2001 SUZUKI GRAND VITARA Air conditioning

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.
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1B-24 AIR CONDITIONING (OPTIONAL)
c) Purge any air existing in center charging hose
When using refrigerant container tap valve, use following
procedure to purge air.
i) Once fully tighten refrigerant container tap valve and then
loosen (open) plate nut slightly.
ii) Open low pressure valve of manifold gauge set a little.
iii) As soon as refrigerant comes out with a “hiss” through a
clearance between refrigerant container and tap valve,
tighten plate nut as well as manifold gauge set low pres-
sure valve.
iv) Turn handle of tap valve 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 of
refrigerant or when low pressure gauge (1) and high pres-
sure gauge (2) must indicated the following specified
amount, close low pressure side valve (3) of manifold gauge
set (4). If equipped with sight glass in this time, look into the
sight glass (6) of condenser outlet pipe (5) and check that
there are no bubbles (7) in it, which means that the system is
fully charged.
Low pressure gauge when charged with specified
amount :
About 200 - 300 kPa (2 - 3 kg/cm
2, 29 - 43 psi)
(At A/C inlet temperature 30 - 35 °C (86 - 95 °F))
High pressure gauge when charged with specified
amount :
About 1370 - 1670 kPa (14 - 17 kg/cm
2, 200 - 244 psi)
(At A/C inlet temperature 30 - 35 °C (86 - 95 °F))
1.“Hiss”
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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
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1B-26 AIR CONDITIONING (OPTIONAL)
Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.
Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system,
install a blind plug or cap to the fitting immediately.
When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
Tighten flared nuts to specified torque.
Tightening torque
8 mm (0.31 in.) pipe : 13 N·m (1.3 kg-m, 9.5 lb-ft)
12.7 mm (0.5 in.) pipe : 22 N·m (2.2 kg-m, 16.0 lb-ft)
16 mm (0.63 in.) pipe : 33 N·m (3.3 kg-m, 24.0 lb-ft)
Route drain hose so that drained water does not make any contact to vehicle components.
Handling refrigerant HFC-134a (R-134a)
When handling refrigerant, always wear goggles to protect your eyes.
Avoid you direct contact to liquid refrigerant.
Do not heat refrigerant container higher than 40 °C (104 °F).
Do not discharge refrigerant into atmosphere.
Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and
will tarnish surfaces of bright metals including chrome.
After recovering refrigerant from system, the amount of compressor oil removed must be measured and the
same amount added to the system.
Refrigerant recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment. Discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to environ-
ments.
Refrigerant charge
Charge a proper amount of refrigerant to A/C system according to charging procedure described in recovery,
evacuation and charging.NOTE:
When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.
CAUTION:
Do not perform an additional refrigerant charging to A/C system. This cause it to overcharge.

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-28 AIR CONDITIONING (OPTIONAL)
Rear A/C Unit (Rear A/C Evaporator)
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant by using recovery and recycling equip-
ment. Be sure to follow the instruction manual for the equip-
ment.
The amount of compressor oil removed must be measured
and the same amount added to the system.
3) Remove rear luggage mat end garnish (1), rear luggage box
(2) (if equipped), rear side sill scuff (3) rear quarter lower trim
(4) and rear quarter upper trim (5).
1. Rear blower fan cover 6. Rear A/C unit mounting clip 11. Solenoid valve mounting bracket Do not reuse
2. Rear A/C unit mounting bush 7. Rear blower motor assembly 12. Solenoid valve Apply compressor
(refrigerant)
oil to O-ring
3. Rear blower fan resistor 8. Rear A/C evaporator temperature controller 13. Rear liquid pipe
4. Rear A/C unit cover 9. Rear expansion valve 14. O-ring
5. Rear A/C evaporator 10. Rear suction pipe 15. Packing
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AIR CONDITIONING (OPTIONAL) 1B-29
4) Loosen floor suction pipe and floor liquid pipe mounting bolt
(1).
5) Remove rear A/C No.1 duct (1).
6) Disconnect rear A/C unit wire couplers (2).
7) Remove rear A/C unit mounting bolts (3), and then remove
rear A/C unit (4).
INSPECTION
Check the following.
Clog of rear A/C evaporator fins.
If any clogs are found, rear A/C evaporator fins should be
washed with water, and should be dried with compressed air.
Rear A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace rear A/C evapora-
tor.
INSTALLATION
Reverse removal procedure to install rear A/C unit noting the fol-
lowing points.
Evacuate and charge system. Refer to “RECOVERY” and
“EVACUATING” in this section.
When the rear A/C evaporator thermistor (temperature sen-
sor) removed, it should be reinstalled in original position.
If rear A/C unit or rear A/C evaporator is replaced, pour 25
cm
3 (25 cc) of refrigerating oil to compressor suction-side.
Rear Expansion Valve
INSPECTION
Refer to “PERFORMANCE DIAGNOSIS” in this section.
2. Muffler
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NOTE:
Cap open fitting immediately to keep moisture out of sys-
tem.
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