Page 75 of 801
YH4
GRAND
VITARA
1. Compressor
2. Magnet clutch
3. Condenser assembly
4. Receiver / dryer
5. Dual pressure switch
6. Expansion valve
7. Evaporator: Liquid
: Vapor
: Superheated vapor
1B-4 AIR CONDITIONING (OPTIONAL)
REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM
Page 76 of 801
YH4
GRAND
VITARA
1. Cooling unit
2. Compressor
3. Condenser assembly
4. Receiver / dryer
5. Discharge hose
6. Suction hose
7. Condenser outlet pipe
8. Liquid pipe9. Expansion valve
10. Ventilation air
11. Foot air
12. Defroster air
13. Demister air
14. Fresh air
15. Recirculation air
16. Heater unit17. Air inlet box
18. Dual pressure switch
19. Low pressure charge valve
20. High pressure charge valve
21. Suction pipe
22. Sight glass
CAMI PRODUCTION VEHICLE IWATA PRODUCTION VEHICLE
AIR CONDITIONING (OPTIONAL) 1B-5
MAJOR COMPONENTS AND LOCATION
Page 77 of 801
YH4
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VITARA
1B-6 AIR CONDITIONING (OPTIONAL)
DIAGNOSIS
GENERAL
ConditionPossible CauseCorrection
Cool air won't come out
(A / C system won't
operative)No refrigerant
Fuse blown
A / C switch faulty
Blower motor switch faulty
A / C thermistor faulty
Dual pressure switch faulty
Wiring or grounding faulty
A / C ON permission signal in ECM
faulty
A / C controller and its circuit faultyRecover, evacuation and charging.
Check ªIG METERº fuse, ªREAR DEFGº
fuse, and ªA / C FUSEº and check for
short circuit to ground.
Check A / C switch.
Check blower motor switch.
Check A / C evaporator thermistor.
Check dual pressure switch.
Repair as necessary.
Check ON permission signal.
Check A / C controller and its circuit.
Cool air won't come out
(A / C compressor won't
operative)Magnet clutch faulty
Compressor relay faulty
Compressor thermal switch faulty
(if equipped)
Drive belt loose or broken
Compressor faulty
A / C ON permission signal in ECM
faulty
A / C controller faultyCheck magnet clutch.
Check compressor thermal switch.
Check compressor relay.
Adjust or replace drive belt.
Check compressor.
Check ON permission signal.
Check A / C controller.
Cool air won't come out
(A / C condenser cooling
fan motor won't
operative)Condenser cooling fan relay faulty
Wiring or grounding faulty
ªA / C condenser cooling fan relayº
signal in ECM faulty
Condenser cooling fan motor faultyCheck condenser cooling fan relay.
Repair as necessary.
Check A / C condenser cooling fan relay
signal.
Check condenser cooling fan motor.
Cool air won't come out
(Blower motor won't
operative)Fuse blown
Blower motor relay faulty
Blower motor resistor faulty
Blower motor switch faulty
Wiring or grounding faulty
Blower motor faultyCheck ªHEATER FUSEº, ªREAR DEFGº
fuse and check for short circuit to
ground.
Check blower motor relay.
Check blower motor resistor.
Check blower motor switch.
Repair as necessary.
Check blower motor.
Cool air won't come out
or insufficient cooling
(A / C system normal
operative)Insufficient or excessive charge of
refrigerant
Refrigerant leak in system
Condenser clogged
A / C evaporator clogged or frosted
A / C thermistor faulty
A / C controller faulty
Expansion valve faulty
Drive belt slipping
Magnetic clutch faultyCheck charge of refrigerant.
Check system for leaks.
Check condenser.
Check A / C evaporator.
Check A / C thermistor.
Check A / C controller.
Check expansion valve.
Check or replace drive belt.
Check magnetic clutch.
Page 83 of 801
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GRAND
VITARA
For CAMI production vehicle
For IWATA production vehicle
1B-12 AIR CONDITIONING (OPTIONAL)
PERFORMANCE DIAGNOSIS
1) Confirm that vehicle and environmental conditions are as fol-
lows.
Vehicle is not exposed to direct sun.
Ambient temperature is within 15C ± 35C (59F ± 95F).
2) Make sure that high pressure valve (1) and low pressure valve
(2) of manifold gauge are firmly closed.
3) Connect high pressure charging hose (3) to high pressure ser-
vice valve (5) on vehicle, and connect low pressure charging
hose (4) to low pressure service valve (6) on vehicle.
4) Bleed the air in charging hoses (3), (4) by loosening their respec-
tive nuts on manifold gauge, utilizing the refrigerant pressure.
When a hiss is heard, immediately tighten nut.
CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.
5) Warm up engine to normal operating temperature (engine cool-
ant temperature at 80 ± 90C (176 ± 194F)) and keep it at spe-
cified idle speed. (Radiator cooling fan should not be working
when checking pressure and temperature.)
6) Turn A / C switch ON, and set blower switch at ªHIº (4th position),
temperature control knob at ªCOOLº, air outlet control knob at
ªFACEº, fresh / circulation control knob at ªCIRCULATIONº.
(Confirm that A / C compressor and condenser fan are working.)
7) Keep all windows, doors and engine food open.
Ambient temperature
15 ± 35C (59F ± 95F)
Engine rpmKeep to 1,500 rpm.
Blower motor switchMax. (4th position)
Temperature controlMax. cool
Air outlet controlFace
Vehicle doorsAll open
Air inlet door positionRecirculation
8) With about 20 mm (0.8 in.) of dry bulb thermometer (1) inserted
into center duct air outlet and another one set near evaporator
air inlet, read temperature indicated on each thermometer.
Page 85 of 801
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GRAND
VITARA
1B-14 AIR CONDITIONING (OPTIONAL)
HIGH PRESSURE CAUGE LOW PRESSURE GAUGE THERMOMETER AT
CENTER DUCT
Insufficient
cooling of
condenser
PERFORMANCE DIAGNOSIS TABLE
TESTING RESULTSPOSSIBLE CAUSEREMEDY
Pressure high
(ªAº area of high side
graph)Refrigerant overcharged
Expansion valve frozen or clogged
Clogged refrigerant passage of high side
Condenser fan malfunction
Dirty or bent condenser fins
Compressor malfunction (Insufficient oil etc.)
Engine overheatRecharge
Check expansion valve
Clean or replace
Check condenser fan
Clean or repair
Check compressor
Check engine cooling
system
Pressure low
(ªBº area of high side
graph)Insufficient refrigerant (Insufficient charge or
leakage)
Expansion valve malfunction (Valve opens too
wide)
Compressor malfunction (Insufficient
compression)Check for leakage, repair if
necessary and recharge
Check expansion valve
Check compressor
Pressure high
(ªAº area of low side
graph)Expansion valve malfunction (Valve opens too
wide)
Compressor malfunction (Insufficient
compression)Check expansion valve
Check compressor
Pressure low
(ªBº area of low side
graph)Insufficient refrigerant (Insufficient charge or
leakage)
Expansion valve malfunction (Valve opens too
narrow)
Clogged refrigerant passage (Crashed pipe)Check for leakage, repair if
necessary and recharge
Check expansion valve
Repair or replace
Outlet air temperature
at center duct is high
(Crossing point is in
area ªAº)Insufficient or excessive charge of refrigerant
Dirty or bent evaporator fins
Air leakage from cooling (heater) unit or air
duct
Malfunctioning, switchover function of damper
in cooling (heater) unit
Compressor malfunctionCheck refrigerant
pressure
Clean or repair
Repair or replace
Repair or replace
Check compressor
Outlet air temperature
at center duct is low
(Crossing point is in
area ªBº)Insufficient air volume from center duct
(Heater blower malfunction)
Compressor malfunctionCheck blower motor and
fan
Check compressor
NOTE:
If ambient temperature is within 30 ± 35C (85 ± 95F), it is possible to do using next page table for more
detail diagnosis.
Page 87 of 801
YH4
GRAND
VITARA
1. Blower motor main relay
2. Blower motor
3. Blower motor resistor
4. Blower motor switch
5. A / C controller
6. ECM
7. Heater mode control switch
8. Evaporator temperature sensor
9. Refrigerant pressure switch10. Compressor relay
11. Compressor
12. Condenser cooling fan relay
13. Condenser cooling fan
14. Fuse box
15. A / C fuse 25 A
16. Ignition switch
17. Main fuse box
18. Battery main fuse 80 A19. Battery
20. Generator
21. Ignition main fuse 60 A
22. Heater/A/C main fuse 60 A
23. Ignition / meter fuse 20 A
24. Rear defogger fuse 15 A
25. Heater fuse 30 A
26. Compressor thermal switch
(only IWATA production vehicle)
FOR LH VEHICLE
1B-16 AIR CONDITIONING (OPTIONAL)
WIRING CIRCUIT
Page 88 of 801
YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-17
1. Blower motor main relay
2. Blower motor
3. Blower motor resistor
4. Blower motor switch
5. A / C controller
6. ECM
7. Heater mode control switch
8. Evaporator temperature sensor
9. Refrigerant pressure switch
FOR RH VEHICLE
10. Compressor relay
11. Compressor
12. Condenser cooling fan relay
13. Condenser cooling fan
14. Fuse box
15. A / C fuse 25 A
16. Ignition switch
17. Main fuse box
18. Battery main fuse 80 A19. Battery
20. Generator
21. Ignition main fuse 60 A
22. Heater/A/C main fuse 60 A
23. Ignition / meter fuse 20 A
24. Rear defogger fuse 15 A
25. Heater fuse 30 A
26. Compressor thermal switch
(only IWATA production vehicle)
Page 90 of 801
YH4
GRAND
VITARA
SYSTEM CIRCUIT
A. To heater fuse
B. To rear defogger fuse
C. To ignition / meter fuse
D. To A / C fuse
E. Only LH vehicle1. Blower motor relay
2. Blower motor
3. Blower motor switch
4. A / C switch
5. Deflloster position switch
6. Deflloster / foot position switch7. Dual pressure (refrigerant
pressure) switch
8. A / C thermistor (evaporator
temperature sensor)
9. Compressor relay
10. Compressor11. Condenser fan motor relay
12. Condenser fan motor
13. A / C controller
14. ECM
15. Compressor thermal switch
(only IWATA production vehicle)
TERMINAL ARRANGEMENT OF A / C CONTROLLER
TERMINAL ARRANGEMENT OF ECM FOR G16, J20 ENGINE
TERMINAL ARRANGEMENT OF ECM FOR H25 ENGINE
H25 engine
E61-27
G16, J20
engines
E61-8
H25 engine
E61-28
G16, J20
engines
E61-17
1919
19H25 engine
E61-5
G16, J20
engines
E61-22
AIR CONDITIONING (OPTIONAL) 1B-19
