evap system SUZUKI GRAND VITARA 2003 2.G Service User Guide

YH4
GRAND
VITARA
1. Electric leak detector
AIR CONDITIONING (OPTIONAL) 1B-29
REMOVING MANIFOLD GAUGE SET
When A / C system has been charged with a specified amount of re-
frigerant, remove manifold gauge set as follows:
1) Close low pressure-side valve of manifold gauge set, (The high
pressure-side valve is closed continuously during the process
of charging.).
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves.
This operation must be performed rapidly.
WARNING:
High pressure-side is naturally under high pressure.
So, care must be used to protect your eyes and skin.
5) Put caps on service valves.
LEAK-TESTING REFRIGERANT SYSTEM
Whenever a refrigerant leak is suspected in the system or any ser-
vice operation has been performed which may result in disturbing
lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general, de-
pend upon the nature of a complaint and the type of a service per-
formed on the system.
LIQUID LEAK DETECTORS
There are a number of fittings and places throughout the air condi-
tioning system where a liquid leak detector solution may be used
to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a swab,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (gas) leak detector is more practical for deter-
mining leaks.
WARNING:

To prevent explosions or fires, make sure that there are no
flammables in the vicinity.

When exposed to fire, the refrigerant turns into a poison-
ous gas (phosgene). Do not inhale this gas.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-39
COOLING UNIT (EVAPORATOR)
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system. Refer to ªDisabling Air Bag Systemº in
Section 10B.
3) 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.
4) For G16 and J20 engine
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.
5) Remove blower motor unit. Refer to Section 1A ªHEATER AND
VENTILATIONº.
6) Disconnect thermistor wire coupler.
7) Remove cooling unit (evaporator).
DISASSEMBLY (FOR CAMI PRODUCTION VEHICLE)
1) Remove filter (2) from cooling unit (3) assembly by removing fil-
ter cover (1).
2) Remove screws (1) to separate evaporator upper and lower
cases from each other.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-41
INSPECTION
1) Check evaporator fins for blockage. If found clogged, use com-
pressed air to clean the fins.
CAUTION:
Do not use water for cleaning of evaporator.
Be careful not to damage evaporator fins. If evaporator
fin is bent, straighten it by using a screwdriver or pair of
pliers. If any leakage is found from fitting or tube, repair
or replace evaporator.
2) Check inlet and outlet fittings for crack or scratch. Repair them
as required.
REASSEMBLY and INSTALLATION
1) Reverse removal and disassembly sequence to install cooling
unit, noting the following points.

Install uniformly the evaporator packing to dash panel hole for
expansion valve.

Adjust fresh air control cable, refer to ªHEATER CONTROL
LEVER ASSEMBLYº in Section 1A.
2) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.
3) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
NOTE:
When the thermistor removed, it should be reinstalled in
original position.
If cooling unit or evaporator is replaced, pour 25 cc of refrig-
erating oil to compressor suction-side.

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
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.

YH4
GRAND
VITARA
1B-46 AIR CONDITIONING (OPTIONAL)
A / C CONTROLLER
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Disable air bag system, if equipped.
Refer to ªDISABLING AIR BAG SYSTEMº in Section 10B.
3) Open glove box, then remove screw.
4) Remove glove box.
5) Disconnect A / C controller coupler (2), evaporator thermistor
coupler (3).
6) Remove A / C controller (1) from heater unit (4).
INSPECTION
Refer to ªINSPECTION OF A / C CONTROLLER AND ITS CIR-
CUITº in this section.
INSTALLATION
1) Install in reverse order of removal procedure.
2) If equipped with air bag system, enable air bag system. Refer to
ªENABLING AIR BAG SYSTEMº in Section 10B.