2002 SUZUKI GRAND VITARA ten

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
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.

YH4
GRAND
VITARA
1. ªHissº
AIR CONDITIONING (OPTIONAL) 1B-27
7) When refrigerant container (3) is emptied, use following proce-
dure 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 refrig-
erant container tap valve (4), use following procedure for re-
placement.
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).
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 ªhissº 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.

YH4
GRAND
VITARA
1. Electric leak detector
AIR CONDITIONING (OPTIONAL) 1B-29
REMOVING MANIFOLD GAUGE SET
When A / C system has been charged with a specified amount of re-
frigerant, remove manifold gauge set as follows:
1) Close low pressure-side valve of manifold gauge set, (The high
pressure-side valve is closed continuously during the process
of charging.).
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves.
This operation must be performed rapidly.
WARNING:
High pressure-side is naturally under high pressure.
So, care must be used to protect your eyes and skin.
5) Put caps on service valves.
LEAK-TESTING REFRIGERANT SYSTEM
Whenever a refrigerant leak is suspected in the system or any ser-
vice operation has been performed which may result in disturbing
lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general, de-
pend upon the nature of a complaint and the type of a service per-
formed on the system.
LIQUID LEAK DETECTORS
There are a number of fittings and places throughout the air condi-
tioning system where a liquid leak detector solution may be used
to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a swab,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (gas) leak detector is more practical for deter-
mining leaks.
WARNING:

To prevent explosions or fires, make sure that there are no
flammables in the vicinity.

When exposed to fire, the refrigerant turns into a poison-
ous gas (phosgene). Do not inhale this gas.

YH4
GRAND
VITARA
1. Suction hose
2. Discharge hose
3. Liquid pipe
4. Condenser outlet pipe
5. Expansion valve
6. Dual pressure switch
7. Suction pipe
: Apply compressor oil
(refrigerant oil) to O-ring.
1B-30 AIR CONDITIONING (OPTIONAL)
ON-VEHICLE SERVICE
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 page 1B-2).
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.
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.

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.

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-31

Tighten flared nuts to specified torque.
Tightening Torque (Flared Nut Used for)
8 mm pipe: 13 N
.m (1.3 kg-m, 9.5 lb-ft)
14.5 mm pipe: 23 N
.m (2.3 kg-m, 16.6 lb-ft)
16 mm pipe: 33 N
.m (3.3 kg-m, 23.8 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 40C (104F).

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.
NOTE:
When handling recovery and recycling equipment, be sure to follow the instruction manual for the equip-
ment.
REFRIGERANT CHARGE
Charge a proper amount of refrigerant to A / C system according to charging procedure described in recovery, evac-
uation and charging.
CAUTION:
Do not perform an additional refrigerant charging to A / C system. This cause it to overcharge.

YH4
GRAND
VITARA
2. Bolt
For CAMI production vehicle
For IWATA production vehicle
AIR CONDITIONING (OPTIONAL) 1B-33
A / C CONDENSER ASSEMBLY
INSPECTION
Check
a) condenser fins for blockage
b) condenser fittings for leakage
c) condenser fins for damage
Clogged condenser fins should be washed with water, and should
be dried with compressed air.
CAUTION:
Be careful not to damage condenser fins. If condenser fin is
bent, straighten it by using a screwdriver or pair of pliers. If
any leakage is found from fitting or tube, repair or replace
condenser.
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Recover refrigerant by using recovery and recycling equipment.
Be sure to follow the instruction manual for the equipment.
The amount of compressor oil removed must be measured and
the same amount added to the system.
3) Remove front bumper assembly and remove lower stay (1) if
equipped (Refer to Section 9 ªBODY SERVICEº).
4) Disconnect compressor discharge hose (1) from condenser in-
let fittings.
CAUTION:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust do not enter
condenser.

YH4
GRAND
VITARA
12
2. Condenser dryer section
1B-36 AIR CONDITIONING (OPTIONAL)
CONDENSER DRYER (RECEIVER / DRYER)
REMOVAL
1) Remove A / C condenser assembly (1) from vehicle (Refer to
ªA / C CONDENSER ASSEMBLY REMOVALº in this section.).
2) Remove the condenser dryer cap from condenser.
3) Remove the filter (1) from the condenser (2).
4) Remove the dryer (1) using a plier (2).
INSTALLATION
Reverse removal sequence to install condenser dryer, according to
instruction manual with supply parts.
NOTE:

When replacing condenser dryer, add 40 cc of refrigerating
oil the same as compressor oil.

Do not remove the dryer from the plastic bag until just before
inserting it into the receiver.

Install the condenser dryer (1) with its double-layer portion
facing the bottom of the receiver.

If condenser dryer cap installing is bolt type, tighten speci-
fied torque for its bolt.
Tightening Torque:
Cap: 12.5 N
.m (1.25 kg-m, 9 lb-ft)