Air Condition SUZUKI SWIFT 2000 1.G RG413 Service Service Manual

1B-26 AIR CONDITIONING (OPTIONAL)
REMOVING MANIFOLD GAUGE SET
When A/C system has been charged with a specified amount of refrigerant, remove manifold gauge set as fol-
lows :
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.
5) Put caps on service valves.
LEAK TEST
Whenever a refrigerant leak is suspected in the system or any
service operation has been performed which may result in dis-
turbing 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,
depend upon the nature of a complaint and the type of a service
performed on the system.
LIQUID LEAK DETECTORS
There are a number of fittings and places throughout the air con-
ditioning 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, such as attached to the cap of a vial, bubbles will form
within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (refrigerant) leak detector is more practical
for determining leaks.
Special tool
(A) : 09990 - 86011 WARNING:
High pressure side is naturally under high pressure. So, care must be used to protect your eyes and
skin.
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 poi-
sonous gas (phosgene). Do not inhale this gas.

AIR CONDITIONING (OPTIONAL) 1B-27
ON-VEHICLE SERVICE
SERVICE PRECAUTION
When servicing air conditioning system, note the following instructions.
REFRIGERANT LINE
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 connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling
nuts and O-ring.
When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
Tighten flared nuts by the following specified torque.
Tightening torque
8 mm pipe : 13 N·m (1.3 kg-m, 9.5 lb-ft)
12 mm pipe : 23 N·m (2.3 kg-m, 16.6 lb-ft)
14.5 mm pipe : 33 N·m (3.3 kg-m, 23.8 lb-ft) 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 refriger-
ant 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.
1. Suction hose:
Apply compressor oil (refrigerant oil) to O-ring.4. Expansion valve:
Apply compressor oil (refrigerant oil) to O-ring.
2. Discharge hose:
Apply compressor oil (refrigerant oil) to O-ring.5. A/C refrigerant pressure switch:
Apply compressor oil (refrigerant oil) to O-ring.
3. Condenser outlet pipe:
Apply compressor oil (refrigerant oil) to O-ring.

1B-28 AIR CONDITIONING (OPTIONAL)
Route drain hose so that drained water does not make any contact to vehicle components.
If pipes or hoses are replaced, replenish specified amount of compressor oil to compressor suction side by
referring to “REPLENISHING COMPRESSOR OIL” in this section.
HANDLING REFRIGERANT HFC-134a (R-134a)
Always wear goggles to protect your eyes.
Avoid you direct contact to liquid refrigerant.
Do not heat refrigerant container higher than 40°C (104°F).
Do not discharge refrigerant into atmosphere.
Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and
will tarnish surfaces of bright metals including chrome.
REFRIGERANT RECOVERY
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment. Discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environ-
ments.
REFRIGERANT CHARGE
After perform replenishing compressor oil and evacuating, charge a proper amount of refrigerant to A/C system
referring to “CHARGING” in this section.
CONDENSER ASSEMBLY
INSPECTION
Check the following.
Clog of condenser fins.
If, any clogs are found, condenser fins should be washed
with water, and should be dried with compressed air.
Condenser fins for leakage and breakage.
If any defects are found, repair or replace condenser.
Condenser fittings for leakage.
If any defects are found, repair or replace condenser. CAUTION:
Do not perform an additional refrigerant charging to A/C system. This cause it to overcharge.
CAUTION:
Be careful not to damage condenser fins. If condenser fin
is bent, straighten it by using flat head screwdriver or
pair of pliers.

AIR CONDITIONING (OPTIONAL) 1B-29
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.
3) Remove front bumper referring to “FRONT BUMPER” in
Section 8.
4) Remove front cross member cover (1) and engine food
cover (2) from vehicle body.
5) Disconnect discharge hose (1) and condenser outlet pipe (2)
from condenser (3).
6) Remove condenser mounting bolts (4).
7) Remove condenser (3).
INSTALLATION
Reverse removal procedure to install condenser noting the follow-
ing instructions.
Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES-
SOR OIL” in this section.
Evacuate and charge refrigerant by referring to “EVACUAT-
ING” and “CHARGING” in this section. NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

1B-30 AIR CONDITIONING (OPTIONAL)
RECEIVER/DRYER
REMOVAL
1) Remove condenser assembly referring to “CONDENSER
ASSEMBLY” in this section.
2) Remove condenser mounting bracket (1) from condenser (2)
as shown.
3) Remove receiver/dryer cap (3) using a hexagon wrench.
4) Remove filter (1) from the receiver/dryer (2).
5) Remove dryer (1) using a plier.
INSTALLATION
Reverse removal procedure to install receiver/dryer noting the fol-
lowing instructions.
Do not remove dryer from the plastic bag until just before
inserting it into the receiver.
Install dryer (1) with its double-layer portion facing the bot-
tom of the receiver.

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-34 AIR CONDITIONING (OPTIONAL)
A/C EVAPORATOR TEMPERATURE SENSOR
Check resistance between terminals for A/C evaporator tempera-
ture sensor (1).
If check results are as not specified, replace A/C evaporator tem-
perature sensor.
A/C evaporator temperature sensor resistance
EXPANSION VALVE
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“RECOVERY” in this section.
3) Remove attaching bolt (1).
4) Remove suction hose (2) and receiver/dryer outlet pipe (3)
from expansion valve (4).
5) Remove expansion valve (4).
INSTALLATION
Reverse removal procedure to install expansion valve noting the
following instructions.
Replenish specified amount of compressor oil to compressor
suction side by referring to “REPLENISHING COMPRES-
SOR OIL” in this section.
Evacuate and charge refrigerant by referring to “EVACUAT-
ING” and “CHARGING” in this section.
INSPECTION
Refer to “PERFORMANCE DIAGNOSIS” in this section. Sensor Temperature Resistance
0°C (32°F) 6.4 – 6.9 k
Ω
ΩΩ Ω
25°C (77°F) 1.8 – 2.2 k
Ω
ΩΩ Ω
NOTE:
When A/C evaporator temperature sensor removed, its
should be reinstalled in original position.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

AIR CONDITIONING (OPTIONAL) 1B-35
A/C REFRIGERANT PRESSURE SWITCH
INSPECTION
1) Check A/C refrigerant pressure switch (1) for continuity at
normal temperature (approximately 25°C (77°F)) when A/C
system has a proper charge of refrigerant and A/C system
(compressor) is under operation. In each of these cases,
switch should show proper continuity.
2) Check continuity between high and low pressure switch ter-
minals (1) at specified pressure as shown.
High and low pressure switch specification
A : Approximately 200 kPa (2.0 kg/cm
2, 28.5 psi)
B : Approximately 230 kPa (2.3 kg/cm
2, 32.5 psi)
C : Approximately 2600 kPa (26 kg/cm
2, 370 psi)
D : Approximately 3200 kPa (32 kg/cm
2, 455 psi)
3) Check continuity between medium pressure switch terminals
(2) at specified pressure as shown as shown.
Medium pressure switch specification
E : Approximately 1100 kPa (11 kg/cm
2, 156 psi)
F : Approximately 1500 kPa (15 kg/cm
2, 213 psi)
Tightening torque
A/C refrigerant pressure switch :
11 N·m (1.1 kg-m, 8.0 lb-ft)
[A] : LH model
[B] : RH model
[A] : High and low pressure
[B] : Middle pressure