charge SUZUKI GRAND VITARA 1998 2.G Service Workshop Manual

YH4
GRAND
VITARA
1A-18 HEATER AND VENTILATION
11) Remove heater core pipe clamps (1) and grommet (2).
12) Pull out heater core (1) from unit (2).
INSTALLATION
1) Install heater unit by reversing removal procedure, noting the
following items.

When installing each part, be careful not to catch any cable or
wiring harness.

When installing steering column assembly, refer to STEER-
ING COLUMN INSTALLATION in Section 3C or 3C1.
2) Install control cables. (Refer to HEATER CONTROL CABLES in
this section.)
3) Fill engine coolant to radiator.
4) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.
5) Evacuate and charge system. Refer to items EVACUATING
SYSTEM and PROCEDURE OF CHARGING in Section 1B.

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
1. Compressor label
2. Service valve SEIKO SEIKI DENSO
AIR CONDITIONING (OPTIONAL) 1B-3
GENERAL DESCRIPTION
The air conditioning system of this model differs by the country of origin (the production plant.).
One is Japan (IWATA) produced, other one is Canada (CAMI) produced.
For the details of the identification, please refer to IDENTIFICATION INFORMATION of Section 0A in this manual.
The compressor used of Japan (IWATA) produced vehicle is made of SEIKO SEIKI and the compressor used of
Canada (CAMI) produced vehicle is made of DENSO.
IDENTIFICATION OF REFRIGERATING
SYSTEM
Whether the A / C equipped with the vehicle being serviced uses re-
frigerant R-134a or R-12 is indicated on the LABEL installed the
compressor.
Also, it can be identified by the shape of the service (charge) valve.
The compressor manufacturer, it can be identified by the LABEL on
compressor body.

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
AIR CONDITIONING (OPTIONAL) 1B-7
ConditionPossible CauseCorrection
Cool air does not come
out or insufficient
cooling (A / C system
normal operative)
Compressor faulty

Air in A / C system

Air leaking from cooling unit or air
duct

Heater and ventilation system faulty

Blower motor faulty

Excessive compressor oil existing in
A / C systemCheck compressor.
Replace condenser dryer, and
evacuation and charging.
Repair as necessary.
Check blower unit.
Check heater control lever assembly.
Check heater assembly.
Check blower motor.
Pull out compressor oil in A / C system
circuit, and replace compressor.
Cool air does not comes
out only intermittently
Wiring connection faulty

Expansion valve faulty

Excessive moisture in A / C system

A / C controller faulty

Magnetic clutch faulty

Excessive charge of refrigerantRepair as necessary.
Check expansion valve.
Replace condenser dryer, and
evacuation and charging.
Check A / C controller.
Check magnetic clutch.
Check charge of refrigerant.
Cool air comes out only
at high speeds
Condenser clogged

Insufficient charge of refrigerant

Air in A / C system

Drive belt slipping

Compressor faultyCheck condenser.
Check charge of refrigerant.
Replace condenser dryer, and
evacuation and charging.
Adjust or replace drive belt.
Check compressor.
Cool air does not comes
out only at high speeds
Excessive charge of refrigerant

A / C evaporator frostedCheck charge refrigerant.
Check A / C evaporator.
Check A / C thermistor.
Insufficient velocity of
cooled air
A / C evaporator clogged or frosted

Air leaking from cooling unit or air
duct

Blower motor faulty

Wiring or grounding faultyCheck A / C evaporator.
Repair as necessary.
Check blower motor.
Repair as necessary.

YH4
GRAND
VITARA
3. Bubbles
1B-10 AIR CONDITIONING (OPTIONAL)
QUICKLY CHECKING OF REFRIGERANT
CHARGE (IF EQUIPPED WITH SIGHT GLASS)
CHARGE OF REFRIGERANT
The following procedure can be used for quickly checking whether
the A / C system has a proper charge of refrigerant or not.
Run engine at fast idle, and operate A / C at its max. cooling capacity
for a few minutes. Then, look at the sight glass (1) on receiver / dryer
(2) and compare what is observed with the symptoms listed in
ªCHECKING REFRIGERANT CHARGEº table given below.
CHECKING REFRIGERANT CHARGE
CONDITIONPOSSIBLE CAUSESCORRECTION
Bubbles observed in sight glassInsufficient charge of refrigerant in
systemCheck system for leaks with a leak
tester.
No bubbles observed in sight glassNo charge or proper or too much
charge of refrigerant in systemRefer to the following item.
No temperature difference
between compressor inlet and
outletEmpty or nearly empty systemRecovery, evacuate and charge
system and then check it for leaks
with a leak tester.
Noticeable temperature difference
between compressor inlet and
outletProper or too much charge of
refrigerant in systemRefer to the following item.
When A / C is turned OFF,
refrigerant in sight glass clears
immediately and remains clearToo much charge of refrigerant in
systemDischarge excess charge of
refrigerant to adjust it to a specified
charge.
When A / C is turned OFF,
refrigerant in sight glass once
produces bubbles and then clearsProper charge of refrigerant in
systemNo correction needed because
charge of refrigerant is normal.

YH4
GRAND
VITARA
1B-14 AIR CONDITIONING (OPTIONAL)
HIGH PRESSURE CAUGE LOW PRESSURE GAUGE THERMOMETER AT
CENTER DUCT
Insufficient
cooling of
condenser
PERFORMANCE DIAGNOSIS TABLE
TESTING RESULTSPOSSIBLE CAUSEREMEDY
Pressure high
(ªAº area of high side
graph)
Refrigerant overcharged

Expansion valve frozen or clogged

Clogged refrigerant passage of high side

Condenser fan malfunction

Dirty or bent condenser fins

Compressor malfunction (Insufficient oil etc.)

Engine overheat
Recharge

Check expansion valve

Clean or replace

Check condenser fan

Clean or repair

Check compressor

Check engine cooling
system
Pressure low
(ªBº area of high side
graph)
Insufficient refrigerant (Insufficient charge or
leakage)

Expansion valve malfunction (Valve opens too
wide)

Compressor malfunction (Insufficient
compression)
Check for leakage, repair if
necessary and recharge

Check expansion valve

Check compressor
Pressure high
(ªAº area of low side
graph)
Expansion valve malfunction (Valve opens too
wide)

Compressor malfunction (Insufficient
compression)
Check expansion valve

Check compressor
Pressure low
(ªBº area of low side
graph)
Insufficient refrigerant (Insufficient charge or
leakage)

Expansion valve malfunction (Valve opens too
narrow)

Clogged refrigerant passage (Crashed pipe)
Check for leakage, repair if
necessary and recharge

Check expansion valve

Repair or replace
Outlet air temperature
at center duct is high
(Crossing point is in
area ªAº)
Insufficient or excessive charge of refrigerant

Dirty or bent evaporator fins

Air leakage from cooling (heater) unit or air
duct

Malfunctioning, switchover function of damper
in cooling (heater) unit

Compressor malfunction
Check refrigerant
pressure

Clean or repair

Repair or replace

Repair or replace

Check compressor
Outlet air temperature
at center duct is low
(Crossing point is in
area ªBº)
Insufficient air volume from center duct
(Heater blower malfunction)

Compressor malfunction
Check blower motor and
fan

Check compressor
NOTE:
If ambient temperature is within 30 ± 35C (85 ± 95F), it is possible to do using next page table for more
detail diagnosis.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-15
AMBIENT TEMPERATURE WITHIN 30 ± 35C (85 ± 95F)
CONDITION
MANIFOLD
GAUGEMPa
(kg/cm2)
(psi)DETAILCAUSECORRECTION
LoHi
0.23 ± 0.35
(2.3 ± 3.5)
(33 ± 50)1.4 ± 1.75
(14 ± 17.5)
(200 ± 249)
Normal condition.ÐÐÐÐ
Negative
pressure0.5 ± 0.6
(5 ± 6)
(71.2 ± 85.3)

The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.

Presence of frost around
tubing to and from receiver /
dryer and expansion valve.
Dust particles or water
droplets are either stuck or
frozen inside expansion
valve, preventing the
refrigerant from flowing.
Clean expansion valve.
Replace it if it cannot be
cleaned.

Replace receiver / dryer.

Evacuate the A / C
system and recharge
with fresh refrigerant.
Normal:
0.23 ± 0.35
(2.3 ± 3.5)
(33 ± 50)

Abnormal:
Negative
pressureNormal:
1.4 ± 1.75
(14 ± 17.5)
(200 ± 249)

Abnormal:
0.69 ± 0.98
(7 ± 10)
(100 ± 142)
During A / C operation, the
low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.
Expansion valve is frozen
due to moisture in the
system, and temporarily
shuts off the refrigeration
cycle.
Replace expansion
valve.

Replace receiver / dryer.

Evacuate A / C system
and recharge with fresh
refrigerant.
0.05 ± 0.15
(0.5 ± 1.5)
(4.2 ± 21.3)
0.69 ± 0.98
(7 ± 10)
(100 ± 142)

Both low and high pressure
sides indicate low readings.

Continuous air bubbles are
visible through sight glass.

Output air is slightly cold.
Insufficient refrigerant in
system. (Refrigerant
leaking)
Using a gas leak
detector, check for leaks
and repair as necessary.

Recharge refrigerant to a
specified amount.
If the pressure reading is
almost 0 when the
manifold gauges are
attached, check for any
leaks, repair them, and
evacuate the system.
0.4 ± 0.6
(4 ± 6)
(56.9 ± 85.3)

Pressure on low pressure
side is high.

Pressure on high pressure
side is low.

Both pressure becoming
equal right after A / C is
turned OFF.
Internal leak in compressor.
Inspect compressor and
repair or replace as
necessary.
035 045

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.

Faulty condenser cooling
operation.

Faulty condenser fan
operation.
Adjust refrigerant to
specified amount.

Clean condenser.

Inspect and repair
condenser fan.
0.35 ± 0.45(3.5 ± 4.5)
(50 ± 64)
1.96 ± 2.45
(20 ± 25)
(285 ± 355)

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
compressor oil and
presence of
contaminants in oil.

Evacuate system and
recharge with fresh
refrigerant.
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
regulated properly.
Replace expansion
valve.

YH4
GRAND
VITARA
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