2003 SUZUKI GRAND VITARA Valve

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
For CAMI production vehicle
For IWATA production vehicle
1B-26 AIR CONDITIONING (OPTIONAL)
CHARGING
CAUTION:

ALWAYS CHARGE THROUGH LOW PRESSURE-SIDE of A / C system at after the initial charging is per-
formed 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 direc-
tions 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 40C (104F) 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 refrig-
erant 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 ser-
vice container.
When charging refrigerant recovered by using the refrigerant and recycling equipment (when recycling
refrigerant), follow the procedure described in the equipment manufacturer's instruction manual.
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 eva-
cuating the system.
2) Connect Low-side hose (1) and High side hose (2) of the man-
ifold 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).
WARNING:
Make sure that high pressure-side valve is closed se-
curely.
5) Start engine and keep engine speed at 1500 r / min. Then, oper-
ate air conditioning.
6) Charge A / C system with refrigerant in vapor state. At this time,
refrigerant container should be held upright.

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
1
1B-40 AIR CONDITIONING (OPTIONAL)
3) Remove upper case (1) and remove evaporator (2) from lower
case (3).
4) Remove following components from evaporator.

Expansion valve (5)

Thermistor (evaporator temperature sensor) (4)
DISASSEMBLY (FOR IWATA PRODUCTION VEHICLE)
1) Remove filter (2) from cooling unit (3) assembly by removing fil-
ter cover (1).
2) Detach clamps (1) to separate evaporator upper and lower
cases from each other.
3) Remove upper case (1) and remove evaporator (2) from lower
case (3).
4) Remove following components from evaporator.

Expansion valve (5)

Thermistor (evaporator temperature sensor) (4)

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-41
INSPECTION
1) Check evaporator fins for blockage. If found clogged, use com-
pressed air to clean the fins.
CAUTION:
Do not use water for cleaning of evaporator.
Be careful not to damage evaporator fins. If evaporator
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 evaporator.
2) Check inlet and outlet fittings for crack or scratch. Repair them
as required.
REASSEMBLY and INSTALLATION
1) Reverse removal and disassembly sequence to install cooling
unit, noting the following points.

Install uniformly the evaporator packing to dash panel hole for
expansion valve.

Adjust fresh air control cable, refer to ªHEATER CONTROL
LEVER ASSEMBLYº in Section 1A.
2) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.
3) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
NOTE:
When the thermistor removed, it should be reinstalled in
original position.
If cooling unit or evaporator is replaced, pour 25 cc of refrig-
erating oil to compressor suction-side.

YH4
GRAND
VITARA
3. Pipe clamp
1B-42 AIR CONDITIONING (OPTIONAL)
EXPANSION VALVE
INSPECTION
Refer to ªTroubleshooting Procedure Using Manifold Gauge Setº in
this section.
REMOVAL
1) 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.
2) Remove front grill.
3) Disconnect suction pipe (1), and liquid pipe (2) from evaporator
(Cooling unit).
CAUTION:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust may not enter
cooling unit.
4) Disconnect suction pipe, and liquid pipe from suction hose (1)
and condenser outlet pipe (2).
5) Remove pipe clamp then remove suction pipe and liquid pipe.
6) Remove expansion valve (1).
INSTALLATION
1) Reverse removal sequence to install expansion valve.
2) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.