1999 SUZUKI GRAND VITARA Service Workshop Manual

YH4
GRAND
VITARA
Fig. A
Fig. B
Fig. C
C51-3-6 For G16
and J20 engines
C51-3-25 For
H25 engine
1B-18 AIR CONDITIONING (OPTIONAL)
INSPECTION OF A / C CONTROLLER AND ITS
CIRCUITS
CAUTION:
A / C controller and ECM cannot be checked by itself.
It is strictly prohibited to connect voltmeter or ohmmeter to
A / C controller and ECM with couplers disconnected from it.
A / C controller (1) and its circuits can be checked at A / C controller
wiring couplers by measuring voltage.
Voltage Check
1) Remove A / C controller (1) from vehicle (refer to ªA / C CON-
TROLLER REMOVALº in this section).
2) Remove ECM (2) from vehicle.
3) Connect A / C controller couplers to A / C controller and connect
ECM couplers to ECM.
4) Check each terminal voltage with couplers connected by refer-
ing to the A / C CONTROLLER VOLTAGE VALUES TABLE the
later.

YH4
GRAND
VITARA
SYSTEM CIRCUIT
A. To heater fuse
B. To rear defogger fuse
C. To ignition / meter fuse
D. To A / C fuse
E. Only LH vehicle1. Blower motor relay
2. Blower motor
3. Blower motor switch
4. A / C switch
5. Deflloster position switch
6. Deflloster / foot position switch7. Dual pressure (refrigerant
pressure) switch
8. A / C thermistor (evaporator
temperature sensor)
9. Compressor relay
10. Compressor11. Condenser fan motor relay
12. Condenser fan motor
13. A / C controller
14. ECM
15. Compressor thermal switch
(only IWATA production vehicle)
TERMINAL ARRANGEMENT OF A / C CONTROLLER
TERMINAL ARRANGEMENT OF ECM FOR G16, J20 ENGINE
TERMINAL ARRANGEMENT OF ECM FOR H25 ENGINE
H25 engine
E61-27
G16, J20
engines
E61-8
H25 engine
E61-28
G16, J20
engines
E61-17
1919
19H25 engine
E61-5
G16, J20
engines
E61-22
AIR CONDITIONING (OPTIONAL) 1B-19

YH4
GRAND
VITARA
1B-20 AIR CONDITIONING (OPTIONAL)
A / C CONTROLLER VOLTAGE VALUES TABLE
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC1-1B/WController main
power supplyGround to
engine (Fig. B)10 ± 14 voltsIgnition switch ON with engine
stopped
AC1-2B/YController main
groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
AC1 4Or
Refrigerant
p
ressure switchGround to
0 ± 1 volt
Refrigerant pressure within 225 kPa
(2.3 kg / cm
2, 32.7 psi) to 2548 kPa
(26 kg / cm
2, 370 psi) with engine
running
AC1-4Orpressure switch
inputengine (Fig. B)
10 ± 14 volts
Refrigerant pressure below
196 kPa (2.0 kg / cm
2, 28 psi) or
above 3140 kPa (32 kg / cm
2, 455 psi)
with engine running
AC1 7G/B
A / C switch input
and / or defroster
Ground to
8 ± 14 volts
Blower fan motor switch and A / C or
defroster position switch (see NOTE)
ON with engine running
AC1-7G/Bposition switch
input (see NOTE)engine (Fig. B)
0 ± 1.5 volts
Blower fan motor switch or A / C or
defroster position switch (see NOTE)
OFF with engine running
AC1 9Gr/W
Signal input from
ECM (A / C ON
Ground to10 ± 14 voltsApprove of A / C ON
AC1-9Gr/W(
permission
signal)engine (Fig. B)0 ± 1 voltA / C ON forbid
AC1-13Y/B
Signal output to
ECM (A / C ON
request signal)Ground to engine
(Fig. B)0 ± 1.5 volts
Blower fan motor switch and A / C or
defroster position switch (see NOTE)
ON with engine running at evaporator
thermistor temperature input more
than approx. 2.5
C (less than 2.5 V
(5840
)) and refrigerant pressure
switch is ON
10 ± 14 voltsExcept the above-mentioned with
engine running
AC1-16P
Compressor
magnet clutch
relay outputGround to engine
(Fig. B)0 ± 1 volt
Blower fan motor switch and A / C or
defroster position switch ON with
engine running at evaporator
thermistor temperature input more
than approx. 2.5
C (less than 2.5 V
(5840
)), refrigerant pressure
switch ON and signal input from ECM
ON
10 ± 14 voltsExcept the above-mentioned with
engine running

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-21
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC2-1L/YSensor groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
1.5 volts
(3150
)Evaporator thermistor temperature at
approx. 15C (59F) with engine
running
AC2-2W/B
Evaporator
thermistor
temperature
(evaporator temp.
sensor) input
Ground to engine
(Fig. B)
2.62 volts
(6.311
)
Evaporator thermistor temperature at
approx. 1C (34F) with engine
running
* If the temperature is less than
approx. 1C, in this case
compressor and condenser fan
should be stop (come back at more
than approx. 2.5C (less than
5840
, 2.5 V))
H25
engine
E61-27 /
G16 J20Gr/W
Signal output to
A / C controller
(A / C ON
Ground to engine
(Fig C)
10 ± 14 volts
Required A / C ON (terminal AC-A13)
at engine running with normal
condition (refer to ªINSPECTION OF
ECM AND ITS CIRCUITº in Section
6E)
G16, J20
engines
E61-8
(
permission
signal)(Fig. C)
0 ± 1 volt
Except the above-mentioned with
engine running
In this case compressor should be
stop
H25
engine
E61-28 /
Y/B
Signal input from
A / C controller
Ground to engine
0 ± 1.5 voltsRequire A / C ON
G16, J20
engines
E61-17Y/B(A / C ON request
signal)
g
(Fig. C)
10 ± 14 voltsTurn off the A / C
H25
engine
E61-5 /
G16, J20
engines
E61-22
Y/L
A / C condenser
cooling fan relay
outputGround to engine
(Fig. C)0 ± 1 volt

Blower fan motor switch and A / C or
defroster position switch (see
NOTE) ON with engine running at
evaporator thermistor temperature
input more than approx. 2.5C (less
than 2.5 V (5840
)), refrigerant
pressure switch ON and signal
input from ECM ON

Engine coolant temperature sensor
more than 113C (236F) with
engine running
10 ± 14 voltsExcept the above-mentioned with
engine running
NOTE:
Defroster position switch circuit is equipped with LH vehicle only.

YH4
GRAND
VITARA
J20 engine
H25 engine G16 engine
1. Generator belt
2. Compressor drive belt3. Compressor pulley
4. Crankshaft pulley
1B-22 AIR CONDITIONING (OPTIONAL)
DRIVE BELT
INSPECTION
For G16 and H25 engines
Refer to Section 3B1 for details.
For J20 engine
Refer to Section 6H for details.

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

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
1B-24 AIR CONDITIONING (OPTIONAL)
RECOVERY
NOTE:

When discharging refrigerant out of A / C system, always re-
cover it by using refrigerant recovery and recycling equip-
ment (1). Discharging it into atmosphere would cause ad-
verse effect to environments.

When handling recovery and recycling equipment, be sure
to follow the instruction manual for the equipment.

YH4
GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
AIR CONDITIONING (OPTIONAL) 1B-25
EVACUATING
EVACUATING PROCEDURE
CAUTION:
Do not evacuate before recovering refrigerant in system.
NOTE:
Whenever opened (exposed to atmospheric air), air condition-
ing system must be evacuated by using a vacuum pump. The
A / C system should be attached with a manifold gauge set, and
should be evacuated for approx. 15 minutes.
1) Connect high charging hose (1) and low charging hose (2) of
manifold gauge set (3) respectively as follows:
High Charging Hose (1)
High pressure charging valve (4)
on Discharge Hose
Low Charging Hose (2)i
Low pressure charging valve (5)
on Suction Pipe
2) Attach center charging hose (6) of manifold gauge set (3) to vac-
uum pump (7).
3) Operate vacuum pump (7), and then open discharge-side valve
(9) (Hi) of manifold gauge set (3).
If there is no blockage in the system, there will be an indication
on high pressure gauge (10).
When this occurs, open the other-side valve (8) (Lo) of the set.
4) Approx. 10 minutes later, low pressure gauge (11) should show
a vacuum lower than ± 760 mmHg providing no leakage exists.
NOTE:

If the system does not show a vacuum below ± 760 mmHg,
close both valves, stop vacuum pump and watch move-
ment of low pressure gauge.

Increase in the gauge reading suggests existence of leak-
age. In this case, repair the system before continuing its
evacuation.

If the gauge shows a stable reading (suggesting no leak-
age), continue evacuation.
5) Evacuation should be carried out for a total of at least 15 minutes.
6) Continue evacuation until low pressure gauge indicates a vacu-
um less than ± 760 mmHg, and then close both valves (8), (9).
7) Stop vacuum pump (7). Disconnect center charging hose (6) from
pump inlet. Now, the system is ready for charging refrigerant.
CHECKING SYSTEM FOR PRESSURE LEAKS
After completing the evacuation, close manifold gauge high pres-
sure valve (HI) and low-pressure valve (LO) and wait 10 minutes.
Verify that low-pressure gauge reading has not changed.
CAUTION:
If the gauge reading moves closer to ª0º, there is a leak
somewhere. Inspect the tubing connections, make neces-
sary corrections, and evacuate system once again, making
sure that there are no leaks.