1998-2003 Suzuki Alto 4 Door Air Conditioning (Optional) User Manual
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Air Conditioning (Optional) for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

1B
GENERAL DESCRIPTION 1B- 2. . . . . . . . . . . . . . . . .
Refrigerant Flow of Air Conditioning
System 1B- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Components and Location 1B- 3. . . . . . . . . .
DIAGNOSIS 1B- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Diagnosis Table 1B- 4. . . . . . . . . . . . . . . . .
Quickly Checking of Refrigerant Charge 1B- 6. . .
Diagnosis Test 1B- 7. . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Circuit 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C System Inspection of ECM and
Its Circuits 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Compressor Drive Belt Inspection 1B-14. . . . .
RECOVERY, EVACUATION AND
CHARGING 1B-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Recovery 1B-15. . . . . . . . . . . . . . . . . . . .
Evacuating and Charging 1B-15. . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 1B-16. . . . . . . . . . . . . . . . . . .
A/C Condenser Assembly 1B-16. . . . . . . . . . . . . . . .
Receiver/Dryer 1B-17. . . . . . . . . . . . . . . . . . . . . . . . .
Radiator (and Condenser) Cooling Fan
Motor 1B-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Unit 1B-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
A/C Evaporator Thermistor 1B-20. . . . . . . . . . . . . . .
Expansion Valve 1B-21. . . . . . . . . . . . . . . . . . . . . . . .
Dual Pressure Switch 1B-21. . . . . . . . . . . . . . . . . . . .
A/C Switch 1B-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator (and Condenser) Cooling Fan
Relay and Compressor Relay 1B-22. . . . . . . . . . .
Compressor 1B-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Magnet Clutch 1B-25. . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly of Compressor 1B-27. . . . . . . . . . . . . .
Checking Components 1B-31. . . . . . . . . . . . . . . . . .
Assembly of Compressor 1B-32. . . . . . . . . . . . . . . .
Assembly of Magnetic Clutch 1B-36. . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS 1B-37. . . . . . . . .
SPECIAL TOOLS 1B-37. . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING (OPTIONAL) 1B-1
SECTION 1B
AIR CONDITIONING (OPTIONAL)
CAUTION:
The air conditioning system of this vehicle uses refrigerant CFC-12 (R-12).
None of refrigerant, compressor oil and component parts is interchangeable between two
types of A/C: one using refrigerant CFC-12 (R-12) and the other using refrigerant HFC-134a
(R-134a).
Be sure to check which refrigerant is used before any service work including inspection and
maintenance. For identification between these two types, refer to the description in 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 oth-
er faulty condition.
For basic servicing method of the air conditioning system that is not described in this section, refer to AIR CONDI-
TIONING BASIC MANUAL (99520-02130).
CONTENTS
Whether the A/C in the vehicle being serviced uses HFC-134a
(R-134a) or CFC-12 (R-12) is indicated on LABEL on the compres-
sor. Also, it can be checked by the shape of the service (charge)
valve.
GENERAL DESCRIPTION
1. Compressor label
2. Service valve
REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM
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-2 AIR CONDITIONING (OPTIONAL)
MAJOR COMPONENTS AND LOCATION
1. Cooling unit
2. Compressor
3. Condenser assembly
4. Receiver/dryer
5. Discharge hose
6. Suction hose
7. Receiver/dryer outlet pipe
8. Condenser outlet pipe
9. Expansion valve
10. Ventilation air
11. Foot air
12. Defroster air
13. Demister air
14. Fresh air
15. Recirculation air
16. Heater unit
AIR CONDITIONING (OPTIONAL) 1B-3
1B-4 AIR CONDITIONING (OPTIONAL)
DIAGNOSIS
GENERAL DIAGNOSIS TABLE
Condition Possible Cause Correction
Cool air won’t come out
(A/C system won’t
operative)
D No refrigerant
D Fuse blown
D A/C switch faulty
D Blower fan switch faulty
D A/C thermistor faulty
D Dual pressure switch faulty
D Wiring or grounding faulty
D ECT sensor faulty
D ECM and its circuit faulty
Recover, evacuation and charging.
Check “HEATER” fuse and check short
circuit to ground.
Check A/C switch.
Check blower fan switch.
Check A/C thermistor.
Check dual pressure switch.
Repair as necessary.
Check ECT sensor.
Check ECM and its circuit.
Cool air won’t come out
(Compressor won’t
operative (won’t rotative))
D Fuse blown
D Compressor relay faulty
D ECM faulty
D Magnet clutch faulty
D Drive belt loosen or broken
D Compressor faulty
Check “A/C” fuse and check short
circuit to ground.
Check compressor relay.
Check magnet clutch.
Adjust or replace drive belt.
Check compressor.
Cool air won’t come out
(Radiator (and condenser)
cooling fan motor won’t
operative)
D “RDTR” fuse blown
D Radiator (and condenser) cooling fan
relay faulty
D Wiring or grounding faulty
D Radiator fan relay signal faulty
D Radiator (and condenser) cooling fan
motor faulty
Replace fuse and check short circuit to
ground.
Check radiator cooling fan relay.
Repair as necessary.
Check radiator fan relay signal.
Check radiator cooling fan motor.
Cool air won’t come out
(Blower motor won’t
operative)
D Fuse blown
D Blower resistor faulty
D Blower fan switch faulty
D Wiring or grounding faulty
D Blower motor faulty
Check “HEATER” fuse main heater
fuse and check short circuit to ground.
Check blower resistor.
Check blower fan switch.
Repair as necessary.
Check blower motor.
AIR CONDITIONING (OPTIONAL) 1B-5
Condition Possible Cause Correction
Cool air won’t come out or
insufficient cooling (A/C
system normal operative)
D Insufficient or excessive charge of
refrigerant
D Condenser clogged
D Evaporator clogged or frosted
D A/C thermistor faulty
D Expansion valve faulty
D Receiver/dryer clogged
D Drive belt slipping
D Magnetic clutch faulty
D Compressor faulty
D Air in A/C system
D Air leaking from cooling unit or air duct
D Heater and ventilation system faulty
D Blower motor faulty
D Excessive compressor oil existing in
A/C system
Check charge of refrigerant.
Check system for leaks.
Check condenser.
Check evaporator and A/C thermistor.
Check A/C thermistor.
Check expansion valve.
Check receiver/dryer.
Check or replace drive belt.
Check magnetic clutch.
Check compressor.
Replace receiver/dryer, and
evacuation and charging.
Repair as necessary.
Check air inlet box.
Check heater control lever assembly.
Check heater unit.
Check blower motor.
Pull out compressor oil in A/C system
circuit, and replace compressor.
Cool air won’t come out
only intermittently
D Wiring connection faulty
D Expansion valve faulty
D Excessive moisture in A/C system
D Magnetic clutch faulty
D Excessive charge of refrigerant
Repair as necessary.
Check expansion valve.
Replace receiver/dryer, and
evacuation and charging.
Check magnetic clutch.
Check charge of refrigerant.
Cool air comes out only at
high speeds
D Condenser clogged
D Insufficient charge of refrigerant
D Air in A/C system
D Drive belt slipping
D Compressor faulty
Check condenser.
Check charge of refrigerant.
Replace receiver/dryer, and
evacuation and charging.
Check or replace drive belt.
Check compressor.
Cool air won’t come out
only at high speeds
D Excessive charge of refrigerant
D Evaporator frosted
Check charge refrigerant.
Check evaporator.
Check A/C thermistor.
Insufficient velocity of
cooled air
D Evaporator clogged or frosted
D Air leaking from cooling unit or air duct
D Blower motor faulty
D Wiring or grounding faulty
Check evaporator.
Check A/C thermistor.
Repair as necessary.
Check blower motor.
Repair as necessary.
QUICKLY CHECKING OF REFRIGERANT
CHARGE
CHARGE OF REFRIGERANT
The following procedure can be used for quickly checking whether
the A/C system has a proper charge of refrigerant or not.
Run engine at fast idle, and operate A/C at its max. cooling capacity
for a few minutes. Then, look at the sight glass (1) on receiver/dryer
(2) and compare what is observed with the symptoms listed in
“CHECKING REFRIGERANT CHARGE” table given below.
3. Bubbles
1B-6 AIR CONDITIONING (OPTIONAL)
CHECKING REFRIGERANT CHARGE
Item
No.
Symptom Charge of refrigerant Correction
1 Bubbles observed in sight glass Insufficient charge of refrigerant
in system
Check system for leaks with a
leak tester.
2 No bubbles observed in sight glass No or insufficient charge of
refrigerant in system
Refer to the items 3 and 4.
3 No temperature difference between
compressor inlet and outlet
Empty or nearly empty system Evacuate and charge system
and then check it for leaks with
a leak tester.
4 Noticeable temperature difference
between compressor inlet and
outlet
Proper or too much charge of
refrigerant in system
Refer to the items 5 and 6.
5 When A/C is turned OFF,
refrigerant in sight glass clears
immediately and remains clear
Too much charge of refrigerant
in system
Discharge excess charge of re-
frigerant to adjust it to a speci-
fied charge.
6 When A/C is turned OFF,
refrigerant in sight glass once
produces bubbles and then clears
Proper charge of refrigerant in
system
NO CORRECTION NEEDED
BECAUSE CHARGE OF RE-
FRIGERANT IS NORMAL.
DIAGNOSIS TEST
1) Confirm that vehicle and environmental conditions are as fol-
lows.
– Vehicle is not exposed to direct sun.
– Ambient temperature is within 15 5C – 35 5C (59 5F – 95 5F).
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 re-
spective nuts on manifold gauge, utilizing the refrigerant pres-
sure. When a hiss is heard, immediately tighten nut.
5) Warm up engine to normal operating temperature (engine cool-
ant temperature at 80 – 90_C, 176 – 194_F) and keep it at speci-
fied idle speed.
6) Turn A/C switch ON, and set blower switch at “HI” (3rd position),
temperature knob at “COOL”, air outlet control knob at “FACE”,
fresh/circulation control knob at “CIRCULATION”. (Confirm that
A/C compressor and condenser fan are working.)
7) Keep all windows, doors and engine food open.
CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.
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.
AIR CONDITIONING (OPTIONAL) 1B-7
A/C inlet air temperature 15 – 355C (59 – 955F)
Engine rpm Keep to 1,500 rpm.
Blower fan motor switch Max. (3rd position)
Temperature control Max. cool
Air outlet control Face
Doors All open
Air inlet damper position Recirculation
9) Check for each pressure of low side and high side if it is within
shaded range of left graph.
NOTE:
Pressure registered on gauge varies with ambient tem-
perature. Therefore, use left graphs when determining if
pressures are normal or not.
Example:
If each gauge reading is out of specified pressure, correct de-
fective part referring to following Diagnosis Test table.
10) Check inlet port temperature-to-outlet port temperature rela-
tionship using graph at the left.
For example, if evaporator inlet port temperature is 25 5C (77
5F) and center duct air outlet temperature is 8 5C (46.4 5F),
their crossing point is within acceptable range as shown in
graph at the left.
11) If crossing point is out of acceptable range, diagnose trouble
referring to following Diagnosis Test table.
1B-8 AIR CONDITIONING (OPTIONAL)
Gauges should read as follows when ambient tempera-
ture is 30 5C.
Pressure on high pressure
gauge (HI):
1.18 – 1.47 MPa
12.0 – 15.0 kg/cm
2
Pressure on high pressure
gauge (LO):
0.2 – 0.3 MPa
2.0 – 3.0 kg/cm
2
AIR CONDITIONING (OPTIONAL) 1B-9
DIAGNOSIS TEST TABLE
TESTING RESULTS POSSIBLE CAUSE REMEDY
E
SSURE GAUGE
Pressure high
(“A” area of high side
graph)
D Refrigerant overcharged
D Expansion valve frozen or clogged
D Clogged refrigerant passage of high side
D Condenser fan malfunction Insufficient
cooling of
D Dirty or bent condenser fins condenser
D Compressor malfunction (Insufficient oil etc.)
D Engine overheat
D Recharge
D Check expansion valve
D Clean or replace
D Check condenser fan
D Clean or repair
D Check compressor
D Check engine cooling
system
HIGH PR
E
Pressure low
(“B” area of high side
graph)
D Insufficient refrigerant (Insufficient charge or
leakage)
D Expansion valve malfunction (valve opens too
wide)
D Compressor malfunction (Insufficient
compression)
D Check for leakage, repair if
necessary and recharge
D Check expansion valve
D Check compressor
E GAUGE
Pressure high
(“A” area of low side
graph)
D Expansion valve malfunction (valve opens too
wide)
D Compressor malfunction (Insufficient
compression)
D Check expansion valve
D Check compressor
LOW PRESSUR
E
Pressure low
(“B” area of low side
graph)
D Insufficient refrigerant (Insufficient charge or
leakage)
D Expansion valve malfunction (valve opens too
narrow)
D Clogged refrigerant passage (crashed pipe)
D Check for leakage, repair if
necessary and recharge
D Check expansion valve
D Repair or replace
M
OMETER AT
T
ER DUCT
Outlet air temperature
at center duct is high
(Crossing point is in
area “A”)
D Insufficient or excessive charge of refrigerant
D Dirty or bent evaporator fins
D Air leakage from cooling (heater) unit or air duct
D Malfunctioning, switchover function of damper
in cooling (heater) unit
D Compressor malfunction
D Check refrigerant pressure
D Clean or repair
D Repair or replace
D Repair or replace
D Check compressor
THERM
CEN
T
Outlet air temperature
at center duct is low
(Crossing point is in
area “B”)
D Insufficient air volume from center duct (Heater
blower malfunction)
D Compressor malfunction
D Check blower motor and
fan
D Check compressor
If ambient temperature is within 30 – 35 5C (86 – 95 5F), it is possible to do using next page table for detail diagnosis.
1B-10 AIR CONDITIONING (OPTIONAL)
DETAIL DIAGNOSIS TABLE AT AMBIENT TEMPERATURE WITHIN 30 – 35 5C (85 – 95 5F)
MPa
MANIFOLD kg/cm
2
GAUGE psi
CONDITION CAUSE CORRECTION
Lo Hi
0.2 – 0.3
2.0 – 3.0
28.4 – 42.6
1.18 – 1.47
12.0 – 15.0
170 – 213
Normal condition.
Negative
pressure
0.5 – 0.6
5 – 6
71.2 – 85.3
D The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.
D Presence of frost around
tubing to and from receiver/
dryer and expansion valve.
D Dust particles or water
droplets are either stuck or
frozen inside expansion
valve, preventing the re-
frigerant from flowing.
D Gas leak from heat-sensi-
tizing tube is preventing
refrigerant flow.
D Clean expansion valve.
Replace it if it cannot be
cleaned.
D Replace receiver/dryer.
D Evacuate the A/C system
and recharge with fresh re-
frigerant.
D If heat-sensitizing tube is
defective, replace expan-
sion valve.
Normal:
0.2 – 0.3
2.0 – 3.0
28.4 – 42.6
Abnormal:
Negative
pressure
µ
Normal:
1.18 – 1.47
12.0 – 15.0
170 – 213
Abnormal:
0.69 – 0.98
7 – 10
99.4 – 142
µ
D During A/C operation, the
low pressure side some-
times indicates negative
pressure, and sometimes
normal pressure. Also
high pressure side reading
fluctuates between the ab-
normal and normal pres-
sure.
D Expansion valve is frozen
due to moisture in the sys-
tem, and temporarily shuts
off the
refrigeration cycle.
D Replace expansion valve.
D Replace receiver/dryer.
D Evacuate A/C system and
recharge with fresh
refrigerant.
0.05 – 0.1
0.5 – 1.0
7.1 – 14.2
0.69 – 0.98
7 – 10
100 – 142
D Both low and high
pressure sides indicate
low readings.
D Continuous air bubbles
are visible through sight
glass.
D Output air is slightly cold.
D Insufficient refrigerant in
system.
(Refrigerant leaking)
D Using a gas leak detector,
check for leaks and repair
as necessary.
D Recharge refrigerant to a
specified amount.
If the pressure reading is al-
most 0 when the
manifold gauges are
attached, check for any
leaks, repair them, and
evacuate the system.
0.4 – 0.6
4 – 6
56.9 – 85.3
D Pressure on low pressure
side is high.
D Pressure on high pressure
side is low.
D Both pressure becoming
equal right after A/C is
turned OFF.
D Internal leak in compres-
sor.
D Inspect compressor and re-
pair or replace as
necessary.
0.25 – 0.3
25 30
1.96 – 2.45
D High pressure reading on
both low and high
pressure sides.
D Air bubbles are not visible
even when engine rpm is
lowered.
D Overcharged A/C system.
D Faulty condenser
cooling operation.
D Faulty condenser fan op-
eration.
D Adjust refrigerant to
specified amount.
D Clean condenser.
D Inspect and repair
condenser fan.
2
.
5
–
3
.
0
35.6 – 42.6
–
285 – 355
D High pressure reading on
both low and high
pressure sides.
D Low pressure side tubing
is not cold when touched.
D Air bubbles are visible
through sight glass.
D Presence of air in A/C sys-
tem.
(Improperly evacuated)
D Replace receiver/dryer.
D Inspect quantity of com-
pressor oil and presence of
contaminants in oil.
D Evacuate system and
recharge with fresh
refrigerant.
0.3 – 0.4
3.0 – 4.0
42.7 – 56.8
1.86 – 1.96
19 – 20
271 – 284
D High pressure reading on
both low and high
pressure sides.
D Large amount of frost or
dew on the low pressure
side tubing.
D Faulty expansion valve or
improper attachment of
heat-sensitizing tube.
D Refrigerant flow is not regu-
lated properly.
D Inspect if heat-sensitizing
tube is properly attached.
D Replace expansion valve.
WIRING CIRCUIT
1. Blower fan motor
2. Blower fan motor resistor
3. Blower fan motor switch
4. Dual pressure switch
5. A/C Switch
6. Fuse box
7. Radiator (and condenser) cooling fan relay
8. Radiator (and condenser) cooling fan motor
9. Compressor
10. Main relay
11. Ignition switch
12. A/C evaporator thermistor
13. ECT sensor
14. Compressor relay
AIR CONDITIONING (OPTIONAL) 1B-11
A/C SYSTEM INSPECTION OF ECM AND ITS
CIRCUITS
ECM and its Circuits can be checked at ECM wiring couplers by
measuring voltage.
CAUTION:
ECM cannot be checked by itself. It is strictly prohibited
to connect voltmeter or ohmmeter to ECM with couplers
disconnected from it.
Fig. A
Fig. B
Voltage Check
1) Remove ECM from vehicle.
2) Connect ECM couplers (2) to ECM (1).
3) Check voltage at each terminal of couplers connected.
Refer to “Inspection of ECM and its circuit” in ENGINE AND
EMISSION CONTROL SYSTEM section.
NOTE:
As each terminal voltage is affected by the battery voltage,
confirm that it is 11V or more when ignition switch is ON.
TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE)
1. Blower fan motor
2. ECM
3. Dual pressure switch
4. A/C switch
5. A/C evaporator thermistor
6. ECT sensor
7. Radiator fan relay
8. Radiator fan
9. Compressor
10. Main relay
11. Engine earth
12. Blower fan motor switch
13. Compressor relay
A. To HTR fuse 15A
B. To A/C fuse 10A
C. To RDTR fuse 30A
D. To IG fuse 15A
E. To FI fuse 15A
1B-12 AIR CONDITIONING (OPTIONAL)
AIR CONDITIONING (OPTIONAL) 1B-13
ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL
Terminal Wire Circuit
Measurement
ground
Normal value Condition
E32-301 B ECM main ground
Ground to
body (Fig A)
–0.4 – 0 volt Engine running
E32-302 B/R
Main power supply
for ECM
Ground to
engine (Fig B)
10 – 14 volts
Ignition switch ON with engine
stopped
E32-313 Bl/B
ECM ground for
power circuit
Ground to
body (Fig A)
–0.4 – 0 volt Engine running
E32-315 B/R
Power supply for
ECM power circuit
Ground to
engine (Fig B)
10 – 14 volts
Ignition switch ON with engine
stopped
E32-319 V/R Main relay drive
Ground to
engine (Fig B)
0.5 – 1.2 volt
Ignition switch ON with engine
stopped
engine
(Fig
B)
0 volt Ignition switch OFF
E32-320 Bl
Radiator (condens-
er) cooling fan relay
out
p
ut
Ground to
engine (Fig B)
0 – 1 volt
Blower fan motor switch and A/C
switch ON or engine coolant temp
sensor more than 100 5C (212 5F)
with engine running
out ut
10 – 14 volts
Except the above-mentioned with
engine running
E32-326 Bl/B
ECM ground for
power circuit
Ground to
body (Fig A)
–0.4 – 0 volt Engine running
E34-09
P/B
Blower load for Ground to
0 – 1 volt
Blower fan motor switch ON with en-
gine running
E34
-
09
P/B
blower fan input engine (Fig B)
10 – 14 volts
Blower fan motor switch OFF with
engine running
E34-19
Or/B
A/C switch in
p
ut
Ground to
0 – 1 volts
Blower fan motor switch and A/C
switch ON with engine running
E34
-
19
Or/B
A/C
switch
in ut
engine (Fig B)
10 – 14 volt
Blower fan motor switch or A/C
switch OFF with engine running
E34-22 B/G
Sensor common
ground
Ground to
body (Fig A)
–0.4 – 0 volt Engine running
E33-207
V/R
Evaporator thermis-
tor temperature
Ground to
2.0 – 2.5 volts
(2100 – 2580 W)
Evaporator thermistor temperature at
approx. 15 5C (59 5F) with engine
running
E33
-
207
V/R
(EVAP temp sen-
sor) input
engine (Fig B)
3.1 – 3.3 volts
(4600 – 5100 W)
Evaporator thermistor temperature at
approx. 0 5C (32 5F) with engine
running
E33-208
Lg/B
Engine coolant
tem
p
erature sensor
Ground to
0.71 – 0.76 volts
(290 – 320 W)
Engine coolant temperature at
approx. 80 5C (176 5F) with engine
running
E33
-
208
Lg/B
tem erature
sensor
input
engine (Fig B)
0.35 – 0.37 volts
(136 – 144 W)
Engine coolant temperature at
approx. 110 5C (230 5F) with engine
running
E33-216
P/B
Compressor mag-
net clutch relay
Ground to
0 – 1 volt
Blower fan motor switch and A/C
switch ON with engine running
E33
-
216
P/B
net
clutch
relay
output
engine (Fig B)
10 – 14 volts
Except the above-mentioned with
engine running
A/C COMPRESSOR DRIVE BELT INSPEC-
TION
1) Check belt for wear and cracks, and replace as required.
2) Check belt tension by measuring how much it deflects when
pushed at intermediate point between compressor pulley (1)
and crankshaft pulley (2) with about 100 N (10 kg, 22 lbs) force.
“a” : 7 – 9 mm (0.27 – 0.35 in.) as deflection/100N
(10 kg, 22 lbs)
If belt tension is without above specification, adjust belt tension
by according to following items.
i) Loosen mounting bolts (1) and adjust bolt (2).
ii) Adjust belt tension rotated compressor (3) by using a wood
bar.
iii) Tighten adjust bolt (2) and mounting bolt (1) as rotated com-
pressor.
iv) Turn the crank pulley one revolution, then check belt tension.
1B-14 AIR CONDITIONING (OPTIONAL)
RECOVERY, EVACUATION AND CHARGING
OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT
Recharge 600 " 60 g of
refrigerant in gas form
REFRIGERANT RECOVERY
When discharging refrigerant out of A/C system, always recover it
by using refrigerant recovery and recycling equipment.
Discharging it into atmosphere would cause adverse effect to envi-
ronments.
NOTE:
When handling recovery and recycling equipment, be sure to
follow the instruction manual for the equipment.
EVACUATING AND CHARGING
Refer to AIR CONDITIONING BASIC MANUAL
(99520-02130).
NOTE:
Specified amount of refrigerant: 600 " 60g
A: High pressure service valve
B: Low pressure service valve
1. Manifold gauge set
2. Low pressure gauge
3. High pressure gauge
4. Recovery equipment
AIR CONDITIONING (OPTIONAL) 1B-15
1. Suction hose:
Apply compressor oil (refrigerant oil) to O-ring.
2. Discharge hose:
Apply compressor oil (refrigerant oil) to O-ring.
3. Receiver/dryer outlet pipe:
Apply compressor oil (refrigerant oil) to O-ring.
4. Condenser outlet pipe:
Apply compressor oil (refrigerant oil) to O-ring.
5. Expansion valve:
Apply compressor oil (refrigerant oil) to O-ring.
6. Dual pressure switch:
Apply compressor oil (refrigerant oil) to O-ring.
A/C CONDENSER ASSEMBLY
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from refrigeration system by using recovery
and recycling equipment.
3) Remove front bumper. Refer to FRONT BUMPER in BODY
SERVICE Section.
4) Disconnect discharge hose from condenser.
5) Disconnect condenser outlet pipe from condenser.
6) Loosen radiator upper mounting bolt.
7) Remove front center member (1) by loosening its mounting
screws (2).
8) Loosen condenser mounting bolt (3).
9) Remove condenser assembly (4).
1B-16 AIR CONDITIONING (OPTIONAL)
ON-VEHICLE SERVICE
NOTE:
When refrigerant line must be disconnected and connected to remove and reinstall any component of A/C
system, be sure to observe the following instructions.
D When disconnecting any line from the system, install a blinding plug or cap to fitting of such line immedi-
ately.
D When connecting hoses and pipes to each other respectively, previously apply a few drops of compres-
sor oil (refrigerating oil) to O-ring.
INSTALLATION
Reverse removal sequence to install condenser, noting the follow-
ing point.
D If condenser is replaced, pour 15 cc of refrigerating oil to com-
pressor suction-side.
D Evacuate and charge system according to previously described
procedure.
INSPECTION
Check the following.
D Condenser fins for leakage, blockage and damage
D Condenser fittings for leakage
Clogged condenser fins should be washed with water, and should
be dried with compressed air.
NOTE:
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 con-
denser.
RECEIVER/DRYER
REMOVAL
1) Recover refrigerant from refrigeration system by using recovery
and recycling equipment.
2) Disconnect receiver/dryer outlet pipe (1) and condenser outlet
pipe (2) from receiver/dryer (3).
3) Loosen receiver/dryer bracket bolts (4).
4) Remove receiver/dryer with its bracket (5).
INSTALLATION
Reverse removal sequence to install receiver/dryer noting the fol-
lowing points.
D If receiver/dryer (1) is replaced, pour 20 cc of refrigerating oil to
compressor suction-side.
D Evacuate and charge system according to previously described
procedure.
D Install receiver/dryer (1) to its bracket (2) as shown in figure.
“a” 205
AIR CONDITIONING (OPTIONAL) 1B-17
RADIATOR (AND CONDENSER) COOLING
FAN MOTOR
INSPECTION
Check continuity between each two terminals about the radiator
(and condenser) cooling fan motor (1).
If check results are continuity, proceed to next operation check.
If not, replace.
Connect battery to radiator (and condenser) cooling fan motor (1)
as shown in figure, then check that the radiator (and condenser)
cooling fan motor operates smoothly.
Reference current : approx. 8.5 – 11.5 A at 12 V
REMOVAL AND INSTALLATION
Refer to RADIATOR in ENGINE COOLING SYSTEM Section.
1B-18 AIR CONDITIONING (OPTIONAL)
COOLING UNIT (EVAPORATOR)
1. Evaporator
2. A/C Evaporator thermistor
(Evaporator temperature sensor)
3. Expansion valve
4. Evaporator case
5. Packing
6. Drain hose
7. Air inlet door
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from refrigeration system by using recovery
and recycling equipment.
3) Remove fresh air control cable (1) and disconnect evaporator
thermistor coupler (2).
4) Loosen suction hose and receiver/dryer outlet hose.
5) Open glove box lid (8).
6) Loosen cooling unit mounting bolts (3), nut (4) and screws (5).
7) Loosen instrument panel mounting bolt (6).
8) Remove cooling unit (7).
INSTALLATION
Reverse removal sequence to install cooling unit, noting the follow-
ing points.
D If cooling unit or evaporator is replaced, pour 25 cc of refrigerat-
ing oil to compressor suction-side.
D Install uniformly the evaporator pipe (1) to grommet.
AIR CONDITIONING (OPTIONAL) 1B-19
D Evacuate and charge system according to previously described
procedure.
D Adjust fresh air control cable, refer to HEATER CONTROL LE-
VER ASSEMBLY in HEATER AND VENTILATION section.
D Install the cutting part of drain hose (1) downward as shown in
figure.
INSPECTION
Check the following
D Evaporator fins for leakage, blockage and damage.
D Evaporator fittings for leakage.
Clogged evaporator fins should be washed with water, and should
be dried with compressed air.
NOTE:
D 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.
D When the thermistor removed, its should be reinstalled in
original position.
A/C EVAPORATOR THERMISTOR
Check resistance between evaporator thermistor (1) terminals.
If check results are as not specified, replace thermistor.
NOTE:
When the thermistor removed, its should be reinstalled in
original position.
1B-20 AIR CONDITIONING (OPTIONAL)
Sensor Temperature (5C (5F)) Resistance (kW)
0 (32) 4.6 – 5.1
15 (59) 2.1 – 2.6
EXPANSION VALVE
INSPECTION
Refer to “Troubleshooting Procedure Using Manifold Gauge Set”
earlier in this Section.
DUAL PRESSURE SWITCH
INSPECTION
1) Check dual pressure switch (1) for continuity at normal temper-
ature (approx. 255C (775F)) when A/C system has a proper
charge of refrigerant and when A/C system (compressor) is un-
der operation. In each of these cases, switch should show prop-
er continuity.
Pressure
AB
CD
2) Check switch for continuity at specified pressure as shown.
A: Approx. 210 kPa (2.1 kg/cm
2
)
B: Approx. 2650 kPa (26.5 kg/cm
2
)
C: Approx. 230 kPa (2.3 kg/cm
2
)
D: Approx. 2060 kPa (20.6 kg/cm
2
)
Tightening torque for dual pressure switch
10 N·m (1.0 kg-m, 8.0 lb-ft)
Continuity
No continuity
A/C SWITCH
REMOVAL
1) Disconnect A/C switch coupler from instrument panel harness.
2) Remove meter cluster, refer HEATER CONTROL LEVER in
section 1A.
3) Pull out A/C switch by unlock the locking part.
INSPECTION
D Press A/C Switch button and check if there is continuity between
terminals “A” and “B”.
D With battery voltage (+) connected to terminal “C” and (–) to ter-
minal “A”, press A/C Switch button and check if indicator lamp
lights.
INSTALLATION
Reverse removal procedure for installation.
1. Blower fan and A/C switch
AIR CONDITIONING (OPTIONAL) 1B-21
RADIATOR (AND CONDENSER) COOLING
FAN RELAY AND COMPRESSOR RELAY
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove radiator cooling fan relay (1) and compressor relay (2)
from vehicle.
3) Check that there is no continuity between terminal “c” and “d”.
If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “b” of relay.
Connect battery negative (–) terminal “a” of relay.
Check continuity between terminal “c” and “d”.
If there is no continuity when relay is connected to the battery,
replace relay.
1B-22 AIR CONDITIONING (OPTIONAL)
COMPRESSOR
REMOVAL
1) RUN engine at idle speed with air conditioning ON for 10 min-
utes. After that stop the engine.
2) Disconnect negative (–) cable at battery.
3) Recover refrigerant from refrigeration system by using recov-
ery and recycling equipment.
4) Remove air cleaner and its hose.
5) Disconnect magnet clutch lead wire coupler.
6) Disconnect suction and discharge hoses from compressor.
NOTE:
Cap open fittings immediately to keep moisture out of
system.
7) Remove compressor mounting bolts (1) and adjusting bolt (2)
as keep compressor in that position.
8) Remove compressor upper bracket (3) by loosening it mount-
ing bolt (4).
9) Remove compressor with magnet clutch assembly (5).
10) If compressor is replaced.
Drain oil from compressor, and measure its amount.
11) Remove compressor lower bracket (6) by loosening mount
bolts (7).
INSTALLATION
Reverse removal procedure noting the following points.
D If compressor is replaced, pour new compressor oil with the
same amount as that drained from compressor in REMOVAL.
Refer to “REPLENISHING COMPRESSOR OIL” in this section.
D Evacuate and charge system according to previously described
procedure.
1. New compressor
2. Removed
compressor
3. Excess oil (A–B)
AIR CONDITIONING (OPTIONAL) 1B-23
D Adjust drive belt tension. Refer to “DRIVE BELT INSPECTION”
in this Section.
CAUTION:
Be sure to use CFC-12 (R-12) compressor oil.
NOTE:
Compressor assembly supplied from factory is filled up
with the following amount of oil.
Oil amount in compressor: 60 – 100 cm
3
(60 – 100 cc, 3.7 – 6.1 in
3
)
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 50cc oil. When replenishing gas only, oil replen-
ishment 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
1. New compressor
2. Removed compressor
3. Excess oil (A–B)
When replacing other part
1B-24 AIR CONDITIONING (OPTIONAL)
Part replaced
Amount of compressor oil
to be replenished
Evaporator 25 cc
Condenser 15 cc
Receiver/dryer 20 cc
Hoses 10 cc each
Pipes 10 cc each
MAGNET CLUTCH
1. Pressure plate
2. Shim
3. Circlip
4. Drive clutch
5. Magnetic clutch coil
6. Compressor
7. Pressure plate nut
INSPECTION
a. Inspect clutch plate and clutch pulley for signs of oil.
b. Check clutch pulley bearings for noise and grease leakage.
c. Using ohmmeter, measure resistance of clutch coil between
clutch lead wire and compressor body ground.
If measured resistance is not within tolerance, replace coil.
Standard resistance: 3.0 – 3.5 W at 20 5C, 68 5F
1) Fix Pressure plate with special tool (A) and then remove pres-
sure plate nut and washer.
Special Tool
(A): 09991-06020
2) Remove pressure plate (1) by using a special tool (B).
Special Tool
(B): 09990-58210
AIR CONDITIONING (OPTIONAL) 1B-25
3) Remove shims from shaft.
4) Remove circlip by using special tool (C).
Special Tool
(C): 09900-06107
5) Whith special tool (D) in place, remove drive clutch (3) from
compressor (2) with puller (1).
6) Disconnect coil lead wire from compressor housing.
7) Remove circlip by using special tool (C).
8) Remove clutch coil (1).
Special Tool
(C): 09900-06107
1B-26 AIR CONDITIONING (OPTIONAL)
DISASSEMBLY OF COMPRESSOR
10. Cylinder seal
11. Compressor cylinder
12. Cylinder seal
13. Suction valve
14. Valve front plate
15. Reed valve
16. Front gasket
17. Cylinder front head
18. Blank
19. “O” ring
20. Seal plate
21. Circlip
22. Oil felt
23. Joint service connector bolt
24. Housing through bolt
1. Joint service connector
2. Diffuser seal
3. “O” ring
4. Diffuser
5. Rear housing
6. Rear gasket
7. Reed valve
8. Valve rear plate
9. Suction valve
AIR CONDITIONING (OPTIONAL) 1B-27
1) Pry out oil ring (1) by using like a screwdriver, and then remove
oil felt (2).
2) Remove key (1) from shaft by using a hammer and punch.
3) Remove circlip (1) by using special tool (E).
Special Tool
(E): 09900-06108
4) Apply compressor oil to inner bore.
5) Remove lip seal by using special tool (F). The following explains
this removal procedure.
a. Fit special tool (F) into the clutch installation boss.
Special Tool
(F): 09990-48220
1B-28 AIR CONDITIONING (OPTIONAL)
b. Turn special tool (F) unit its protrusion (1) engages with the
groove (3) provided on lip seal (2).
c. Check that special tool (F) goes down slightly when the protru-
sion (1) and groove (3) are engaged.
d. Turn special tool (F) by 305 – 605.
e. Pull up special tool (F) to remove lip seal (1).
6) Remove joint service connector (1).
7) Remove “O” rings from service connector and discard them.
8) Drain oil into container.
9) Remove front housing.
NOTE:
Do not reuse five washers.
1. Bolt
2. Washer
AIR CONDITIONING (OPTIONAL) 1B-29
10) Remove front housing (2) by prying its protrusion (1).
NOTE:
Be careful not to scratch sealing surface of front housing.
11) Remove front valve plate (2).
Remove two pins (1) from cylinder block.
12) Remove the rear housing (2) by prying its protrusion (1).
NOTE:
Be careful not to scratch sealing surface of rear housing.
13) Remove rear valve plate (2).
Remove two pins (1) from rear housing.
14) Remove front and rear “O” rings (2) from cylinder block (1) and
discard them.
1B-30 AIR CONDITIONING (OPTIONAL)
AIR CONDITIONING (OPTIONAL) 1B-31
CHECKING COMPONENTS
Clean all parts with cleaning solvent and apply compressor oil to them.
PARTS NAME CHECK POINT REMEDY
Lip seal
1. Check sealing surface for scratches and corro-
sion.
Replace
Valve plate
1. Check both surfaces for scratches and corro-
sion.
Replace or polish with
fine oil stone.
Red valve
1. Check reed for cracks, scratches, deformation
and corrosion.
Replace
Front housing
1. Check sealing surface for cracks scratches and
deformation.
Replace
Piston/Cylinder block
1. Check cylinder bore for scratches and corrosion.
2. Check radial bearings for poor contact, worn-out
needle, scoring or pit.
3. Check shaft for excessive axial play.
4. Check piston for excessive axial play.
Replace
Replace
Replace
Replace
Rear housing
1. Check sealing surface for cracks, scratches and
deformation.
Replace
ASSEMBLY OF COMPRESSOR
NOTE:
D Do not re-use gasket shaft seal, O-rings, or washers. Use
overhaul gasket kit.
D Before starting assembly, make sure all parts and work-
bench are clean.
1) Install rear valve plate (2) on rear cylinder.
a. Install two pins in rear cylinder.
b. Lubricate new O-ring with compressor oil.
Install O-ring in rear cylinder.
c. Install suction reed valve (1), rear valve plate (2), and discharge
reed valve (3) onto rear cylinder top.
For installing positions, refer to the figure.
NOTE:
D Front and rear reed valves (suction and discharge) are
the same.
D Rear valve plate is marked “R”.
4. Pin holes
d. Lubricate gasket (1) with compressor oil. Install gasket (1) on
valve plate.
NOTE:
D Front and rear gasket are different, so do not interchange
them.
D Assemble gasket so that their protruded surfaces face up-
ward.
1B-32 AIR CONDITIONING (OPTIONAL)
2) Install rear housing (2) on rear cylinder.
Housing protrusion (1) is positioned at the top.
3) Install front valve plate (2) on front cylinder.
a. Install two pins in front cylinder.
b. Lubricate new O-ring with compressor oil.
Install O-ring in front cylinder.
c. Install suction reed valve (1), front valve plate (2), and discharge
reed valve (3) onto front cylinder top.
For installing positions, refer to figure.
NOTE:
D Front and rear reed valves (suction and discharge) are
the same.
D Front valve plate is marked “F”.
4. Pin holes
d. Lubricate gasket (1) with compressor oil. Install gasket (1) on
valve plate.
NOTE:
D Front and rear gaskets are different, so do not inter-
change them. (To differentiate them, refer to description
on rear valve plate.)
D Assemble gaskets so that their protruded surfaces face
upward.
4) Install front housing (1) on front cylinder and tighten five through
bolts.
a. Using a torque wrench and hexagon wrench, gradually tighten
five through bolts.
NOTE:
Housing protrusion (2) is positioned at the top.
Tightening Torque
(a): 26 N·m (2.0 kg-m, 19 lb-ft)
AIR CONDITIONING (OPTIONAL) 1B-33
5) Install lip seal.
a. Coat special tool (G) surface with oil and install it to the shaft (1).
Special Tool
(G): 09990-58230
b. Apply oil lip seal O-ring and install it over special tool (E). When
fitting lip seal over the special tool, care should be taken so as
not to confuse its designated direction. The illustration left
shows the designated direction.
CAUTION:
Do not reuse lip seal once removed from compressor.
1. Lip seal
2. O-ring
3. Seal
c. Press it slowly by hand until lip seal (4) contacts the stopper (3)
of front housing (2) by using special tool (H).
Special Tool
(H): 09990-58220
NOTE:
With lip seal pressed in completely, its upper face must
come to the position lower than the circlip fitting groove.
Check this condition visually. Do not use a press machine,
hammer, etc. when pressing.
1. Circlip installation groove
6) Install circlip.
7) Install key (1) in shaft groove.
a. Tap key lightly by using a plastic hammer and special tool (I).
Special Tool
(I): 09990-28210
1B-34 AIR CONDITIONING (OPTIONAL)
8) Install new oil felt (1) to inside the bore, and then install ring (2)
to inside the bore.
2. Ring
9) Pour compressor oil into compressor.
NOTE:
Compressor assembly supplied from factory is filled up
with 60 – 100 cc oil. Therefore, when replacing compres-
sor assembly with new one, drain 40 cc oil from it.
The rest 40 cc oil remain in parts except compressor.
Additional oil after
compressor overhauling: 40 cc (2.4 cu. in.)
Oil capacity in
air conditioner system: 60 – 100 cc (3.7 – 6.1 in
3
.)
10) Install service connector.
a. Lubricate new O-rings (3) with compressor oil and install them
in service connector (1).
b. Install service connector (1) to compressor.
NOTE:
Suction port has larger internal opening than discharge
port.
Tightening Torque
(a): 26 N·m (2.6 kg-m, 19 lb-ft)
2. Diffuser seal
4. Diffuser
11) Check shaft rotating torque.
Rotating Torque
Less than 3.0 N·m (0.3 kg-m, 2.2 lb-ft)
AIR CONDITIONING (OPTIONAL) 1B-35
ASSEMBLY OF MAGNETIC CLUTCH
1) Install magnetic clutch coil (5).
2) Install drive clutch (4).
a. Install drive clutch (4) to compressor (6) shaft.
b. Using snap ring pliers, install snap ring (3).
1. Pressure plate
2. Shim
3) Install pressure plate.
a. Adjust clearance between pressure plate (1) and drive clutch
(2) by putting shims on compressor shaft.
Standard clearance “a”: 0.4 – 0.7 mm (0.016 – 0.028 in.)
b. Fix pressure plate (1) with special tool (A) then tighten pressure
plate fixing nut as specified below.
Special Tool
(A): 09991-06020
Tightening Torque:
16.5 N·m (16.5 kg-m, 12.0 lb-ft)
1B-36 AIR CONDITIONING (OPTIONAL)

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