2000 SUZUKI SWIFT condenser

1B-12 AIR CONDITIONING (OPTIONAL)
PERFORMANCE DIAGNOSIS TABLE
HIGH PRESSURE GAUGE
LOW PRESSURE GAUGE
THERMOMETER AT CENTER DUCT
NOTE:
If ambient temperature is approximately 30°C (86°F), it is possible to diagnose A/C system in detail
referring to “DETAIL DIAGNOSIS TABLE (AMBIENT TEMPERATURE AT 30 °C (86°F))” under “PER-
FORMANCE DIAGNOSIS” in this section.
Condition Possible Cause Correction
Pressure high
(“A” area of high side
graph)Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high side Clean or replace.
Radiator/condenser cooling fan malfunction (Insufficient
cooling of condenser)Check radiator/condenser cooling fan.
Dirty or bent condenser fins (Insufficient cooling of con-
denser)Clean or repair.
Compressor malfunction (Insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system referring to
Section 6B.
Pressure low
(“B” area of high side
graph)Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.
Condition Possible Cause Correction
Pressure high
(“C” area of low side
graph)Expansion valve malfunction (valve opens too wide) Check expansion valve.
Compressor malfunction (Insufficient compression) Check compressor.
Pressure low
(“D” area of low side
graph)Insufficient refrigerant (Insufficient charge or leakage) Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too narrow) Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.
Condition Possible Cause Correction
Outlet air temperature at
center duct is high
(Crossing point is in area
“E”)Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in cooling
(heater) unitRepair or replace.
Compressor malfunction Check compressor.
Outlet air temperature at
center duct is low
(Crossing point is in area
“F”)Insufficient air volume from center duct (Heater blower
malfunction)Check blower motor and fan.
Compressor malfunction Check compressor.

1B-14 AIR CONDITIONING (OPTIONAL)
0.35 – 0.45
(3.5 – 4.5)
(50 – 64)2.0 – 2.5
(20 – 25)
(285 – 355)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 Adjust refrigerant to specified
amount.
Faulty condenser cooling
operationClean condenser.
Faulty radiator/condenser
cooling fan operationInspect and repair radiator/
condenser cooling fan.
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 compres-
sor oil and presence of con-
taminants in oil.
Evacuate system and
recharge with fresh refriger-
ant.
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 regu-
lated properlyReplace expansion valve. Condition
Possible Cause Correction MANIFOLD
GAUGEMPa
(kg/cm
2)
(psi)Detail
Lo Hi

1B-16 AIR CONDITIONING (OPTIONAL)
ELECTRICAL DIAGNOSIS
WIRING DIAGRAM
1. Blower fan motor 6. Radiator/condenser cooling fan relay No.2 11. Ignition switch 16. Main fuse box
2. Blower fan motor resistor 7. Radiator/condenser cooling fan relay No.3 12. A/C evaporator temperature sensor 17. Generator
3. Blower fan switch and A/C switch 8. Radiator/condenser cooling fan motor 13. ECT sensor 18. Compressor
4. A/C refrigerant pressure switch 9. Compressor thermal switch 14. Lighting switch
5. Radiator/condenser cooling fan relay No.1 10. Main relay 15. Circuit fuse box

1B-18 AIR CONDITIONING (OPTIONAL)
System Circuit
Terminal arrangement of ECM coupler (Viewed from harness side)
1. Blower fan motor 8. Main relay A. To “HTR” fuse (25 A) in circuit fuse box
2. Blower fan switch 9. Radiator/condenser cooling fan motor relay No.1 B. To main fuse (15 A)
3. A/C switch 10. Radiator/condenser cooling fan motor relay No.2 C. To main fuse (30 A)
4. A/C refrigerant pressure switch 11. Radiator/condenser cooling fan motor relay No.3
5. Compressor 12. Radiator/condenser cooling fan motor
6. A/C evaporator temperature sensor 13. Engine earth
7. ECT sensor 14. ECM

AIR CONDITIONING (OPTIONAL) 1B-19
ECM Voltage Values Table for Relation of A/C Control
Terminal Wire Circuit Measurement
groundNormal value Condition
C41-1 PNK/BLK Compressor magnet
clutch outputGround to engine
(Fig B)12 – 15 V Except the above-mentioned condition with engine
running
0 – 1 V Blower fan switch and A/C switch ON with engine
running
C41-5 BLK/RED Main power supply for
ECMGround to engine
(Fig B)10 – 14 V Ignition switch ON with engine stopped
C41-6 BLK/RED Main power supply for
ECMGround to engine
(Fig B)10 – 14 V Ignition switch ON with engine stopped
C41-10 BRN/
WHTMain relay drive Ground to engine
(Fig B)0.5 – 1.2 V Ignition switch ON with engine stopped
10 – 14 V Ignition switch OFF
C41-16 YEL/GRN A/C switch input Ground to engine
(Fig B)12 – 15 V Blower fan switch or A/C switch OFF with engine
running
0 – 1 V Blower fan switch and A/C switch ON with engine
running
C41-18 BLU Radiator/condenser
cooling fan relay out-
put 1Ground to engine
(Fig B)0 – 1 V Blower fan switch and A/C switch ON
Engine coolant temperature at more than 97.5°C
(207.5°F) with engine running
12 – 15 V Blower fan motor switch or A/C switch OFF
Engine coolant temperature at less than 97.5°C
(207.5°F) with engine running
C42-1 BLK/ORN Main ground for ECM Ground to body
(Fig A)–0.5 – 1 V Engine running
C42-2 BLK ECM ground for
power circuitGround to body
(Fig A)–0.5 – 1 V Engine running
C42-3 BLK/ORN ECM ground for
power circuitGround to body
(Fig A)–0.5 – 1 V Engine running
C42-10 ORN Sensor ground for
ECT sensorGround to body
(Fig A)–0.5 – 1 V Engine running
C42-14 LT GRN/
BLKECT sensor input Ground to engine
(Fig B)0.71 – 0.75 V
(298 – 320 Ω
)Engine coolant temperature at approximately 80°C
(176°F) with engine running
0.35 – 0.37 V
(135 – 144 Ω
)Engine coolant temperature at Approximately
110°C (230°F) with engine running
If the temperature is more than 114°C (232°F),
compressor and condenser cooling fan should be
stop (come back at less than 112°C (230°F))
C42-18 PNK/GRN Medium pressure
switch inputGround to engine
(Fig B)–0.5 – 1 V Medium pressure switch of A/C refrigerant pres-
sure switch ON
12 – 15 V Medium pressure switch of A/C refrigerant pres-
sure switch OFF
G02-3 PPL/YEL Radiator/Condenser
cooling fan relay out-
put 2Ground to engine
(Fig B)0 – 1 V Blower fan motor switch ON, A/C switch ON and
medium pressure switch OFF
Engine coolant temperature at more than 102.5°C
(216.5°F) with engine running
12 – 15 V Blower fan motor switch OFF, A/C switch OFF or
medium pressure switch ON
Engine coolant temperature at less than 102.5°C
(216.5°F) with engine running
G02-10 ORN Sensor ground for A/C
evaporator tempera-
ture sensorGround to engine
(Fig A)–0.5 – 1 V Engine running
G02-13 PNK/BLU Blower fan speed
inputGround to engine
(Fig B)0 – 1 V Blower fan motor switch “ML”, “MH”, or “H” with
engine running
4 – 7 V Blower fan motor switch “L” position with engine
running
12 – 15 V Blower fan motor switch OFF with engine running
G02-14 WHT/BLK A/C evaporator tem-
perature sensor inputGround to engine
(Fig B)2.09 – 2.17 V
(1940 – 2060 Ω
)A/C evaporator temperature at approximately 25°C
(77°F) with engine running
3.52 – 3.59 V
(6450 – 6850 Ω
)A/C evaporator temperature at approximately 0°C
(32°F) with engine running
If the temperature is less than approximately 2.5°C
(36.5°F), compressor and condenser cooling fan
should be stop (come back at more than approxi-
mately 4°C (39.2°F)

1B-22 AIR CONDITIONING (OPTIONAL)
WHEN REPLACING COMPRESSOR
Compressor oil is sealed in each new compressor by the amount
required for A/C system. Therefore, when using a new compres-
sor for replacement, drain oil from it by the amount calculated as
follows.
“C” = “A” – “B”
“C” : Amount of oil to be drained
“A” : Amount of oil sealed in a new compressor
“B” : Amount of oil remaining in removed compressor
Oil amount in compressor
: 120 cm
3 (120 cc, 7.32 cu-in)
WHEN REPLACING OTHER PART
Replenish the following amount of oil to compressor.
Amount of compressor oil to be replenished
EVACUATING
EVACUATING PROCEDURE
CAUTION:
Be sure to use HFC-134a (R-134a) compressor oil.
NOTE:
Compressor assembly supplied from factory is filled up
with the following amount of oil.
1. New compressor
2. Removed compressor
3. Excess oil (“A” – “B”)
Replaced part Amount of compressor oil
Evaporator
25 cm
3 (25 cc, 1.53 cu-in)
Condenser
15 cm
3 (15 cc, 0.92 cu-in)
Dryer
20 cm
3 (20 cc, 1.22 cu-in)
Hoses
10 cm
3 (10 cc, 0.61 cu-in) each
Pipes
10 cm
3 (10 cc, 0.61 cu-in) each
CAUTION:
Do not evacuate before recovering refrigerant in system.
NOTE:
Whenever opened (exposed to atmospheric air), air con-
ditioning system must be evacuated by using a vacuum
pump. The A/C system should be attached with a mani-
fold gauge set, and should be evacuated for approxi-
mately 15 minutes.

AIR CONDITIONING (OPTIONAL) 1B-23
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 condenser outlet pipe
Low charging hose (2) → Low pressure charging valve (5)
on suction pipe
2) Attach center charging hose (6) of manifold gauge set (3) to
vacuum pump (7).
3) Operate vacuum pump (7), and then open discharge side
valve (Hi) (8) of manifold gauge set (3).
If there is no blockage in the system, there will be an indica-
tion on high pressure gauge (9).
In this case, open the other side valve (Lo) (10) of the set
and repair the system.
4) Approximately 10 minutes later, low pressure gauge (11)
should show a vacuum lower than –760 mmHg providing no
leakage exists.
5) Evacuation should be carried out for a total of at least 15
minutes.
6) Continue evacuation until low pressure gauge (9) indicates a
vacuum less than –760 mmHg, and then close both valves
(8), (10).
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 and low pressure valve and wait 10 minutes. Verify
that low pressure gauge reading has not changed.NOTE:
 If the system does not show a vacuum below –760
mmHg, close both valves, stop vacuum pump and
watch movement of low pressure gauge.
 Increase in the gauge reading suggests existence of
leakage. In this case, repair the system before continu-
ing its evacuation.
 If the gauge shows a stable reading (suggesting no
leakage), continue evacuation.
CAUTION:
If the gauge reading moves closer to “0”, there is a leak
somewhere. Inspect the tubing connections, make nec-
essary corrections, and evacuate system once again,
making sure that there are no leaks.

AIR CONDITIONING (OPTIONAL) 1B-25
7) When refrigerant container (1) is emptied, use the following
procedure to replace it with a new refrigerant container (1).
a) Close low pressure valve.
b) Replace empty container (1) with a refrigerant container
which has been charged with refrigerant. When using
refrigerant container tap valve (2), use the following proce-
dure for replacement.
i) Retract needle (3) and remove refrigerant container tap
valve (2) by loosening its plate nut (4).
ii) Install previously-removed refrigerant container tap valve
(2) to a new refrigerant container (1).
c) Purge any air existing in center charging hose
When using refrigerant container tap valve, use the follow-
ing procedure to purge air.
i) Once fully tighten refrigerant container tap valve (1), and
then loosen (open) plate nut (2) slightly.
ii) Open low pressure side valve (3) of manifold gauge set
(4) a little.
iii) As soon as refrigerant comes out with a “hiss” through a
clearance between refrigerant container and tap valve,
tighten plate nut (2) as well as low pressure side valve (3).
iv) Turn handle of tap valve (1) clockwise so that its needle is
screwed into the new container to make a hole for refriger-
ant flow.
8) After the system has been charged with specified amount
(330 – 390 g) of refrigerant or when low pressure gauge (1)
and high pressure gauge (2) have indicated the following
specified amount, close low pressure side valve (3) on mani-
fold gauge set (4). At this time, look into the sight glass (5) of
condenser outlet pipe (6) and check that there are no bub-
bles (7) in it, which means that the system is fully charged.
Low side and high side pressure example
Gauges should read as follows when ambient tempera-
ture is 30°C (86 °F).
Pressure
on high pressure gauge1400 – 1750 kPa
14.0 – 17.5 kg/cm
2
199.1 – 248.9 psi
Pressure
on low pressure gauge230 – 350 kPa
2.3 – 3.5 kg/cm
2
32.7 – 49.8 psi