Temperature SUZUKI GRAND VITARA 1999 2.G Service Owner's Manual

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1B-20 AIR CONDITIONING (OPTIONAL)
A / C CONTROLLER VOLTAGE VALUES TABLE
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC1-1B/WController main
power supplyGround to
engine (Fig. B)10 ± 14 voltsIgnition switch ON with engine
stopped
AC1-2B/YController main
groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
AC1 4Or
Refrigerant
p
ressure switchGround to
0 ± 1 volt
Refrigerant pressure within 225 kPa
(2.3 kg / cm
2, 32.7 psi) to 2548 kPa
(26 kg / cm
2, 370 psi) with engine
running
AC1-4Orpressure switch
inputengine (Fig. B)
10 ± 14 volts
Refrigerant pressure below
196 kPa (2.0 kg / cm
2, 28 psi) or
above 3140 kPa (32 kg / cm
2, 455 psi)
with engine running
AC1 7G/B
A / C switch input
and / or defroster
Ground to
8 ± 14 volts
Blower fan motor switch and A / C or
defroster position switch (see NOTE)
ON with engine running
AC1-7G/Bposition switch
input (see NOTE)engine (Fig. B)
0 ± 1.5 volts
Blower fan motor switch or A / C or
defroster position switch (see NOTE)
OFF with engine running
AC1 9Gr/W
Signal input from
ECM (A / C ON
Ground to10 ± 14 voltsApprove of A / C ON
AC1-9Gr/W(
permission
signal)engine (Fig. B)0 ± 1 voltA / C ON forbid
AC1-13Y/B
Signal output to
ECM (A / C ON
request signal)Ground to engine
(Fig. B)0 ± 1.5 volts
Blower fan motor switch and A / C or
defroster position switch (see NOTE)
ON with engine running at evaporator
thermistor temperature input more
than approx. 2.5
C (less than 2.5 V
(5840
)) and refrigerant pressure
switch is ON
10 ± 14 voltsExcept the above-mentioned with
engine running
AC1-16P
Compressor
magnet clutch
relay outputGround to engine
(Fig. B)0 ± 1 volt
Blower fan motor switch and A / C or
defroster position switch ON with
engine running at evaporator
thermistor temperature input more
than approx. 2.5
C (less than 2.5 V
(5840
)), refrigerant pressure
switch ON and signal input from ECM
ON
10 ± 14 voltsExcept the above-mentioned with
engine running

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AIR CONDITIONING (OPTIONAL) 1B-21
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC2-1L/YSensor groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
1.5 volts
(3150
)Evaporator thermistor temperature at
approx. 15C (59F) with engine
running
AC2-2W/B
Evaporator
thermistor
temperature
(evaporator temp.
sensor) input
Ground to engine
(Fig. B)
2.62 volts
(6.311
)
Evaporator thermistor temperature at
approx. 1C (34F) with engine
running
* If the temperature is less than
approx. 1C, in this case
compressor and condenser fan
should be stop (come back at more
than approx. 2.5C (less than
5840
, 2.5 V))
H25
engine
E61-27 /
G16 J20Gr/W
Signal output to
A / C controller
(A / C ON
Ground to engine
(Fig C)
10 ± 14 volts
Required A / C ON (terminal AC-A13)
at engine running with normal
condition (refer to ªINSPECTION OF
ECM AND ITS CIRCUITº in Section
6E)
G16, J20
engines
E61-8
(
permission
signal)(Fig. C)
0 ± 1 volt
Except the above-mentioned with
engine running
In this case compressor should be
stop
H25
engine
E61-28 /
Y/B
Signal input from
A / C controller
Ground to engine
0 ± 1.5 voltsRequire A / C ON
G16, J20
engines
E61-17Y/B(A / C ON request
signal)
g
(Fig. C)
10 ± 14 voltsTurn off the A / C
H25
engine
E61-5 /
G16, J20
engines
E61-22
Y/L
A / C condenser
cooling fan relay
outputGround to engine
(Fig. C)0 ± 1 volt

Blower fan motor switch and A / C or
defroster position switch (see
NOTE) ON with engine running at
evaporator thermistor temperature
input more than approx. 2.5C (less
than 2.5 V (5840
)), refrigerant
pressure switch ON and signal
input from ECM ON

Engine coolant temperature sensor
more than 113C (236F) with
engine running
10 ± 14 voltsExcept the above-mentioned with
engine running
NOTE:
Defroster position switch circuit is equipped with LH vehicle only.

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Charge 440
50 g, 14.2
1.9 oz of
refrigerant in gas form
AIR CONDITIONING (OPTIONAL) 1B-23
REFRIGERANT RECOVERY, EVACUATION AND CHARGING
WARNING:

Your eyes should not be exposed to refrigerant (liquid).
Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. ± 6C
(42.8F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a seri-
ous injury. To protect your eyes against such accident, it is necessary to always wear goggles. Should
it occur that HFC-134a (R-134a) strikes your eye(s), consult a doctor immediately.
± DO NOT USE YOUR HAND TO RUB THE AFFECTED EYE(S). INSTEAD, use quantities of fresh cold
water to splash it over the affected area to gradually raise temperature of such area above freezing
point.
± Obtain proper treatment as soon as possible from a doctor or eye specialist.

Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.

Refrigerant must not be handled near where welding or steam cleaning is performed.

Refrigerant should be kept at a cold and dark place. It should never be stored where a high tempera-
ture is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).

Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazardous
to health.
OPERATION PROCEDURE FOR CHARGING A / C WITH REFRIGERANT

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For CAMI production vehicle
For IWATA production vehicle
1B-28 AIR CONDITIONING (OPTIONAL)
8) After the system has been charged with specified amount of re-
frigerant or when low pressure gauge (1) and high pressure
gauge (2) have indicated about 2 and 15 kg / cm
2 respectively,
close low pressure side vale (3) of manifold gauge set (4). If
equipped with sight glass in this time, look into the sight glass (6)
of condenser outlet pipe (5) and check that there are no bubbles
(7) in it, which means that the system is fully charged.
Low pressure gauge when charged with specified amount:
About 200 ± 300 kPa (2 ± 3 kg / cm
2, 29 ± 43 psi)
(At A / C inlet temperature 30 ± 35
C, 86 ± 95
F)
High pressure gauge when charged with specified amount:
About 1370 ± 1670 kPa (14 ± 17 kg / cm
2, 200 ± 244 psi)
(At A / C inlet temperature 30 ± 35
C, 86 ± 95
F)

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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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1
1B-40 AIR CONDITIONING (OPTIONAL)
3) Remove upper case (1) and remove evaporator (2) from lower
case (3).
4) Remove following components from evaporator.

Expansion valve (5)

Thermistor (evaporator temperature sensor) (4)
DISASSEMBLY (FOR IWATA PRODUCTION VEHICLE)
1) Remove filter (2) from cooling unit (3) assembly by removing fil-
ter cover (1).
2) Detach clamps (1) to separate evaporator upper and lower
cases from each other.
3) Remove upper case (1) and remove evaporator (2) from lower
case (3).
4) Remove following components from evaporator.

Expansion valve (5)

Thermistor (evaporator temperature sensor) (4)

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1. Evaporator thermistorTemperature
Resistance ( )


AIR CONDITIONING (OPTIONAL) 1B-43
A / C EVAPORATOR THERMISTOR
(EVAPORATOR TEMPERATURE SENSOR)
A thermistor is a temperature sensor to sense the temperature of
air discharged from evaporator. The electrical characteristic is
shown in the figure.
When temperature is lower than preset temperature, amplifier
makes magnet clutch turn off to prevent evaporator from frosting.
INSPECTION
Check resistance between A / C evaporator thermistor (1) termi-
nals.
If check results are as not specified, replace thermistor.
Sensor Temperature
Resistance
0
C, 32
F7.0 ± 7.7 k

25
C, 77
F2.1 ± 2.4 k

REMOVAL
Refer to ªCOOLING UNIT (EVAPORATOR)º in this section.
INSTALLATION
1) Reverse removal sequence to install thermistor.
2) Enable air bag system. Refer to ªENABLING AIR BAG SYS-
TEMº in Section 10B.
3) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.

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Pressure ABCD SWITCH
ON
(Continuity)
OFF
(No continuity)
AIR CONDITIONING (OPTIONAL) 1B-47
DUAL PRESSURE SWITCH
INSPECTION
1) Check dual pressure switch (1) on liquid pipe for continuity at
normal temperature (approx. 25
C (77
F)) when A / C system
has a proper charge of refrigerant and when A / C system (com-
pressor) is under operation. In each of these cases, switch
should show proper continuity.
2) Using a manifold gauge set, check switch for operation at speci-
fied pressure as shown, refer to ªPERFORMANCE DIAGNO-
SISº in this section.
Switch ON : above ªCº and below ªDº
Switch OFF : below ªAº or above ªBº
ªAº: Approx. 200 kPa (2.0 kg / cm
2)
ªBº: Approx. 3200 kPa (32 kg / cm
2)
ªCº: Approx. 230 kPa (2.3 kg / cm
2)
ªDº: Approx. 2800 kPa (28 kg / cm
2)
Tightening torque:
Dual pressure switch: 10 N
.m (1.0 kg-m, 7.5 lb-ft)

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POWER STEERING (P / S) SYSTEM 3B1-9
IDLE UP SYSTEM
IDLE UP SYSTEM CHECK
1) Warm up engine to normal operating temperature.
2) Turn A / C switch OFF, if equipped.
3) Turn steering wheel fully and check idle speed.
Engine idle speed drops a little momentarily when steering
wheel is turned fully but returns to its specified level immediately.
If power steering pressure switch connector is connected, check
the same with that connector disconnected. Momentary drop of
engine idle speed should be less when it is connected than when
disconnected.
FLUID
FLUID LEAKAGE CHECK
Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is provided. Then
visually check gear box, P / S pump and P / S fluid reservoir themselves and each joint of their connecting pipes for
leakage.
CAUTION:
Never keep steering wheel turned fully for longer than 10 seconds.

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1. P / S fluid reservoir
2. Attachment
3. Gasket4. Union bolt
5. High pressure side
6. Low pressure side
1. P / S fluid reservoir
2. Gauge valve (open)
3. P / S pump4. P / S gear box
5. High pressure side
6. Low pressure side
3B1-10 POWER STEERING (P / S) SYSTEM
HYDRAULIC PRESSURE IN P / S CIRCUIT
HYDRAULIC PRESSURE CHECK
1) After cleaning joint of high pressure hose and P / S pump thor-
oughly, disconnect hose from pump and install special tool (oil
pressure gauge, attachment and hose).
Tighten each flare nut to specified torque.
CAUTION:
Take care not to cause damage to A / C condenser during
service operation, if equipped.
Special Tool
(A): 09915-77410 (Oil pressure gauge)
(B): 09915-77420
2) Check each connection for fluid leakage and bleed air.
Refer to ªAIR BLEEDING PROCEDUREº in this section.
3) With engine idling, turn steering wheel and warm up engine till
temperature of fluid in P/S fluid reservoir rises to 50 ± 60
C (122
± 140
F).
4) Check back pressure by measuring hydraulic pressure with en-
gine idling and hands off steering wheel.
Back pressure: Lower than 1000 kPa (10 kg / cm
2, 142 psi)
When back pressure is higher than specified values, check con-
trol valve and piping for clogging.