2001 SUZUKI GRAND VITARA Engine

1B-18 AIR CONDITIONING (OPTIONAL)
Terminal Wire CircuitMeasurement
groundNormal value Condition
AC-B-2WHT/
BLKA/C evaporator
temperature
sensor (A/C
evaporator ther-
mistor) inputGround to
engine (Fig B)1.8 V
(3520 Ω)A/C evaporator temperature sen-
sor temperature at approx. 15 °C
(59 °F) with engine running
2.51 V
(5.855 Ω)A/C evaporator temperature sen-
sor temperature at approx. 4.5 °C
(34 °F) with engine running
If the temperature is less than
approx. 4.5 °C, in this case com-
pressor and condenser fan
should be stop (come back at
more than approx. 6.1 °C (less
than 5403 Ω, 2.4 V))
E61-8GRY/
WHTSignal output to
A/C controller
(A/C ON permis-
sion signal)Ground to
engine (Fig C)10 – 14 VRequired A/C ON (terminal AC-
A13) at engine running with nor-
mal condition (refer to “INSPEC-
TION OF ECM AND ITS
CIRCUIT” in Section 6E)
0 – 1 VExcept the above-mentioned with
engine running
In this case compressor should
be stop
E61-17YEL/
BLKSignal input from
A/C controller
(A/C ON request
signal)Ground to
engine (Fig C)0 – 1.5 V Require A/C ON
10 – 14 V Turn off the A/C
E61-22YEL/
BLUCondenser cool-
ing fan motor
relay outputGround to
engine (Fig C)0 – 1 VBlower fan motor switch and A/C
or defroster switch ON with
engine running at A/C evaporator
temperature sensor temperature
input more than approx. 2.5 °C
(less than 2.5 V (5840 Ω)), refrig-
erant pressure switch ON and
signal input from ECM ON
Engine coolant temperature sen-
sor more than 113 °C (236 °F)
with engine running
10 – 14 VExcept the above-mentioned with
engine running

1B-22 AIR CONDITIONING (OPTIONAL)
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.
Charging
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.
CAUTION:
ALWAYS CHARGE THROUGH LOW PRESSURE-SIDE of A/C system at after the initial charging is
performed from the high-pressure side with the engine stopped.
NEVER CHARGE TO HIGH PRESSURE-SIDE of A/C system with engine running.
Do not charge while compressor is hot.
When installing tap valve to refrigerant container to make a hole there through, carefully follow
directions given by manufacturer.
A pressure gauge should always be used before and during charging.
The refrigerant container should be emptied of refrigerant when discarding it.
The refrigerant container should not be heated up to 40 °C (104 °F) or over.
Refrigerant container should not be reversed in direction during charging. Reversing in direction
causes liquid refrigerant to enter compressor, causing troubles, such as compression of liquid
refrigerant and the like.
NOTE:
The air conditioning system contains HFC-134a (R-134a).
Described here is a method to charge the air conditioning system with refrigerant from the refrigerant
service container.
When charging refrigerant recovered by using the refrigerant and recycling equipment (when recy-
cling refrigerant), follow the procedure described in the equipment manufacturer’s instruction manual.

AIR CONDITIONING (OPTIONAL) 1B-23
The initial charging of the A/C system is performed from the high-
pressure side with the engine stopped.
And next, this method must be followed by charging from the low-
pressure side with the engine running.
1) Check to make sure that hoses are routed properly after
evacuating the system.
2) Connect Low-side hose (1) and High side hose (2) of the
manifold gauge set (3) in position. Thus open refrigerant
container valve (4) to purge the charging line.
3) Open the high-pressure side valve (6) and charge refrigerant
to system.
4) After a while, open the low-pressure side valve (5) and close
the high-pressure side valve (6).
5) Start engine and keep engine speed at 1500 rpm. Then,
operate air conditioning.
6) Charge A/C system with refrigerant in vapor state. At this
time, refrigerant container should be held upright.
7) When refrigerant container (3) is emptied, the use following
procedure to replace it with a new refrigerant container (3).
a) Close low pressure valve.
b) Replace empty container (3) with a refrigerant container
which has been charged with refrigerant. When using
refrigerant container tap valve (4), use following procedure
for replacement.
i) Retract needle (1) and remove refrigerant container tap
valve (4) by loosening its plate nut (2).
ii) Install previously-removed refrigerant container tap valve
(4) to a new refrigerant container (3). WARNING:
Make sure that high pressure-side valve is closed
securely.
NOTE:
Dual A/C model must be operated rear A/C system, too.
153
64
2

AIR CONDITIONING (OPTIONAL) 1B-25
On-Vehicle Service
Precaution
When servicing air conditioning system, the following rules must be observed.
Piping
When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling
nuts and O-ring. 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 refrigerant 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.
CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
(For identification between these two types, refer to “REFRIGERANT TYPE” in this section.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
NOTE:
Single A/C model is the same as SQ625 (H25 engine) model. Refer to the same section of the Service
Manual mentioned in FOREWORD of this manual.
[A]: Dual A/C model 1. Suction hose 4. Condenser outlet pipe 7. Front suction pipe
Apply compressor oil (refrigerant oil) to O-ring. 2. Discharge hose 5. Expansion valve 8. Rear liquid pipe
3. Front liquid pipe 6. Dual (refrigerant) pressure switch 9. Rear suction pipe
1
6 43 75
9
8
2 [A]

AIR CONDITIONING (OPTIONAL) 1B-27
Replenishing compressor oil
When replacing air conditioning parts with new ones, it is neces-
sary to replenish oil by the amount supposedly remaining in each
part.
WHEN CHANGING GAS ONLY
When it is unavoidable to change gas without replacing any com-
ponent part for engine removal and installation or for some other
reason, replenish 20 cm
3 (20cc) oil. When replenishing gas only,
oil replenishment is not necessary.
WHEN REPLACING COMPRESSOR
Compressor oil is sealed in each new compressor by the amount
required for air conditioner cycle. Therefore, when using a new
compressor for replacement, drain oil from it by the amount calcu-
lated 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
Amount of oil in new compressor :
Dual A/C model 140 cm
3 (140 cc)
Single A/C model 100 cm
3 (100 cc)
WHEN REPLACING OTHER PART
Amount of compressor oil : 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.
Replaced part Amount of compressor oil
to be replenished
Evaporator
25 cm
3 (25 cc)
Rear evaporator
(for dual A/C model)25 cm
3 (25 cc)
Condenser
15 cm
3 (15 cc)
Receiver/dryer
20 cm
3 (20 cc)
Hoses
10 cm
3 (10 cc) each
Pipes
10 cm
3 (10 cc) each
1. New compressor
2. Removed compressor
3. Excess oil (A–B)

1B-38 AIR CONDITIONING (OPTIONAL)
Compressor Assembly
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.
2) Close Hi (4) and Lo (5) side valves.
3) Run engine at fast idle.
4) Check compressor for the following items.
If any of the above checks indicated a defect, repair com-
pressor.
High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.
Metallic sound.
Leakage from compressor. CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
For identification between these two types, refer to page 66.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect refrigerant or compressor oil will result in leakage of refrigerant, damage in parts or
other faulty condition.
When servicing the compressor, keep dirt or foreign material away from getting on or into the com-
pressor parts and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any “On-
vehicle” repair or before removal of the compressor. The parts must be kept clean at all times and any
parts to be reassembled should be cleaned with Trichloromethane, naphtha, kerosene or equivalent
solvent and dried with dry air. Use only lint free cloths to wipe parts.
The operations described are based on bench overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of accessibility of the components.
When compressor is removed from the vehicle for servicing, the oil remaining in the compressor
should be discarded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair pro-
cedures require that the system be discharged of refrigerant.
2. High pressure side (Delivery side hose)
3. Low pressure side (Suction side pipe)
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2
3

AIR CONDITIONING (OPTIONAL) 1B-39
REMOVAL
1) Run engine at idle with A/C ON for 10 minutes.
2) Disconnect negative (–) cable at battery.
3) Recover refrigerant from refrigeration system using recovery
and recycling equipment.
4) Remove P/S pump referring to step 4) to 7) of “REMOVAL”
under “P/S PUMP” in Section 3B1.
5) Disconnect magnet clutch connector.
6) Disconnect suction hose (1) and discharge hose (2) from
compressor.
7) Remove compressor (1) from its mount (2).NOTE:
The amount of compressor oil at removed must be mea-
sured and the same amount must be poured when install-
ing the compressor.
NOTE:
It is not necessary to drain P/S fluid.
NOTE:
Cap open fitting immediately to keep moisture out of sys-
tem.
2
1
NOTE:
If compressor assembly is replaced. Drain oil from com-
pressor, and measure its amount.
1 2

POWER STEERING (P/S) SYSTEM 3B1-3
Hydraulic Pressure in P/S Circuit
Hydraulic pressure check
1) After cleaning joint of high pressure hose and P/S pump
thoroughly, disconnect hose from pump and install special
tool (oil pressure gauge, attachment and hose).
Special tool
(A) : 09915-77410
(B) : 09915-77420
2) Check each connection for fluid leakage and bleed air.
Refer to “AIR BLEEDING PROCEDURE” in this section.
3) With engine idling, turn steering wheel and warm up engine
till temperature of fluid in P/S fluid reservoir rises to 50 –
60°C (122 – 140°F).
4) Check back pressure by measuring hydraulic pressure with
engine idling and hands off steering wheel.
When back pressure is higher than specified values, check
control valve and piping for clogging.
Back pressure :
Lower than 1000 kPa (10 kg/cm
2, 142 psi) CAUTION:
Take care not to cause damage to A/C condenser during
service operation, if equipped.
1. P/S fluid reservoir
2. Attachment
3. Gasket
4. Union bolt
5. High pressure side
6. Low pressure side
1. P/S fluid reservoir 4. P/S gear box
2. Gauge valve (open) 5. High pressure side
3. P/S pump 6. Low pressure side