Get Air Conditioning (Optional) -> On-Vehicle Service Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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

2) Check switch for continuity at specified pressure as shown.

A: Approx. 210 kPa (2.1 kg/cm

)

B: Approx. 2650 kPa (26.5 kg/cm

)

C: Approx. 230 kPa (2.3 kg/cm

)

D: Approx. 2060 kPa (20.6 kg/cm

)

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

(60 – 100 cc, 3.7 – 6.1 in

)

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

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

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)

Air Conditioning (Optional) -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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