Relay and A / C
Condenser Cooling Fan Relay 1B-48. . . . . . . .
Compressor Assembly 1B-49. . . . . . . . . . . . . . . .
Magnet Clutch Assembly
(For Denso Compressor) 1B-53. . . . . . . . . . .
Magnet Clutch Assembly
(For Seiko Seiki Compressor) 1B-56. . . . . . .
Lip Type Seal (For Seiko Seiki) 1B-59. . . . . . .
REQUIRED SERVICE MATERIAL1B-61 . . . . . . . .
SPECIAL TOOLS1B-61 . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
1. Compressor
2. Magnet clutch
3. Condenser assembly
4. Receiver / dryer
5. Dual pressure switch
6. Expansion valve
7. Evaporator: Liquid
: Vapor
: Superheated vapor
1B-4 AIR CONDITIONING (OPTIONAL)
REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM

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
1B-6 AIR CONDITIONING (OPTIONAL)
DIAGNOSIS
GENERAL
ConditionPossible CauseCorrection
Cool air won't come out
(A / C system won't
operative)
No refrigerant

Fuse blown

A / C switch faulty

Blower motor switch faulty

A / C thermistor faulty

Dual pressure switch faulty

Wiring or grounding faulty

A / C ON permission signal in ECM
faulty

A / C controller and its circuit faultyRecover, evacuation and charging.
Check ªIG METERº fuse, ªREAR DEFGº
fuse, and ªA / C FUSEº and check for
short circuit to ground.
Check A / C switch.
Check blower motor switch.
Check A / C evaporator thermistor.
Check dual pressure switch.
Repair as necessary.
Check ON permission signal.
Check A / C controller and its circuit.
Cool air won't come out
(A / C compressor won't
operative)
Magnet clutch faulty

Compressor relay faulty

Compressor thermal switch faulty
(if equipped)

Drive belt loose or broken

Compressor faulty

A / C ON permission signal in ECM
faulty

A / C controller faultyCheck magnet clutch.
Check compressor thermal switch.
Check compressor relay.
Adjust or replace drive belt.
Check compressor.
Check ON permission signal.
Check A / C controller.
Cool air won't come out
(A / C condenser cooling
fan motor won't
operative)
Condenser cooling fan relay faulty

Wiring or grounding faulty

ªA / C condenser cooling fan relayº
signal in ECM faulty

Condenser cooling fan motor faultyCheck condenser cooling fan relay.
Repair as necessary.
Check A / C condenser cooling fan relay
signal.
Check condenser cooling fan motor.
Cool air won't come out
(Blower motor won't
operative)
Fuse blown

Blower motor relay faulty

Blower motor resistor faulty

Blower motor switch faulty

Wiring or grounding faulty

Blower motor faultyCheck ªHEATER FUSEº, ªREAR DEFGº
fuse and check for short circuit to
ground.
Check blower motor relay.
Check blower motor resistor.
Check blower motor switch.
Repair as necessary.
Check blower motor.
Cool air won't come out
or insufficient cooling
(A / C system normal
operative)
Insufficient or excessive charge of
refrigerant

Refrigerant leak in system

Condenser clogged

A / C evaporator clogged or frosted

A / C thermistor faulty

A / C controller faulty

Expansion valve faulty

Drive belt slipping

Magnetic clutch faultyCheck charge of refrigerant.
Check system for leaks.
Check condenser.
Check A / C evaporator.
Check A / C thermistor.
Check A / C controller.
Check expansion valve.
Check or replace drive belt.
Check magnetic clutch.

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.