cooling gauge SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

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
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.

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
3. Pipe clamp
1B-42 AIR CONDITIONING (OPTIONAL)
EXPANSION VALVE
INSPECTION
Refer to ªTroubleshooting Procedure Using Manifold Gauge Setº in
this section.
REMOVAL
1) Recover refrigerant by using recovery and recycling equipment.
Be sure to follow the instruction manual for the equipment. The
amount of compressor oil removed must be measured and the
same amount added to the system.
2) Remove front grill.
3) Disconnect suction pipe (1), and liquid pipe (2) from evaporator
(Cooling unit).
CAUTION:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust may not enter
cooling unit.
4) Disconnect suction pipe, and liquid pipe from suction hose (1)
and condenser outlet pipe (2).
5) Remove pipe clamp then remove suction pipe and liquid pipe.
6) Remove expansion valve (1).
INSTALLATION
1) Reverse removal sequence to install expansion valve.
2) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.

YH4
GRAND
VITARA
3F-2 WHEELS AND TIRES
The metric term for tire inflation pressure is the kilopascal (kPa).
Tire pressures will usually be printed in both kPa and psi on the Tire
Placard. Metric tire gauges are available from tool suppliers. The
chart, left table, converts commonly used inflation pressures from
kPa to psi.kPakgf / cm2psi
160
180
200
220
240
260
280
300
320
3401.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.423
26
29
32
35
38
41
44
47
50
Conversion:1 psi = 6.895 kPa
1 kgf / cm
2 = 98.066 kPa
WHEELS REPLACEMENT
Wheels must be replaced if they are bent, dented, have excessive
lateral or radial runout, leak air through welds, have elongated bolt
holes, if lug nuts won't stay tight, or if they are heavily rusted.
Wheels with greater runout than shown in left figure may cause ob-
jectional vibrations.
Wheels for replacement must be equivalent to the originally
equipped wheels in load capacity, diameter, rim width, off-set and
mounting configuration. A wheel of improper size or type may affect
wheel and bearing life, brake cooling, speedometer / odometer cal-
ibration, ground clearance to the body and chassis.
To measure the wheel runout, it is necessary to use accurate dial
indicator. The tire may be on or off the wheel. The wheel should be
installed to the wheel balancer of the like for proper measurement.
Take measurements of both lateral runout and radial runout at both
inside and outside of the rim flange. With dial indicator set in place
securely, turn the wheel one full revolution slowly and record every
reading of the indicator.
When the measured runout exceeds the specification and correc-
tion by the balancer adjustment is impossible, replace the wheel.
If the reading is affected by welding, paint or scratch, it should be
ignored.
Lateral runout limit ªaº: 1.20 mm (0.047 in.)
Radial runout limit ªbº: 1.20 mm (0.047 in.)
METRIC LUG NUTS AND WHEEL STUDS
All models use metric lug nuts and wheel studs (size M12 x 1.25).