cooling SUZUKI SWIFT 2000 1.G RG413 Service User Guide

1B-10 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 15 – 35°C (59 – 95°F).
2) Make sure that high pressure valve (1) and low pressure
valve (2) of manifold gauge set (3) are firmly closed.
3) Connect high pressure charging hose (4) to high pressure
service valve (5), and connect low pressure charging hose
(6) to low pressure service valve (7).
4) Bleed the air in charging hoses (4), (6) by loosening their
respective nuts on manifold gauge set (3), utilizing the refrig-
erant pressure. When a hissing sound is heard, immediately
tighten nut.
5) Warm up engine to normal operating temperature (engine
coolant temperature at 80 – 90°C (176 – 194°F)) and keep it
at specified idle speed. (Radiator cooling fan should not be
working when checking pressure and temperature.)
6) Turn A/C switch to ON position, and set blower fan switch at
“H” (4th position), temperature dial at “COOL”, air outlet con-
trol dial at “FACE” and fresh/recirculation control dial at
“RECIRCULATION”. (Confirm that A/C compressor and radi-
ator/condenser cooling fan are working.)
Keep all windows, doors and engine food open.
Performance diagnosis condition
7) With dry bulb thermometer (1) inserted into center duct air
outlet and another one set near evaporator air inlet, read
temperature indicated on each thermometer. CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.
Ambient temperature 15 – 35°C (59 – 95°F)
Engine rpm Keep to 1,500 rpm.
Blower fan switch“H” (4th position)
Temperature control“Cool”
Air outlet control“Face”
Vehicle Doors All open
Air inlet door position Recirculation

1B-12 AIR CONDITIONING (OPTIONAL)
PERFORMANCE DIAGNOSIS TABLE
HIGH PRESSURE GAUGE
LOW PRESSURE GAUGE
THERMOMETER AT CENTER DUCT
NOTE:
If ambient temperature is approximately 30°C (86°F), it is possible to diagnose A/C system in detail
referring to “DETAIL DIAGNOSIS TABLE (AMBIENT TEMPERATURE AT 30 °C (86°F))” under “PER-
FORMANCE DIAGNOSIS” in this section.
Condition Possible Cause Correction
Pressure high
(“A” area of high side
graph)Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high side Clean or replace.
Radiator/condenser cooling fan malfunction (Insufficient
cooling of condenser)Check radiator/condenser cooling fan.
Dirty or bent condenser fins (Insufficient cooling of con-
denser)Clean or repair.
Compressor malfunction (Insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system referring to
Section 6B.
Pressure low
(“B” area of high side
graph)Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.
Condition Possible Cause Correction
Pressure high
(“C” area of low side
graph)Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.
Pressure low
(“D” area of low side
graph)Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too narrow) Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.
Condition Possible Cause Correction
Outlet air temperature at
center duct is high
(Crossing point is in area
“E”)Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in cooling
(heater) unitRepair or replace.
Compressor malfunction Check compressor.
Outlet air temperature at
center duct is low
(Crossing point is in area
“F”)Insufficient air volume from center duct (Heater blower
malfunction)Check blower motor and fan.
Compressor malfunction Check compressor.

1B-14 AIR CONDITIONING (OPTIONAL)
0.35 – 0.45
(3.5 – 4.5)
(50 – 64)2.0 – 2.5
(20 – 25)
(285 – 355)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 Adjust refrigerant to specified
amount.
Faulty condenser cooling
operationClean condenser.
Faulty radiator/condenser
cooling fan operationInspect and repair radiator/
condenser cooling fan.
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 compres-
sor oil and presence of con-
taminants in oil.
Evacuate system and
recharge with fresh refriger-
ant.
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 regu-
lated properlyReplace expansion valve. Condition
Possible Cause Correction MANIFOLD
GAUGEMPa
(kg/cm
2)
(psi)Detail
Lo Hi

1B-16 AIR CONDITIONING (OPTIONAL)
ELECTRICAL DIAGNOSIS
WIRING DIAGRAM
1. Blower fan motor 6. Radiator/condenser cooling fan relay No.2 11. Ignition switch 16. Main fuse box
2. Blower fan motor resistor 7. Radiator/condenser cooling fan relay No.3 12. A/C evaporator temperature sensor 17. Generator
3. Blower fan switch and A/C switch 8. Radiator/condenser cooling fan motor 13. ECT sensor 18. Compressor
4. A/C refrigerant pressure switch 9. Compressor thermal switch 14. Lighting switch
5. Radiator/condenser cooling fan relay No.1 10. Main relay 15. Circuit fuse box

1B-18 AIR CONDITIONING (OPTIONAL)
System Circuit
Terminal arrangement of ECM coupler (Viewed from harness side)
1. Blower fan motor 8. Main relay A. To “HTR” fuse (25 A) in circuit fuse box
2. Blower fan switch 9. Radiator/condenser cooling fan motor relay No.1 B. To main fuse (15 A)
3. A/C switch 10. Radiator/condenser cooling fan motor relay No.2 C. To main fuse (30 A)
4. A/C refrigerant pressure switch 11. Radiator/condenser cooling fan motor relay No.3
5. Compressor 12. Radiator/condenser cooling fan motor
6. A/C evaporator temperature sensor 13. Engine earth
7. ECT sensor 14. ECM

AIR CONDITIONING (OPTIONAL) 1B-19
ECM Voltage Values Table for Relation of A/C Control
Terminal Wire Circuit Measurement
groundNormal value Condition
C41-1 PNK/BLK Compressor magnet
clutch outputGround to engine
(Fig B)12 – 15 V Except the above-mentioned condition with engine
running
0 – 1 V Blower fan switch and A/C switch ON with engine
running
C41-5 BLK/RED Main power supply for
ECMGround to engine
(Fig B)10 – 14 V Ignition switch ON with engine stopped
C41-6 BLK/RED Main power supply for
ECMGround to engine
(Fig B)10 – 14 V Ignition switch ON with engine stopped
C41-10 BRN/
WHTMain relay drive Ground to engine
(Fig B)0.5 – 1.2 V Ignition switch ON with engine stopped
10 – 14 V Ignition switch OFF
C41-16 YEL/GRN A/C switch input Ground to engine
(Fig B)12 – 15 V Blower fan switch or A/C switch OFF with engine
running
0 – 1 V Blower fan switch and A/C switch ON with engine
running
C41-18 BLU Radiator/condenser
cooling fan relay out-
put 1Ground to engine
(Fig B)0 – 1 V Blower fan switch and A/C switch ON
Engine coolant temperature at more than 97.5°C
(207.5°F) with engine running
12 – 15 V Blower fan motor switch or A/C switch OFF
Engine coolant temperature at less than 97.5°C
(207.5°F) with engine running
C42-1 BLK/ORN Main ground for ECM Ground to body
(Fig A)–0.5 – 1 V Engine running
C42-2 BLK ECM ground for
power circuitGround to body
(Fig A)–0.5 – 1 V Engine running
C42-3 BLK/ORN ECM ground for
power circuitGround to body
(Fig A)–0.5 – 1 V Engine running
C42-10 ORN Sensor ground for
ECT sensorGround to body
(Fig A)–0.5 – 1 V Engine running
C42-14 LT GRN/
BLKECT sensor input Ground to engine
(Fig B)0.71 – 0.75 V
(298 – 320 Ω
)Engine coolant temperature at approximately 80°C
(176°F) with engine running
0.35 – 0.37 V
(135 – 144 Ω
)Engine coolant temperature at Approximately
110°C (230°F) with engine running
If the temperature is more than 114°C (232°F),
compressor and condenser cooling fan should be
stop (come back at less than 112°C (230°F))
C42-18 PNK/GRN Medium pressure
switch inputGround to engine
(Fig B)–0.5 – 1 V Medium pressure switch of A/C refrigerant pres-
sure switch ON
12 – 15 V Medium pressure switch of A/C refrigerant pres-
sure switch OFF
G02-3 PPL/YEL Radiator/Condenser
cooling fan relay out-
put 2Ground to engine
(Fig B)0 – 1 V Blower fan motor switch ON, A/C switch ON and
medium pressure switch OFF
Engine coolant temperature at more than 102.5°C
(216.5°F) with engine running
12 – 15 V Blower fan motor switch OFF, A/C switch OFF or
medium pressure switch ON
Engine coolant temperature at less than 102.5°C
(216.5°F) with engine running
G02-10 ORN Sensor ground for A/C
evaporator tempera-
ture sensorGround to engine
(Fig A)–0.5 – 1 V Engine running
G02-13 PNK/BLU Blower fan speed
inputGround to engine
(Fig B)0 – 1 V Blower fan motor switch “ML”, “MH”, or “H” with
engine running
4 – 7 V Blower fan motor switch “L” position with engine
running
12 – 15 V Blower fan motor switch OFF with engine running
G02-14 WHT/BLK A/C evaporator tem-
perature sensor inputGround to engine
(Fig B)2.09 – 2.17 V
(1940 – 2060 Ω
)A/C evaporator temperature at approximately 25°C
(77°F) with engine running
3.52 – 3.59 V
(6450 – 6850 Ω
)A/C evaporator temperature at approximately 0°C
(32°F) with engine running
If the temperature is less than approximately 2.5°C
(36.5°F), compressor and condenser cooling fan
should be stop (come back at more than approxi-
mately 4°C (39.2°F)

AIR CONDITIONING (OPTIONAL) 1B-31
Tighten receiver/dryer cap to specified torque
Tightening torque
Receiver / dryer cap : 13 N·m (1.3 kg-m, 9.5 lb-ft)
Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES-
SOR OIL” in this section.
RADIATOR/CONDENSER COOLING FAN
MOTOR
REMOVAL AND INSTALLATION
For details, refer to “RADIATOR” in Section 6B.
INSPECTION
1) Check continuity terminal “a” – “b” and “c” – “d” about the
radiator/condenser cooling fan motor (1).
If check results are no continuity, replace radiator/condenser
cooling fan motor.
2) Check no continuity “a” – “c” and “b” – “d” about the radiator/
condenser cooling fan motor (1).
If check result are continuity, replace radiator/condenser
cooling fan motor.
3) Connect battery to radiator/condenser cooling fan motor ter-
minal “a” – “b” and “c” – “d” as shown in figure, then check
that the radiator/condenser cooling fan motor operates
smoothly.
Reference current of radiator/condenser cooling fan
motor at 12 V
“a” – “b” : 7.8 – 11.8 A
“c” – “d” : 4.8 – 8.8 A

1B-32 AIR CONDITIONING (OPTIONAL)
COOLING UNIT (EVAPORATOR)
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.
3) Remove glove box.
1. A/C evaporator 6. Dash packing 11. O-ring
2. A/C evaporator temperature sensor 7. Packing 12. Door link
3. Expansion valve 8. Fresh air duct case 13. Lower packing
4. Evaporator case
: Apply sealant 99000-31160 to hatched part “A”.9. Clamp Do not reuse.
5. Cooling unit packing 10. Air inlet door
CAUTION:
Be careful not to damage A/C evaporator fins. If A/C
evaporator fin is bent, straighten it by using flat head
screwdriver or pair of pliers.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

AIR CONDITIONING (OPTIONAL) 1B-33
4) Remove fresh air control cable (1) and A/C evaporator tem-
perature sensor coupler.
5) Disconnect suction hose (1) and condenser outlet hose (2)
by removing attaching bolt (3).
6) Remove cooling unit mounting nuts (4) and screws (5).
7) Remove cooling unit (6).
INSPECTION
Check the following.
Clog of A/C evaporator fins.
If any clogs are found, A/C evaporator fins should be
washed with water, and should be dried with compressed
air.
A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace A/C evaporator.
A/C evaporator fittings for leakage.
If any defects are found, repair or replace A/C evaporator.
INSTALLATION
Reverse removal procedure to install cooling unit noting the fol-
lowing instructions.
If A/C evaporator temperature sensor removed, its should be
reinstalled in original position.
Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES-
SOR OIL” in this section.
Install uniformly the packing (1) to installation hole.
Evacuate and charge refrigerant by referring to “EVACUAT-
ING” and “CHARGING” in this section.
Adjust fresh air control cable, refer to “HEATER LEVER
ASSEMBLY” in Section 1A.

1B-36 AIR CONDITIONING (OPTIONAL)
A/C SWITCH
REMOVAL AND INSTALLATION
Refer to “HEATER CONTROL ASSEMBLY” in Section 1A.
INSPECTION
Press A/C switch button and check if there is continuity
between terminals “A” and “B”.
Connect battery voltage (+) to terminal “C” and (–) to termi-
nal “A”, and then press A/C Switch button and check if indi-
cator lamp lights.
RADIATOR/CONDENSER COOLING FAN
MOTOR RELAY No.1, No.2 and No.3
INSPECTION
Refer to “RADIATOR FAN RELAY” in Section 6B.
COMPRESSOR
REMOVAL
1) Run engine at idle speed with air conditioning ON for 10 min-
utes. After that stop the engine.
2) Disconnect negative (–) cable at battery.
3) Recover refrigerant from refrigeration system by referring to
“RECOVERY” in this section.
4) Remove front bumper by referring to “FRONT BUMPER” in
Section 8.
5) Remove engine food cover (1) from vehicle body.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.