2007 SUZUKI SWIFT Refrigerant

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Charge
CAUTION!
• Because the sight glass is not used for this A/C system, do not perform an additional
charge to the A/C system. To charge the
proper amount of refrigerant, recover and
evacuate the A/C system first. And then,
charge the proper amount of refrigerant
into the A/C system.
• Always charge refrigerant through low pressure side of A/C system after the initial
charge is performed from the high
pressure side with the engine stopped.
• Never charge refrigerant through high pressure side of A/C system with engine
running.
• Do not charge refrigerant while compressor is hot.
• When installing tap valve to refrigerant container to make a hole there through,
carefully follow dire ctions given by
manufacturer.
• A pressure gauge should always be used before and during refrigerant charge.
• 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 refrigerant
charge. 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 recycling refrigerant),
follow the procedure described in the
equipment manufacturer’s instruction
manual.

Charge proper amount of refrigerant accurately in
accordance with the following procedure.
Specified amount of refrigerant
370 ± 20 g (13.0 ± 0.7 oz)
The initial charge of the A/C system is performed
through 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 if hoses are routed properly after evacuating the system.
2) Connect low charging hose (1) and high charging hose (2) of the manifold gauge set (3) in position.
Then, open refrigerant container valve (4) to purge
the charging line.
3) Open the high pressure side valve (5) and charge refrigerant to system.
4) After a while, open the low pressure side valve (6) and close the high pressure side valve.
WARNING!
Make sure that high pressure side valve is
closed securely.

5) Start engine and keep engine speed at 1500 r/min, and then operate A/C system.
6) Charge A/C system with refrigerant in vapor state. At this time, refrigerant container should be held
upright.
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7) When refrigerant container (1) is emptied, use the following procedure to replace it with a new
refrigerant container.
a) Close low pressure valve.
b) Replace empty container with a refrigerant container which has been charged with
refrigerant. When using refrigerant container tap
valve (2), use the following procedure for
replacement.
i) Retract needle (3) and remove refrigerant container tap valve by loosening its plate nut
(4).
ii) Install the refrigerant container tap valve to a new refrigerant container.
c) Purge any air existing in center charging hose. When using refrigerant container tap valve, use
the following procedure to purge air.
i) Once fully tighten refrigerant container tap valve (1), and then loosen (open) plate nut
(2) slightly.
ii) Open low pressure side valve (3) of manifold
gauge set (4) 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 low pressure side valve.
iv) Turn handle of tap valve clockwise so that its needle is screwed into the new container to
make a hole for refrigerant flow. 8) After the system has been charged with specified
amount (370 ± 20 g) of refrigerant or when low
pressure gauge (1) and high pressure gauge (2)
have indicated the following specified value, close
low pressure side valve (3) on manifold gauge set
(4).
Low side and high side pressure example
I2RH01720018-01
I2RH01720019-01
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
Pressure
on high pressure gauge 1590 – 1940 kPa
15.9 – 19.4 kg/cm
2
226 – 276 psi
Pressure
on low pressure gauge 270 – 430 kPa
2.7 – 4.3 kg/cm
2
38 – 61 psi
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I4RS0A720016-01

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Removal of Manifold Gauge Set
WARNING!
High pressure side is under high pressure.
Therefore, be careful not to get injured
especially on your eyes and skin.

For the A/C system charged with the specified amount of
refrigerant, 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 quickly.
5) Put caps on service valves.
Check A/C System for Refrigerant Leaks
Whenever a refrigerant leak is suspected in the system
or any service operation has been performed which may
result in malfunction of lines and connections, it is
advisable to check for leaks.
Common sense should be used during refrigerant leak
test, since the need and extent of any such test will, in
general, depend upon the nature of a complaint and the
type of a service performed on the system.
Liquid leak detector
WARNING!
• To prevent explosions and fires, make sure that there are no flammables in the vicinity.
• When the refrigerant exposed to fire, it turns into a poisonous gas (phosgene). Do
not inhale this gas.

There is a number of fittings and places throughout the
A/C 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, such as attached to the cap of a vial,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator
and condenser, an electronic (refrigerant) leak detector
is more practical fo r determining leaks.
Special tool
(A): 09990–86012
Condenser Assembly On-Vehicle InspectionS7RS0B7216002
Check the followings.
• Clog of condenser fins If any clog is found, cond enser fins should be washed
with water and should be dried with compressed air.
• Condenser fins for leakage and breakage If any defects are found, repair or replace condenser.
• Condenser fittings for leakage. If any defects are found, repair or replace condenser.
Condenser Assembly Removal and InstallationS7RS0B7216003
CAUTION!
Do not damage condenser fins. If condenser
fin is bent, straighten it by using flat head
screwdriver or pair of pliers.

Removal
1) Recover refrigerant from A/C system referring to “Operation Procedure for Refrigerant Charge”.
NOTE
The amount of removed compressor oil must
be measured for replenishing compressor
oil.

2) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
3) Disconnect discharge hose (1) and liquid pipe (2) from condenser assembly (3).
4) Remove condenser assembly mounting bolts (4).
(A)
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5) Remove condenser assembly (1) as shown.
Installation
Reverse the removal procedure to install condenser
noting the following instructions.
• Replenish specified amount of compressor oil to compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Receiver/Dryer Removal and InstallationS7RS0B7216031
Removal
1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove receiver/dryer bolt (1), and then remove receiver/dryer (2) from condenser.
3) Remove joints (3) and O-rings (4). Installation
Reverse the removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “When replacing
other parts” in “Operation Procedure for Refrigerant
Charge”.
• Use new receiver/dryer and O-ring.
• Do not remove plug from receiver/dryer until just before installin g it condenser.
• Apply compressor oil to O-ring.
: Compressor oil 99000–99015–00A
(MATSUSHITADENKI GU10)
• Tighten receiver/dryer bolts to the specified torque. Tightening torque
Receiver/dryer bolt: 10 N· m (1.0 kgf-m, 7.5 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
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HVAC Unit Removal and InstallationS7RS0B7216006
Removal1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
4) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
5) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
6) Remove instrument panel from vehicle body referring to “Audio Unit Re moval and Installation in
Section 9C”.
7) Loosen suction hose and liquid pipe bolt (4).
8) Remove nuts (3).
9) Remove HVAC unit from vehicle body. Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole uniformly.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust control cables referr ing to “HVAC Control Unit
Removal and Installati on in Section 7A”.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Evaporator InspectionS7RS0B7216007
Check the followings.
• Clog of A/C evaporator fins.If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage. If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage. If any defects are found, repair or replace A/C
evaporator.
2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing
3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever21. Filter cover (if equipped)
4. HVAC Air filter (if equipped) 10. Blower lower case 16. Evaporator22. Drain hose
5. Heater unit upper case 11. Blower motor 17. O-ring23. Cable lock clamp
6. Foot duct 12. Heater unit lower case 18. Expansion valve: Do not reuse.
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Expansion Valve Removal and InstallationS7RS0B7216010
Removal1) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Loosen a bolt (1) and remove pipes from expansion valve (2).
3) Loosen bolts (3) and remove expansion valve.
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of expansion valve and pipes.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Tightening torque
Expansion valve mount bolt: 3.5 N·m (0.35 kgf-m,
2.5 lb-ft)
Expansion Valve InspectionS7RS0B7216011
Refer to “A/C System Performance Inspection”.
A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
S7RS0B7216012
1) Disconnect A/C refrigerant pressure sensor connector.
2) Turn ignition switch to ON position.
3) Check if voltage between “RED” wire terminal and “ORN” wire terminal of A/C refrigerant pressure
sensor connector is 4.75 V to 5.25 V.
If not, check A/C refrigerant pressure sensor circuit.
4) Connect A/C refrigerant pressure sensor connector with ignition switch turned OFF.
5) Connect manifold gauge set to the charging valves.
6) Check A/C refrigerant pressure sensor voltage of ECM connector referring to “A/C System Inspection
at ECM”.
If voltage is not as specified below, replace A/C
refrigerant pressure sensor. A/C refrigerant pressure sensor voltage
specifications (A/C refrigerant pressure measured
by manifold gauge)
0.8 MPa (8.0 kg/cm2, 116 psi): 1.46 – 1.71 V
1.4 MPa (14 kg/cm2, 203 psi): 2.28 – 2.53 V
1.6 MPa (16 kg/cm2, 232 psi): 2.55 – 2.80 V
1.8 MPa (18 kg/cm2, 261 psi): 2.82 – 3.03 V
A/C Refrigerant Pressure Sensor Removal and
Installation
S7RS0B7216013
Removal
1) Recover refrigerant from the A/C system with the recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Disconnect negative (–) cable from battery.
3) Disconnect A/C refrigerant pressure sensor connector.
4) Remove A/C refrigerant pressure sensor (1) from liquid pipe (2).
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of A/C refrigerant
pressure sensor.
• Tighten A/C refrigerant pressure sensor to specified torque.
Tightening torque
A/C refrigerant pressure sensor (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
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(a)I4RS0A720031-01

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Compressor Drive Belt Removal and
Installation
S7RS0B7216017
Removal1) Loosen tension pulley nut (1).
2) Loosen belt tension by loosening tension pulley adjusting bolt (2).
3) Remove compressor drive belt (3).
Installation
Reverse removal procedure noting the following
instruction.
• Adjust belt tension referring to “Compressor Drive Belt Inspection and Adjustment”.
Compressor Assembly Removal and
Installation
S7RS0B7216018
Removal
1) Run engine at idle speed with A/C ON for 10 minutes.
2) Stop the engine.
3) Disconnect negative (–) cable from battery.
4) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
5) Remove compressor drive belt referring to “Compressor Drive Belt Re moval and Installation”.
6) Remove right side engine under cover.
7) Disconnect magnet clutch lead wire coupler (1).
8) Disconnect discharge hose (2) and suction hose (3) from compressor (4).
NOTE
Cap open fittings immediately to keep
moisture out of the system.

9) Remove compressor mounting bolts (1), and then remove compressor (2 ) from its bracket.
Installation
Reverse removal procedure noting the following
instructions.
• If compressor is replaced, pour new compressor oil referring to “Replenishi ng Compressor Oil” in
“Operation Procedure for Refrigerant Charge”.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust drive belt tension referring to “Compressor Drive Belt Inspecti on and Adjustment”.
I4RS0A720034-01
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4) Install magnet clutch lead wire clamp.
5) Install magnet clutch pulley (1).
6) Install new circlip (2) directing chamfer side (3) upward.
Special tool
(B): 09900–06107
7) Tighten armature plate bolt to specified torque. Tightening torque
Armature plate bolt (a): 15 N·m (1.5 kgf-m, 11.0
lb-ft)
Special tool
(A): 09991–06310
8) Adjust clearance between magnet clutch plate (1) and magnet clutch pulley by putting shim(s) on
compressor shaft. To measure the clearance,
perform the following steps.
a) Put compressor in a vise (2).
b) Set dial gauge (3) on magnet clutch plate, and then adjust its pointer at 0.
c) Connect battery positive terminal (+) to magnet clutch coil lead wire.
d) Connect battery negative terminal (–) to compressor body assemb ly. (At this point,
magnet clutch plate and magnet clutch pulley are
kept in contact.) e) Disconnect battery negative terminal (–) to
compressor body assembly. (At this point,
magnet clutch plate and magnet clutch pulley are
not in contact.)
f) Read stroke of magnet clutch plate from dial gauge by performing step d) and e) repeatedly.
(Stroke of magnet clutch plate is clearance
between magnet clutch plate and magnet clutch
pulley.)
Standard clearance between magnet clutch plate
and magnet clutch plate
0.3 – 0.5 mm (0.012 – 0.020 in.)
Relief Valve InspectionS7RS0B7216028
By using special tool, chec k if there is refrigerant
leakage. If there is refrigerant leakage, replace the relief
valve.
Special tool
(A): 09990–86012
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(a)
(A)
I4RS0A720045-01
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(A)
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