air condition SUZUKI SWIFT 2000 1.G RG413 Service Repair Manual

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.

AIR CONDITIONING (OPTIONAL) 1B-37
6) Remove compressor drive belt (1) by loosening tension pul-
ley nut (2) and adjusting bolt (3).
7) Disconnect magnet clutch lead wire coupler.
8) Disconnect suction pipe (4) and discharge hose (5) from
compressor (6).
9) Remove compressor mounting bolts (7), and then remove
compressor (6) from its bracket.
INSTALLATION
Reverse removal procedure to install compressor noting the fol-
lowing instructions.
If compressor is replaced, pour new compressor oil by refer-
ring to “REPLENISHING COMPRESSOR OIL” in this sec-
tion.
Evacuate and charge system by referring to “RECOVERY”
in this section.
Adjust drive belt tension by referring to “COMPRESSOR
DRIVE BELT” in this section. NOTE:
Cap open fittings immediately to keep moisture out of
system.

1B-38 AIR CONDITIONING (OPTIONAL)
MAGNET CLUTCH
INSPECTION
Check clutch plate and clutch pulley for wear and oil soaked
conditions respectively.
Check clutch pulley bearing for noise, wear and grease leak-
age.
Measure clutch coil for resistance at 20°C (68°F).
If the measured resistance does not remain within tolerance,
replace magnet clutch assembly.
Clutch coil resistance
: 3.4 – 4.1
Ω
ΩΩ Ω
1. Compressor thermal switch 6. Clutch coil a. Front head bolt
: Tighten bolt (a) first, and next (b)
2. Compressor body 7. Clutch pulley b. Front head bolt
: Tighten bolt (a) first, and next (b)
3. O-ring 8. Circlip c. Clutch plate bolt
4. Lip type seal 9. Circlip Tightening torque
5. Front head 10. Clutch plate Do not reuse.

AIR CONDITIONING (OPTIONAL) 1B-39
Use an ohmmeter to check thermal switch (1) for continuity.
If it is no continuity, replace it.
REMOVAL
1) Remove compressor from vehicle. Refer to “COMPRES-
SOR” in this section.
2) Fix clutch plate (1) with special tool and remove clutch plate
bolt (2) and washer (3).
Special tool
(A) : 09991-06020
3) Using special tool, remove clutch plate (1).
Special tool
(A) : 09991-06030
4) Remove shims from shaft.
5) Using special tool, remove circlip.
Special tool
(A) : 09900-06107
6) Remove clutch coil lead wire clamp by loosening its screw
and disconnect clutch coil lead wire from thermal switch lead
wire.

1B-40 AIR CONDITIONING (OPTIONAL)
7) Remove clutch pulley (2) with puller (1).
8) Remove clutch coil.
9) Remove circlip (1) by using special tool.
Special tool
(A) : 09900-06107
10) Remove clutch coil (2) from compressor (3).
INSTALLATION
1) Install clutch coil (2).
Protrusion on under side of clutch coil must match hole in
compressor (3) to prevent movement ant correctly locate
lead wire.
2) Using special tool, install new circlip (1) as shown.
Special tool
(A) : 09900-06107
3) Install clutch pulley (1).
a) Set clutch pulley (1) squarely over clutch pulley installation
boss.
b) Place special tool onto clutch coil bearing.
Ensure that edge rests only on inner race of bearing.
Special tool
(A) : 09991-06010
c) Install circlip. NOTE:
 Be careful not to damage pulley when tapping clutch
pulley.
 Be careful not to scratch bearing.
CAUTION:
Be careful not to scratch bearing seal.

AIR CONDITIONING (OPTIONAL) 1B-41
4) Adjust clearance, between clutch plate (1) and clutch pulley
(2) by putting shim on compressor shaft.
Clearance between clutch plate and clutch pulley
“a” : 0.3 – 0.6 mm (0.012 - 0.024 in.)
5) Tighten new clutch plate bolt (2) to specified torque as
shown.
Tightening torque
Clutch plate bolt (a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
Special tool
(A) : 09991-06020
LIP TYPE SEAL
REMOVAL
1) Remove magnet clutch referring to “MAGNET CLUTCH” in
this section.
2) Remove front head (1) mounting bolts (2).
3) Remove front head (1) by pushing cylinder shaft (2).
4) Remove O-ring (3).
1. Clutch plate
3. Washer
NOTE:
Be careful not to remove cylinder from front head.

1B-42 AIR CONDITIONING (OPTIONAL)
5) Remove lip type seal from front head (1) using special tool.
Special tool
(A) : 09923-73210
INSTALLATION
1) Press-fit new lip type seal (1) into front head (2) using spe-
cial tool.
Special tool
(A) : 09991-06050
2) Coat special tool surface with oil and place it on cylinder
shaft (1).
Special tool
(A) : 09991-06040
3) Install new O-ring (1) to case.
4) Apply compressor oil to lip type seal and O-ring (1).
5) Install front head (2).
Special tool
(A) : 09991-06040
CAUTION:
Do not reuse lip type seal (1) once removed from com-
pressor.
[A] : Obverse side
[B] : Back side

AIR CONDITIONING (OPTIONAL) 1B-43
6) Tighten new front head mounting bolts (a), (b).
Tightening torque
Front head bolt (a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
Front head bolt (b) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
REQUIRED SERVICE MATERIAL
NOTE:
 Be sure to use new front head mounting bolts.
 Tighten bolt (a) first, and next (b).
MaterialRecommended SUZUKI product
(Part Number)Use
Compressor oil
(Refrigerant oil)COMPRESSOR OIL RS20 (150 cc)
99000-99088O-ring
Each component
Refrigerant REFRIGERANT DRUM (200 g)
95794-50G00Refrigerant charge
Sealant SUZUKI BOND No.1216B
99000-31160Cooling unit

1B-44 AIR CONDITIONING (OPTIONAL)
SPECIAL TOOL
09900-06107 09990-06010 09990 -86011
Snap ring pliers
(Opening type)Manifold gauge set
See NOTE below.Gas leak detector
09991-06010 09991-06020 09991-06030 09991-06040
Magnet clutch pulley
installerArmature plate spanner Armature plate remover Lip type seal protector
09991-06050 09923-73210
Lip type seal installer Bearing remover
NOTE:
This kit includes the following items.
1. Manifold gauge, 2. Changing hose, 3. Quick connector, 4. Refrigerant container tap valve,
5. Refrigerant container T joint, 6. Packing set

3-2 STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS
GENERAL DIAGNOSIS
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be consid-
ered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Pro-
ceed with the following preliminary inspection and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged
parts.
3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loosen and/or rough wheel
bearings.
DIAGNOSIS TABLE
Condition Possible Cause Correction
Vehicle Pulls (Leads)
Mismatched or uneven tires Replace tire.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging springs Replace spring.
Radial tire lateral force Replace tire.
Disturbed front end alignment Check and adjust front end align-
ment.
Brake dragging in one road wheel Repair brake.
Loose, bent or broken front or rear suspension
partsTighten or replace suspension
parts.
Abnormal or
Excessive Tire WearSagging or broken spring Replace spring.
Tire out of balance Adjust balance or replace tire.
Disturbed front end alignment Check and adjust front end align-
ment.
Faulty strut (shock absorber) Replace strut.
Hard driving Replace tire.
Overloaded vehicle Replace tire.
Not rotating tire Replace or rotate tire.
Worn or loose wheel bearing Replace wheel bearing.
Wobbly wheel or tire Replace wheel or tire.
Tires not adequately inflated Adjust tire pressure.
Wheel Tramp
Blister or bump on tire Replace tire.
Improper strut (shock absorber) action Replace strut.
Shimmy, Shake or
VibrationTire or wheel out of balance Balance wheels or replace tire and/
or wheel.
Loosen wheel bearings Replace wheel bearing.
Worn tie rod ends Replace tie rod end.
Worn lower ball joints Replace front suspension arm.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire/wheel
assemblyReplace tire or wheel.
Disturbed front end alignment Check and adjust front end align-
ment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear case bolts Tighten case bolts.