sec 8 SUZUKI GRAND VITARA 2004 2.G Service Manual PDF
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2004, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 2004 2.GPages: 801, PDF Size: 12.15 MB
Page 123 of 801
YH4
GRAND
VITARA
1B-52 AIR CONDITIONING (OPTIONAL)
G16 engine
J20 engine
3. Compressor pulley
4. Crankshaft pulley
FOR CAMI PRODUCTION VEHICLE
1) Pour new compressor oil. The amount must be the same with
the amount measured in REMOVAL.
NOTE:
Compressor assembly supplied from factory is filled up
with the following amount of oil.
Amount of oil in compressor: 120 cm
3 (120 cc, 7.5 in3)
2)For G16 engine:
Install compressor assembly temporarily to bracket, then install
compressor drive belt (2).
For J20 engine:
Install compressor assembly to its bracket.
Tighten bolts (a).
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Connect suction and discharge hoses to compressor assembly.
4)For G16 engine:
Tension compressor drive belt (2) by tightening compressor as-
sembly mounting bolts. Refer to Section 3B1 for drive belt ten-
sion.
Tighten bolt (a) first, then (b).
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
For J20 engine:
Install generator belt (1). Refer to Section 6H for details.
5) Connect thermal protector lead wire.
6) Evacuate and charge system according to previously described
procedure.
CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.
Page 124 of 801
YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-53
1. Clutch plate bolt
2. Clutch plate
3. Circlip
4. Clutch pulley
5. Shim
6. Clutch coil
7. Compressor 567
MAGNET CLUTCH ASSEMBLY (FOR DENSO)
INSPECTION
Inspect clutch plate and clutch pulley for signs of oil.
Check clutch pulley for noise and grease leakage.
Using an ohmmeter, measure resistance of clutch coil between
clutch lead wire (1) and compressor body (2).
If measured resistance is not within tolerance, replace magnet
clutch assembly.
Standard resistance: 3.5 ± 5.0 at 20C, 68F
REMOVAL
1) Remove compressor assembly from vehicle. Refer to ªCOM-
PRESSOR ASSEMBLYº in this section.
2) Fix clutch plate (1) with special tool (A) and remove clutch plate
bolt.
Special Tool
(A): 09991-06020
NOTE:
Do not reuse clutch plate bolt.
3) Using special tool (B), remove clutch plate (1).
Special Tool
(B): 09991-06030
Page 127 of 801
YH4
GRAND
VITARA
1B-56 AIR CONDITIONING (OPTIONAL)
1. Clutch plate bolt
2. Clutch plate
3. Circlip
4. Clutch pulley
5. Washer
6. Shim
7. Oil felt ring
8. Clutch coil
9. Lip type seal
10. Compressor front head
11. Compressor body component
12. O-ring
13. Compressor thermal switch
3. Washer
(if equipped)1. Thermal switch
2. Ohmmeter
MAGNET CLUTCH ASSEMBLY (FOR SEIKO SEIKI)
INSPECTION
MAGNET CLUTCH
Inspect clutch plate and clutch pulley for signs of oil.
Check clutch pulley bearings for noise and grease leakage.
Using and ohmmeter, measure resistance of clutch coil between
clutch coil lead wire (1) and compressor body.
If measured resistance is not within tolerance, replace coil.
Standard resistance: 2.5 ± 4.5 at 20C, 68F
COMPRESSOR THERMAL SWITCH
Use an ohmmeter to check thermal switch for continuity. If there is
no continuity, replace it.
REMOVAL
1) Remove compressor assembly from vehicle. Refer to COM-
PRESSOR ASSEMBLY in this section.
2) Fix clutch plate (1) with special tool (A) and remove clutch plate
bolt (2).
Special Tool
(A): 09991-06020
NOTE:
Do not reuse armature plate nut.
Page 130 of 801
YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-59
PUSH
3. Cylinder
4. Case
5. O-ring
2. Bearing puller
LIP TYPE SEAL (FOR SEIKO SEIKI)
REMOVAL
1) Remove magnet clutch assembly, referring to ªMAGNET
CLUTCH ASSEMBLYº in this section.
2) Remove compressor front head (1) mounting bolt (10 pcs.).
3) Remove compressor front head (1) by pushing cylinder shaft
(2).
NOTE:
Be careful not to remove cylinder from case.
4) Remove O-ring.
5) Remove lip seal from compressor front head (1).
INSTALLATION
1) Press-fit lip seal (1) into compressor front head (2) using special
tool (E).
Special Tool
(E): 09991-06050
CAUTION:
Do not reuse mechanical seal once removed from com-
pressor.
Page 133 of 801
YH4
GRAND
VITARA
3
STEERING, SUSPENSION, WHEELS AND TIRES 3-1
GENERAL DIAGNOSIS3-1 . . . . . . . . . . . . . . . . .
Diagnosis Table 3-1. . . . . . . . . . . . . . . . . . . . . .
TIRE DIAGNOSIS3-6 . . . . . . . . . . . . . . . . . . . . . .
Irregular and / or Premature Wear 3-6. . . . . . .
Wear Indicator 3-6. . . . . . . . . . . . . . . . . . . . . . . Radial Tire Waddle 3-6. . . . . . . . . . . . . . . . . . .
Radial Tire Lead 3-8. . . . . . . . . . . . . . . . . . . . . .
VIBRATION DIAGNOSIS3-8 . . . . . . . . . . . . . . .
SECTION 3
STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT END ALIGNMENT3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER STEERING SYSTEM3B1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BAG STEERING WHEEL AND COLUMN3C1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SUSPENSION3D-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION3E-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEELS AND TIRES3F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS
GENERAL DIAGNOSIS
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered
when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged parts.
3) Spin front wheel. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and / or rough wheel bear-
ings.
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Vehicle Pulls (Leads)Mismatched or uneven tires.
Tires not adequately inflated.
Broken or sagging springs.
Radial tire lateral force.
Disturbed front end alignment.
Disturbed rear axle alignment.
Brake dragging in one road wheel.
Loose, bent or broken front or rear
suspension parts.Replace tire.
Adjust tire pressure.
Replace spring.
Replace tire.
Check front end alignment.
Check rear axle alignment.
Repair front brake.
Tighten or replace suspension part.
Page 134 of 801
YH4
GRAND
VITARA
3-2 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Abnormal or
Excessive Tire WearSagging or broken springs.
Tire out of balance.
Disturbed front end alignment.
Faulty shock absorber.
Hard driving.
Overloaded vehicle.
Tires not rotating.
Worn or loose road wheel bearings.
Wobbly wheel or tires.
Tires not adequately inflated.Replace spring.
Adjust balance or replace tire.
Check front end alignment.
Replace shock absorber.
Replace tire.
Replace tire.
Replace or rotate tire.
Replace wheel bearing.
Replace wheel or tire.
Adjust the pressure.
Wheel TrampBlister or bump on tire.
Improper shock absorber action.Replace tire.
Replace shock absorber.
Shimmy, Shake or
VibrationTire or wheel out of balance.
Loose wheel bearings.
Worn tie rod ends.
Worn lower ball joints.
Excessive wheel runout.
Blister or bump on tire.
Excessively loaded radial runout of
tire / wheel assembly.
Disturbed front end alignment.
Loose or worn tie-rod end.
Loose steering gear case bolts.Balance wheels or replace tire and /
or wheel.
Replace wheel bearing.
Replace tie rod end.
Replace front suspension control
arm.
Repair or replace wheel and / or tire.
Replace tire.
Replace tire or wheel.
Check front end alignment.
Tighten or replace tie-rod end.
Tighten case bolts.
Hard SteeringBind in tie rod end ball studs or
lower ball joints.
Disturbed front end alignment.
Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)
Tire not adequately inflated.
Bind in steering column.
Low fluid level, loose drive belt or
malfunction of power steering system.
(if equipped with P / S)Replace tie rod end or front
suspension control arm.
Check front end alignment.
Check and adjust steering gear box.
Inflate tires to proper pressure.
Repair or replace.
Check and correct.
Page 135 of 801
YH4
GRAND
VITARA
STEERING, SUSPENSION, WHEELS AND TIRES 3-3
ConditionPossible CauseCorrection
Too Much Play in
SteeringWheel bearings worn.
Loose steering gear case bolts.
Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)
Worn steering shaft joints.
Worn tie rod ends or tie rod
inside ball joints.
Worn lower ball joints.Replace wheel bearing.
Tighten.
Check and adjust rack and pinion
torque.
Replace joint.
Replace tie rod end or steering
gear case.
Replace front suspension control
arm.
Poor ReturnabilityBind in tie rod end ball studs.
Bind in ball joints.
Bind in steering column.
Poorly lubricated rack and pinion.
(if equipped with manual steering gear
case)
Disturbed front end alignment.
Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)
Tires not adequately inflated.Replace tie rod end.
Replace ball joint.
Repair or replace.
Check, repair or lubricate rack and
pinion.
Check and adjust front end
alignment.
Check and adjust rack and pinion
torque.
Adjust pressure.
Steering Noise
(Rattle or Chuckle)Loose bolts and nuts.
Broken or otherwise damaged wheel
bearings.
Worn or sticky tie rod ends.
Rack and pinion not properly adjusted.
(if equipped with manual steering gear
case)Retighten.
Replace.
Replace.
Check and adjust rack and pinion
torque.
Abnormal Noise,
Front EndWorn, sticky or loose tie rod
ends, lower ball joints, tie rod
inside ball joints or drive shaft
joints.
Damaged shock absorbers, struts
or mountings.
Worn control arm bushings.
Loose stabilizer bar.
Loose wheel nuts.
Loose suspension bolts or nuts.
Broken or otherwise damaged
wheel bearings.
Broken suspension springs.
Poorly lubricated or worn strut
bearings.Replace tie rod end, control arm,
steering gear case or drive shaft
joint.
Replace or repair.
Replace.
Tighten bolts or replace bushes.
Tighten wheel nuts.
Tighten suspension bolts or nuts.
Replace wheel bearing.
Replace spring.
Lubricate or replace strut bearing.
Page 136 of 801
YH4
GRAND
VITARA
3-4 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Wander or Poor
Steering StabilityMismatched or uneven tires.
Loose ball joints and tie rod
ends.
Faulty shock absorbers / struts or
mounting.
Loose stabilizer bar.
Broken or sagging springs.
Rack and pinion not properly adjusted.
(if equipped with manual steering
gear case)
Disturbed front end alignment.Replace tire or inflate tires to
proper pressure.
Replace suspension control arm or
tie rod end.
Replace absorber / strut or repair
mounting.
Tighten or replace stabilizer bar or
bushes.
Replace spring.
Check or adjust rack and pinion
torque.
Check and adjust front end alignment.
Erratic Steering when
BrakingWorn wheel bearings.
Broken or sagging springs.
Leaking wheel cylinder or caliper.
Warped discs.
Badly worn brake linings.
Drum is out of round in some brakes.
Wheel tires are inflated unequally.
Defective wheel cylinders.
Disturbed front end alignment.Replace wheel bearing.
Replace spring.
Repair or replace wheel cylinder or
caliper.
Replace brake disc.
Replace brake shoe lining.
Replace brake drum.
Inflate tires to proper pressure.
Replace or repair wheel cylinder.
Check front end alignment.
Low or Uneven Trim
Height
Right-to-left trim height
(H) difference should be
within 15 mm (0.6 in.)
with curb weight.
*Same with rear side.Broken or sagging springs.
Overloaded.
Incorrect springs.Replace spring.
Check loading.
Replace spring.
Ride Too SoftFaulty shock absorber or struts.Replace shock absorber or strut.
Suspension BottomsOverloaded.
Faulty shocks or struts.
Incorrect broken or sagging springs.Check loading.
Replace shock absorber or strut.
Replace spring.
Page 137 of 801
YH4
GRAND
VITARA
STEERING, SUSPENSION, WHEELS AND TIRES 3-5
ConditionPossible CauseCorrection
Body Leans or Sways
in CornersLoose stabilizer bar.
Faulty shock absorbers, struts
or mounting.
Broken or sagging springs.
Overloaded.Tighten stabilizer bar bolts or
replace bushes.
Replace shock absorber, strut or
tighten mounting.
Replace spring.
Check loading.
Cupped TiresFront struts defective.
Worn wheel bearings.
Excessive tire or wheel run-out.
Worn ball joints.
Tire out of balance.Replace strut.
Replace wheel bearing.
Replace tire or wheel disc.
Replace front suspension control
arm.
Adjust tire balance.
Page 142 of 801
YH4
GRAND
VITARA
3A
Alignment service data (without load)
Toe-in (Toe-in gauge measurement)
ªBº ± ªAº: 0 2 mm (0 0.08 in.)
Camber angle ªCº: 0' 1
Caster: 240' 1
*1. Forward
*2. Body center[A] : Top view
[B] : Front view
1. Center line of wheel
FRONT END ALIGNMENT 3A-1
SECTION 3A
FRONT END ALIGNMENT
CONTENTS
DIAGNOSIS3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toe-Setting3A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camber3A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Checks Prior to Adjusting Front Alignment 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toe Adjustment3A-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camber and Caster Adjustment 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Angle3A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION
Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts
and the ground. Generally, the only adjustment required for front alignment is toe setting.
Camber and caster can't be adjusted. Therefore, should camber or caster be out of specification due to the damage
caused by hazardous road conditions or collision, whether the damage is in body or in suspension should be deter-
mined. If the body is damaged, it should be repaired and if suspension is damaged, it should replaced.
TOE SETTING
Toe is the turning in or out of the front wheels. The purpose of a toe specification is to ensure parallel rolling of the
front wheels (Excessive toe-in or toe-out may increase tire wear).
Amount of toe can be obtained by subtracting ªAº front ªBº as shown in above figure and therefore is given in mm
(in.).