2001 SUZUKI GRAND VITARA Owners Manual

1A-4 HEATER AND VENTILATION

AIR CONDITIONING (OPTIONAL) 1B-1
1B
SECTION 1B
AIR CONDITIONING (OPTIONAL)
CONTENTS
General Description ....................................... 1B-3
Refrigerant Type .......................................... 1B-3
Refrigerant Flow of Air Conditioning System 1B-3
Major Components And Location ................. 1B-4
Diagnosis ........................................................ 1B-6
General ........................................................ 1B-6
Main A/C system (front A/C system) ........ 1B-6
Rear A/C system ...................................... 1B-8
Quickly Checking of Refrigerant Charge
(If Equipped with Sight Glass) ...................... 1B-9
Performance Diagnosis .............................. 1B-10
Performance diagnosis table .................. 1B-12
Detail diagnosis table (at ambient temperature within 30 - 35 °C
(85 - 95 °F)) ............................................ 1B-13
Wiring Circuit.............................................. 1B-14
Inspection of A/C Controller and Its
Circuits ....................................................... 1B-15
Voltage check......................................... 1B-15
Refrigerant Recovery, Evacuation and
Charging ....................................................... 1B-19
Operation Procedure for Charging A/C with
Refrigerant ................................................. 1B-19
Recovery .................................................... 1B-20
Evacuating ................................................. 1B-21
Evacuating procedure ............................ 1B-21
Checking system for pressure leaks ...... 1B-22 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a (R-134a).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. 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:
 For the descriptions (items) not found in this section, refer to the same section of the Service Man-
ual mentioned in FOREWORD of this manual.
 For basic servicing method of the air conditioning system that is not described in this section, refer
to “AIR CONDITIONING BASIC MANUAL (99520-02130)”.

1B-2 AIR CONDITIONING (OPTIONAL)
Charging .................................................... 1B-22
On-Vehicle Service ...................................... 1B-25
Precaution .................................................. 1B-25
Piping ..................................................... 1B-25
Handling refrigerant HFC-134a (R-134a) 1B-26
Refrigerant recovery............................... 1B-26
Refrigerant charge ................................. 1B-26
Replenishing compressor oil .................. 1B-27
Rear A/C Unit (Rear A/C Evaporator) ........ 1B-28
Rear Expansion Valve ............................... 1B-29
Rear A/C Evaporator Temperature
Controller ................................................... 1B-30
Refrigerant Pipes and Hoses ..................... 1B-31
Solenoid Valve ........................................... 1B-32
Rear Blower Motor Assembly .................... 1B-33Rear Blower Motor Relay and Solenoid
Valve Relay................................................ 1B-34
Rear A/C Main Switch................................ 1B-34
Rear Blower Motor Resistor....................... 1B-35
Rear Blower Motor Switch ......................... 1B-36
Rear A/C No.1 and No.2 Duct ................... 1B-37
Rear A/C No.1 duct ................................ 1B-37
Rear A/C No.2 duct ................................ 1B-37
Compressor Assembly............................... 1B-38
Magnet Clutch............................................ 1B-41
Required Service Materials ......................... 1B-44
Tightening Torque Specification................ 1B-44
Special Tools ............................................... 1B-44

AIR CONDITIONING (OPTIONAL) 1B-3
General Description
Refrigerant Type
Whether the A/C in the vehicle being serviced uses HFC-134a
(R-134a) or CFC-12 (R-12) is indicated on LABEL on the com-
pressor. Also, it can be checked by the shape of the service
(charge) valve.
Refrigerant Flow of Air Conditioning System
[A] : HFC-134a (R-134a)
[B] : CFC-12 (R-12)
1. Compressor label
2. Service valve
NOTE:
For single A/C model, refer to the same section of the Service Manual mentioned in FOREWORD of
this manual.
[A] : Dual A/C model 3. Condenser assembly 6. Expansion valve 9. Rear expansion valve
1. Compressor 4. Receiver/dryer 7. A/C evaporator 10. Rear A/C evaporator
2. Magnet clutch 5. Dual pressure switch 8. Solenoid valve
[A]10
8
9
5
7
6
3
2
14 : Liquid
: Vapor
: Superheated Vapor

1B-4 AIR CONDITIONING (OPTIONAL)
Major Components And Location
[A] : Dual A/C model 6. Receiver/dryer 13. Suction pipe 20. Ventilation air
[B] : Single A/C model 7. Front expansion valve 14. Discharge pipe 21. Rear A/C air
1. Front cooling unit 8. Heater unit 15. Recirculation air 22. Room air
2. Front A/C evaporator 9. Rear A/C unit 16. Fresh air 23. Solenoid valve
3. Front blower fan motor 10. Rear blower fan motor 17. Defroster air 24. Rear A/C evaporator
4. Compressor 11. Rear expansion valve 18. Demister air
5. Condenser assembly 12. Liquid pipe 19. Foot air
17 17
18 18
16 [A]
[B]15
21
2211
23
9
24
10 141320
21
19 19
4 12
6 312
78
17 17
18 18
16
15
20
19 19 1
2
8 5
7
12
6
513
4 14

AIR CONDITIONING (OPTIONAL) 1B-5
[A] : Dual A/C LH steering model 4. Condenser 11. Low pressure charge valve
[B] : Dual A/C RH steering model 5. Sight glass 12. Floor liquid pipe
[C] : Single A/C LH steering model 6. Refrigerant (dual) pressure sensor 13. Floor suction pipe
[D] : Single A/C RH steering model 7. Discharge pipe 14. Rear A/C unit
1. Front cooling unit 8. Liquid pipe 15. Rear A/C duct No.1
2. Heater unit 9. Suction pipe 16. Rear A/C duct No.2
3. Compressor 10. High pressure charge valve
[A]
[B]
[C][D]
10
7
9 3 4 6 5 1181
213
12 16
1514
1 2
13
12 16
1514
7
10
5
6
4
38
9 11
1 2
7
10
5
6
4
38
9 11
10
7
9 3 4 6 5 1181
2

1B-6 AIR CONDITIONING (OPTIONAL)
Diagnosis
General
Main A/C system (front A/C system)
Condition Possible Cause Correction
Cool air does not
come out (A/C system
does not operative)No refrigerant Perform recover, evacuation and
charging.
Fuse blown Check “IG METER”, “REAR DEFG”
and “A/C” fuses, and check for
short circuit to ground.
A/C switch faulty Check A/C switch.
Blower motor switch faulty Check blower motor switch.
A/C evaporator temperature sensor (A/C evap-
orator thermistor) faultyCheck A/C evaporator tempera-
ture sensor (A/C evaporator ther-
mistor).
Refrigerant (dual) pressure switch faulty Check refrigerant (dual) pressure
switch.
Wiring or grounding faulty Repair as necessary.
A/C ON permission signal in ECM faulty Check A/C ON permission signal.
A/C controller and its circuit faulty Check A/C controller and its circuit.
Cool air does not
come out (A/C com-
pressor does not
operative (won’t rota-
tive))Magnet clutch faulty Check magnet clutch.
Compressor relay faulty Check compressor thermal switch.
Compressor relay faulty Check compressor relay.
Drive belt loose or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
A/C ON permission signal in ECM faulty Check A/C ON permission signal.
A/C controller faulty Check A/C controller.
Cool air does not
come out (A/C con-
denser cooling fan
motor does not opera-
tive)Condenser cooling fan motor relay faulty Check condenser cooling fan motor
relay.
Wiring or grounding faulty Repair as necessary.
A/C condenser fan motor relay signal in ECM
faultyCheck A/C condenser cooling fan
motor relay signal.
Condenser cooling fan motor faulty Check condenser cooling fan
motor.
Cool air does not
come out (Blower
motor does not opera-
tive)Fuse blown Check “FRONT BLOW” and
“REAR DEFG” fuses, and check for
short circuit to ground.
Blower motor relay faulty Check blower motor relay.
Blower motor resistor faulty Check blower motor resistor.
Blower motor switch faulty Check blower motor switch.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor.

AIR CONDITIONING (OPTIONAL) 1B-7
Cool air does not
come out or insuffi-
cient cooling (A/C sys-
tem normal operative)Insufficient or excessive charge of refrigerant Check charge of refrigerant.
Refrigerant leak in system Check system for leaks.
Condenser clogged Check condenser.
A/C evaporator clogged or frosted Check A/C evaporator.
A/C evaporator temperature sensor (A/C evap-
orator thermistor) faultyCheck A/C evaporator tempera-
ture sensor (A/C evaporator ther-
mistor).
A/C controller faulty Check A/C controller.
Expansion valve faulty Check expansion valve.
Drive belt slipping Check or replace drive belt.
Magnetic clutch faulty Check magnetic clutch.
Cool air does not
come out or insuffi-
cient cooling (A/C sys-
tem normal operative)Compressor faulty Check compressor.
Air in A/C system Replace condenser dryer, and then
perform evacuation and charging.
Air leaking from cooling unit or air duct Repair as necessary.
Heater and ventilation system faulty Check air inlet box assembly.
Check heater control lever assem-
bly.
Check heater assembly.
Blower motor faulty Check blower motor.
Excessive compressor oil existing in A/C sys-
temPull out compressor oil in A/C sys-
tem circuit, and replace compres-
sor.
Cool air does not
comes out only inter-
mittentlyWiring connection faulty Repair as necessary.
Expansion valve faulty Check expansion valve.
Excessive moisture in A/C system Replace condenser dryer, and then
perform evacuation and charging.
A/C controller faulty Check A/C controller.
Magnetic clutch faulty Check magnetic clutch.
Excessive charge of refrigerant Check charge of refrigerant.
Cool air comes out
only at high speedsCondenser clogged Check condenser.
Insufficient charge of refrigerant Check charge of refrigerant.
Air in A/C system Replace condenser dryer, and then
perform evacuation and charging.
Drive belt slipping Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air does not
comes out only at high
speedsExcessive charge of refrigerant Check charge refrigerant.
A/C evaporator frosted Check A/C evaporator.
Check A/C thermistor.
Insufficient velocity of
cooled airA/C evaporator clogged or frosted Check A/C evaporator.
Air leaking from cooling unit or air duct Repair as necessary.
Blower motor faulty Check blower motor.
Wiring or grounding faulty Repair as necessary. Condition Possible Cause Correction