AIR CONDITIONING (OPTIONAL) 1B-1

SECTION 1B

AIR CONDITIONING (OPTIONAL)

1B
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
GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . 1B- 2 Receiver/Dryer . . . . . . . . . . . . . . . . . . . . . . . . . 1B-17
Refrigerant Flow of Air Conditioning Radiator (and Condenser) Cooling Fan
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 2 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18
Major Components and Location . . . . . . . . . . 1B- 3 Cooling Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-19
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 4 A/C Evaporator Thermistor . . . . . . . . . . . . . . . 1B-20
General Diagnosis Table . . . . . . . . . . . . . . . . . 1B- 4 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . 1B-21
Quickly Checking of Refrigerant Charge . . . 1B- 6 Dual Pressure Switch . . . . . . . . . . . . . . . . . . . . 1B-21
Diagnosis Test . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- 7 A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-21
Wiring Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-11 Radiator (and Condenser) Cooling Fan
A/C System Inspection of ECM and Relay and Compressor Relay . . . . . . . . . . . 1B-22
Its Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22
A/C Compressor Drive Belt Inspection . . . . . 1B-14 Magnet Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25
Disassembly of Compressor . . . . . . . . . . . . . . 1B-27
RECOVERY, EVACUATION AND
Checking Components . . . . . . . . . . . . . . . . . . 1B-31
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . 1B-15 Assembly of Compressor . . . . . . . . . . . . . . . . 1B-32
Evacuating and Charging . . . . . . . . . . . . . . . . 1B-15 Assembly of Magnetic Clutch . . . . . . . . . . . . . 1B-36
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 1B-16 REQUIRED SERVICE MATERIALS . . . . . . . . . 1B-37
A/C Condenser Assembly . . . . . . . . . . . . . . . . 1B-16 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . 1B-37
1B-2 AIR CONDITIONING (OPTIONAL)

GENERAL DESCRIPTION
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.

1. Compressor label
2. Service valve

REFRIGERANT FLOW OF AIR CONDITIONING SYSTEM

: Liquid

: Vapor

: Superheated Vapor

1. Compressor
2. Magnet clutch
3. Condenser assembly
4. Receiver/dryer
5. Dual pressure switch
6. Expansion valve
7. Evaporator
 AIR CONDITIONING (OPTIONAL) 1B-3

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
1B-4 AIR CONDITIONING (OPTIONAL)

DIAGNOSIS
GENERAL DIAGNOSIS TABLE

Condition Possible Cause Correction

Cool air won’t come out
No refrigerant Recover, evacuation and charging.
(A/C system won’t
Fuse blown Check “HEATER” fuse and check short
operative) circuit to ground.

A/C switch faulty Check A/C switch.

Blower fan switch faulty Check blower fan switch.

A/C thermistor faulty Check A/C thermistor.

Dual pressure switch faulty Check dual pressure switch.

Wiring or grounding faulty Repair as necessary.

ECT sensor faulty Check ECT sensor.

ECM and its circuit faulty Check ECM and its circuit.

Cool air won’t come out
Fuse blown Check “A/C” fuse and check short
(Compressor won’t circuit to ground.
operative (won’t rotative))
Compressor relay faulty Check compressor relay.

ECM faulty

Magnet clutch faulty Check magnet clutch.

Drive belt loosen or broken Adjust or replace drive belt.

Compressor faulty Check compressor.

Cool air won’t come out
“RDTR” fuse blown Replace fuse and check short circuit to
(Radiator (and condenser) ground.
cooling fan motor won’t
Radiator (and condenser) cooling fan Check radiator cooling fan relay.
operative) relay faulty

Wiring or grounding faulty Repair as necessary.

Radiator fan relay signal faulty Check radiator fan relay signal.

Radiator (and condenser) cooling fan Check radiator cooling fan motor.
motor faulty

Cool air won’t come out
Fuse blown Check “HEATER” fuse main heater
(Blower motor won’t fuse and check short circuit to ground.
operative)
Blower resistor faulty Check blower resistor.

Blower fan switch faulty Check blower fan switch.

Wiring or grounding faulty Repair as necessary.

Blower motor faulty Check blower motor.
 AIR CONDITIONING (OPTIONAL) 1B-5

Condition Possible Cause Correction

Cool air won’t come out or
Insufficient or excessive charge of Check charge of refrigerant.
insufficient cooling (A/C refrigerant Check system for leaks.
system normal operative)
Condenser clogged Check condenser.

Evaporator clogged or frosted Check evaporator and A/C thermistor.

A/C thermistor faulty Check A/C thermistor.

Expansion valve faulty Check expansion valve.

Receiver/dryer clogged Check receiver/dryer.

Drive belt slipping Check or replace drive belt.

Magnetic clutch faulty Check magnetic clutch.

Compressor faulty Check compressor.

Air in A/C system Replace receiver/dryer, and
evacuation and charging.

Air leaking from cooling unit or air duct Repair as necessary.

Heater and ventilation system faulty Check air inlet box.
Check heater control lever assembly.
Check heater unit.

Blower motor faulty Check blower motor.

Excessive compressor oil existing in Pull out compressor oil in A/C system
A/C system circuit, and replace compressor.

Cool air won’t come out
Wiring connection faulty Repair as necessary.
only intermittently
Expansion valve faulty Check expansion valve.

Excessive moisture in A/C system Replace receiver/dryer, and
evacuation and charging.

Magnetic clutch faulty Check magnetic clutch.

Excessive charge of refrigerant Check charge of refrigerant.

Cool air comes out only at
Condenser clogged Check condenser.

high speeds
Insufficient charge of refrigerant Check charge of refrigerant.

Air in A/C system Replace receiver/dryer, and
evacuation and charging.

Drive belt slipping Check or replace drive belt.

Compressor faulty Check compressor.

Cool air won’t come out
Excessive charge of refrigerant Check charge refrigerant.
only at high speeds
Evaporator frosted Check evaporator.
Check A/C thermistor.

Insufficient velocity of
Evaporator clogged or frosted Check evaporator.

cooled air Check A/C thermistor.

Air leaking from cooling unit or air duct Repair as necessary.

Blower motor faulty Check blower motor.

Wiring or grounding faulty Repair as necessary.
1B-6 AIR CONDITIONING (OPTIONAL)

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
3. Bubbles “CHECKING REFRIGERANT CHARGE” table given below.

CHECKING REFRIGERANT CHARGE

Item
Symptom Charge of refrigerant Correction
No.
1 Bubbles observed in sight glass Insufficient charge of refrigerant Check system for leaks with a
in system leak tester.
2 No bubbles observed in sight glass No or insufficient charge of Refer to the items 3 and 4.
refrigerant in system
3 No temperature difference between Empty or nearly empty system Evacuate and charge system
compressor inlet and outlet and then check it for leaks with
a leak tester.
4 Noticeable temperature difference Proper or too much charge of Refer to the items 5 and 6.
between compressor inlet and refrigerant in system
outlet
5 When A/C is turned OFF, Too much charge of refrigerant Discharge excess charge of re-
refrigerant in sight glass clears in system frigerant to adjust it to a speci-
immediately and remains clear fied charge.
6 When A/C is turned OFF, Proper charge of refrigerant in NO CORRECTION NEEDED
refrigerant in sight glass once system BECAUSE CHARGE OF RE-
produces bubbles and then clears FRIGERANT IS NORMAL.
 AIR CONDITIONING (OPTIONAL) 1B-7

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
C – 35
C (59
F – 95
F).
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.

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 – 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.

A/C inlet air temperature 15 – 35
C (59 – 95
F)

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
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.
1B-8 AIR CONDITIONING (OPTIONAL)

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:
Gauges should read as follows when ambient tempera-
ture is 30
C.
Pressure on high pressure 1.18 – 1.47 MPa
gauge (HI): 12.0 – 15.0 kg/cm2
Pressure on high pressure 0.2 – 0.3 MPa
gauge (LO): 2.0 – 3.0 kg/cm2

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
C (77

F) and center duct air outlet temperature is 8
C (46.4
F),
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.
 AIR CONDITIONING (OPTIONAL) 1B-9

DIAGNOSIS TEST TABLE

TESTING RESULTS POSSIBLE CAUSE REMEDY

Pressure high
Refrigerant overcharged
Recharge

(“A” area of high side
Expansion valve frozen or clogged
Check expansion valve
graph)
Clogged refrigerant passage of high side
Clean or replace

Condenser fan malfunction Insufficient
Check condenser fan
ESSURE GAUGE

cooling of

Dirty or bent condenser fins condenser
Clean or repair

Compressor malfunction (Insufficient oil etc.)
Check compressor

Engine overheat
Check engine cooling
system
HIGH PRE

Pressure low
Insufficient refrigerant (Insufficient charge or
Check for leakage, repair if
(“B” area of high side leakage) necessary and recharge
graph)
Expansion valve malfunction (valve opens too
Check expansion valve
wide)

Compressor malfunction (Insufficient
Check compressor
compression)

Pressure high
Expansion valve malfunction (valve opens too
Check expansion valve
(“A” area of low side wide)
E GAUGE

graph)
Compressor malfunction (Insufficient
Check compressor

compression)
LOW PRESSURE

Pressure low
Insufficient refrigerant (Insufficient charge or
Check for leakage, repair if
(“B” area of low side leakage) necessary and recharge
graph)
Expansion valve malfunction (valve opens too
Check expansion valve
narrow)

Clogged refrigerant passage (crashed pipe)
Repair or replace

Outlet air temperature
Insufficient or excessive charge of refrigerant
Check refrigerant pressure
at center duct is high
Dirty or bent evaporator fins
Clean or repair
MOMETER AT

(Crossing point is in
Air leakage from cooling (heater) unit or air duct
Repair or replace
TER DUCT

area “A”)
Malfunctioning, switchover function of damper
Repair or replace

in cooling (heater) unit

Compressor malfunction
Check compressor
CENT
THERM

Outlet air temperature
Insufficient air volume from center duct (Heater
Check blower motor and
at center duct is low blower malfunction) fan
(Crossing point is in
Compressor malfunction
Check compressor
area “B”)

If ambient temperature is within 30 – 35
C (86 – 95
F), 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
C (85 – 95
F)

MPa
MANIFOLD kg/cm2
GAUGE psi CONDITION CAUSE CORRECTION
Lo Hi
0.2 – 0.3 1.18 – 1.47
2.0 – 3.0 12.0 – 15.0 Normal condition.
28.4 – 42.6 170 – 213

The low pressure side
Dust particles or water
Clean expansion valve.
reads a negative pressure, droplets are either stuck or Replace it if it cannot be
and the high pressure side frozen inside expansion cleaned.
reads an extremely low valve, preventing the re-
Replace receiver/dryer.
0.5 – 0.6 pressure. frigerant from flowing.
Evacuate the A/C system
Negative 5–6
pressure
Presence of frost around
Gas leak from heat-sensi- and recharge with fresh re-
71.2 – 85.3 tubing to and from receiver/ frigerant.
tizing tube is preventing
dryer and expansion valve.
If heat-sensitizing tube is
refrigerant flow.
defective, replace expan-
sion valve.
Normal: Normal:
During A/C operation, the
Expansion valve is frozen
Replace expansion valve.
0.2 – 0.3 1.18 – 1.47 low pressure side some- due to moisture in the sys-
Replace receiver/dryer.
2.0 – 3.0 12.0 – 15.0 times indicates negative tem, and temporarily shuts
Evacuate A/C system and
28.4 – 42.6 170 – 213 pressure, and sometimes off the recharge with fresh


normal pressure. Also refrigeration cycle. refrigerant.
Abnormal: Abnormal: high pressure side reading
Negative 0.69 – 0.98 fluctuates between the ab-
pressure 7 – 10 normal and normal pres-
99.4 – 142 sure.

Both low and high
Insufficient refrigerant in
Using a gas leak detector,
pressure sides indicate system. check for leaks and repair
low readings. (Refrigerant leaking) as necessary.

Continuous air bubbles
Recharge refrigerant to a
0.05 – 0.1 are visible through sight specified amount.
0.5 – 1.0 glass. If the pressure reading is al-
7.1 – 14.2
Output air is slightly cold. most 0 when the
manifold gauges are
0.69 – 0.98
attached, check for any
7 – 10
leaks, repair them, and
100 – 142 evacuate the system.

Pressure on low pressure
Internal leak in compres-
Inspect compressor and re-
side is high. sor. pair or replace as
0.4 – 0.6
Pressure on high pressure necessary.
4–6 side is low.
56.9 – 85.3
Both pressure becoming
equal right after A/C is
turned OFF.

High pressure reading on
Overcharged A/C system.
Adjust refrigerant to
both low and high
Faulty condenser specified amount.
pressure sides. cooling operation.
Clean condenser.

Air bubbles are not visible
Faulty condenser fan op-
Inspect and repair
even when engine rpm is eration. condenser fan.
0.25 – 0.3 1.96 – 2.45 lowered.
2 5 – 3.0
2.5 30 20 – 25
High pressure reading on
Presence of air in A/C sys-
Replace receiver/dryer.
35.6 – 42.6 285 – 355 both low and high tem.
Inspect quantity of com-
pressure sides. (Improperly evacuated) pressor oil and presence of

Low pressure side tubing contaminants in oil.
is not cold when touched.
Evacuate system and

Air bubbles are visible recharge with fresh
through sight glass. refrigerant.

High pressure reading on
Faulty expansion valve or
Inspect if heat-sensitizing
0.3 – 0.4 1.86 – 1.96 both low and high improper attachment of tube is properly attached.
3.0 – 4.0 19 – 20 pressure sides. heat-sensitizing tube.
Replace expansion valve.
42.7 – 56.8 271 – 284
Large amount of frost or
Refrigerant flow is not regu-
dew on the low pressure lated properly.
side tubing.
 AIR CONDITIONING (OPTIONAL) 1B-11

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
1B-12 AIR CONDITIONING (OPTIONAL)

Fig. A 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. 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.

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

TERMINAL ARRANGEMENT OF ECM COUPLER (VIEWED FROM HARNESS SIDE)

 AIR CONDITIONING (OPTIONAL) 1B-13

ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL

Measurement
Terminal Wire Circuit Normal value Condition
ground
Ground to
E32-301 B ECM main ground –0.4 – 0 volt Engine running
body (Fig A)
Main power supply Ground to Ignition switch ON with engine
E32-302 B/R 10 – 14 volts
for ECM engine (Fig B) stopped
ECM ground for Ground to
E32-313 Bl/B –0.4 – 0 volt Engine running
power circuit body (Fig A)
Power supply for Ground to Ignition switch ON with engine
E32-315 B/R 10 – 14 volts
ECM power circuit engine (Fig B) stopped
Ignition switch ON with engine
Ground to 0.5 – 1.2 volt
E32-319 V/R Main relay drive stopped
engine (Fig B)
0 volt Ignition switch OFF
Blower fan motor switch and A/C
switch ON or engine coolant temp
Radiator (condens- 0 – 1 volt
Ground to sensor more than 100
C (212
F)
E32-320 Bl er) cooling fan relay
engine (Fig B) with engine running
output
out ut
Except the above-mentioned with
10 – 14 volts
engine running
ECM ground for Ground to
E32-326 Bl/B –0.4 – 0 volt Engine running
power circuit body (Fig A)
Blower fan motor switch ON with en-
0 – 1 volt
Blower load for Ground to gine running
E34-09 P/B
blower fan input engine (Fig B) Blower fan motor switch OFF with
10 – 14 volts
engine running
Blower fan motor switch and A/C
0 – 1 volts
Ground to switch ON with engine running
E34-19 Or/B input
A/C switch in ut
engine (Fig B) Blower fan motor switch or A/C
10 – 14 volt
switch OFF with engine running
Sensor common Ground to
E34-22 B/G –0.4 – 0 volt Engine running
ground body (Fig A)
Evaporator thermistor temperature at
2.0 – 2.5 volts
Evaporator thermis- approx. 15
C (59
F) with engine
(2100 – 2580
)
tor temperature Ground to running
E33-207 V/R
(EVAP temp sen- engine (Fig B) Evaporator thermistor temperature at
3.1 – 3.3 volts
sor) input approx. 0
C (32
F) with engine
(4600 – 5100
)
running
Engine coolant temperature at
0.71 – 0.76 volts
approx. 80
C (176
F) with engine
Engine coolant (290 – 320
)
Ground to running
E33-208 Lg/B temperature
tem erature sensor
engine (Fig B) Engine coolant temperature at
input 0.35 – 0.37 volts
approx. 110
C (230
F) with engine
(136 – 144
)
running
Blower fan motor switch and A/C
Compressor mag- 0 – 1 volt
Ground to switch ON with engine running
E33-216 P/B net clutch relay
engine (Fig B) Except the above-mentioned with
output 10 – 14 volts
engine running
1B-14 AIR CONDITIONING (OPTIONAL)

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.
 AIR CONDITIONING (OPTIONAL) 1B-15

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
1. Manifold gauge set
2. Low pressure gauge
3. High pressure gauge A: High pressure service valve
4. Recovery equipment B: Low pressure service valve
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.

When disconnecting any line from the system, install a blinding plug or cap to fitting of such line immedi-
ately.

When connecting hoses and pipes to each other respectively, previously apply a few drops of compres-
sor oil (refrigerating oil) to O-ring.

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).
 AIR CONDITIONING (OPTIONAL) 1B-17

INSTALLATION
Reverse removal sequence to install condenser, noting the follow-
ing point.

If condenser is replaced, pour 15 cc of refrigerating oil to com-
pressor suction-side.

Evacuate and charge system according to previously described
procedure.

INSPECTION
Check the following.

Condenser fins for leakage, blockage and damage

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.

If receiver/dryer (1) is replaced, pour 20 cc of refrigerating oil to
compressor suction-side.

Evacuate and charge system according to previously described
procedure.

Install receiver/dryer (1) to its bracket (2) as shown in figure.
“a” 20

1B-18 AIR CONDITIONING (OPTIONAL)

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.
 AIR CONDITIONING (OPTIONAL) 1B-19

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.

If cooling unit or evaporator is replaced, pour 25 cc of refrigerat-
ing oil to compressor suction-side.

Install uniformly the evaporator pipe (1) to grommet.
1B-20 AIR CONDITIONING (OPTIONAL)

Evacuate and charge system according to previously described

procedure.

Adjust fresh air control cable, refer to HEATER CONTROL LE-
VER ASSEMBLY in HEATER AND VENTILATION section.

Install the cutting part of drain hose (1) downward as shown in
figure.

INSPECTION
Check the following

Evaporator fins for leakage, blockage and damage.

Evaporator fittings for leakage.
Clogged evaporator fins should be washed with water, and should
be dried with compressed air.

NOTE:

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.

When the thermistor removed, its should be reinstalled in
original position.

A/C EVAPORATOR THERMISTOR

Check resistance between evaporator thermistor (1) terminals.

Sensor Temperature (
C (
F)) Resistance (k
)

0 (32) 4.6 – 5.1
15 (59) 2.1 – 2.6

If check results are as not specified, replace thermistor.

NOTE:
When the thermistor removed, its should be reinstalled in
original position.
 AIR CONDITIONING (OPTIONAL) 1B-21

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. 25
C (77
F)) 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.

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

A: Approx. 210 kPa (2.1 kg/cm2)
Continuity
C D B: Approx. 2650 kPa (26.5 kg/cm2)
C: Approx. 230 kPa (2.3 kg/cm2)
No continuity D: Approx. 2060 kPa (20.6 kg/cm2)
A B
Pressure
Tightening torque for dual pressure switch
10 N·m (1.0 kg-m, 8.0 lb-ft)

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

Press A/C Switch button and check if there is continuity between
terminals “A” and “B”.

With battery voltage (+) connected to terminal “C” and (–) to ter-
minal “A”, press A/C Switch button and check if indicator lamp
lights.

INSTALLATION
1. Blower fan and A/C switch Reverse removal procedure for installation.
1B-22 AIR CONDITIONING (OPTIONAL)

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.
 AIR CONDITIONING (OPTIONAL) 1B-23

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.

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.

Evacuate and charge system according to previously described
1. New compressor
procedure.
2. Removed
compressor
3. Excess oil (A–B)
1B-24 AIR CONDITIONING (OPTIONAL)

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 cm3
(60 – 100 cc, 3.7 – 6.1 in3)
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
1. New compressor
2. Removed compressor “A”: Amount of oil sealed in a new compressor
3. Excess oil (A–B) “B”: Amount of oil remaining in removed compressor

When replacing other part

Amount of compressor oil
Part replaced
to be replenished
Evaporator 25 cc
Condenser 15 cc
Receiver/dryer 20 cc
Hoses 10 cc each
Pipes 10 cc each
 AIR CONDITIONING (OPTIONAL) 1B-25

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
C, 68
F

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
1B-26 AIR CONDITIONING (OPTIONAL)

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
 AIR CONDITIONING (OPTIONAL) 1B-27

DISASSEMBLY OF COMPRESSOR

10. Cylinder seal

11. Compressor cylinder
12. Cylinder seal
13. Suction valve
14. Valve front plate
15. Reed valve
1. Joint service connector 16. Front gasket
2. Diffuser seal 17. Cylinder front head
3. “O” ring 18. Blank
4. Diffuser 19. “O” ring
5. Rear housing 20. Seal plate
6. Rear gasket 21. Circlip
7. Reed valve 22. Oil felt
8. Valve rear plate 23. Joint service connector bolt
9. Suction valve 24. Housing through bolt
1B-28 AIR CONDITIONING (OPTIONAL)

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
 AIR CONDITIONING (OPTIONAL) 1B-29

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 30
– 60
.

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
1B-30 AIR CONDITIONING (OPTIONAL)

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.
 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- Replace
sion.

Valve plate 1. Check both surfaces for scratches and corro- Replace or polish with
sion. fine oil stone.

Red valve 1. Check reed for cracks, scratches, deformation Replace

and corrosion.

Front housing 1. Check sealing surface for cracks scratches and Replace
deformation.

Piston/Cylinder block 1. Check cylinder bore for scratches and corrosion. Replace
2. Check radial bearings for poor contact, worn-out Replace
needle, scoring or pit.
3. Check shaft for excessive axial play. Replace
4. Check piston for excessive axial play. Replace

Rear housing 1. Check sealing surface for cracks, scratches and Replace
deformation.
1B-32 AIR CONDITIONING (OPTIONAL)

ASSEMBLY OF COMPRESSOR
NOTE:

Do not re-use gasket shaft seal, O-rings, or washers. Use
overhaul gasket kit.

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:

Front and rear reed valves (suction and discharge) are
the same.

Rear valve plate is marked “R”.

4. Pin holes

d. Lubricate gasket (1) with compressor oil. Install gasket (1) on

valve plate.

NOTE:

Front and rear gasket are different, so do not interchange
them.

Assemble gasket so that their protruded surfaces face up-
ward.
 AIR CONDITIONING (OPTIONAL) 1B-33

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:

Front and rear reed valves (suction and discharge) are
the same.

Front valve plate is marked “F”.

4. Pin holes

d. Lubricate gasket (1) with compressor oil. Install gasket (1) on

valve plate.
NOTE:

Front and rear gaskets are different, so do not inter-
change them. (To differentiate them, refer to description
on rear valve plate.)

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)
1B-34 AIR CONDITIONING (OPTIONAL)

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

1. Circlip installation groove 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.
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
 AIR CONDITIONING (OPTIONAL) 1B-35

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 in3.)

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.
2. Diffuser seal
4. Diffuser
Tightening Torque
(a): 26 N·m (2.6 kg-m, 19 lb-ft)
11) Check shaft rotating torque.
Rotating Torque
Less than 3.0 N·m (0.3 kg-m, 2.2 lb-ft)
1B-36 AIR CONDITIONING (OPTIONAL)

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)
 AIR CONDITIONING (OPTIONAL) 1B-37

REQUIRED SERVICE MATERIALS

RECOMMENDED
MATERIALS USE
SUZUKI PRODUCT

Compressor oil
O-ring

COMPRESSOR OIL DENSO : ND-OIL6
(Refrigerant oil)
Each component

REFRIGERANT DRUM
Refrigerant
Refrigerant charge
95793-60D00-000

SPECIAL TOOLS

09900-06107 09900-06108
Snap ring pliers Snap ring pliers 09990-28210 09990-48220
(Opening type) (Closing type) Key pressor Lip seal remover

09990-58220 09990-58210 09990-58230 09951-65510

Lip seal pressor Pressure plate remover Lip seal protector Shaft protector

09991-06020
Armature plate spanner