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A/C-HEATER SYSTEM - MANUAL

ArticIe Text
1994 Suzuki Swift
For Xeon
Copyright 1998 Mitchell Repair nformation Company, LLC
Tuesday, December 02, 2003 06:38PM
ARTICLE BEGINNING
1994 AIR CONDITIONING & HEAT
Suzuki Manual A/C-Heater System
Swift
A/C SYSTEM SPECIFICATIONS
MANUAL A/C SYSTEM SPECIFICATIONS TABLE

Application Specification
Compressor Type ................................ Nippondenso 10-Cyl.
Compressor Belt Deflection (1) .............. 21/64-13/32" (8-10 mm)
System Oil Capacity ................................... 2.0-3.4 ozs.
Refrigerant Capacity (2)
R-12 ................................................... 17.6 ozs.
R-134a ................................................. 17.6 ozs.
System Operating Pressures (2)
R-12
High Side ........................ 206-213 psi (14.5-15.0 kg/cm)
Low Side ............................. 21-28 psi (1.5-2.0 kg/cm)
R-134a
High Side ........................ 256-313 psi (18.0-22.0 kg/cm)
Low Side ............................. 21-28 psi (1.5-2.0 kg/cm)
(1) - With 22 lbs. (10 kg) pressure applied at belt center.
(2) - Swift may use either R-12 or R-134a refrigerant. Check underhood
A/C specification label or A/C compressor label prior to
servicing vehicle.

DESCRIPTION & OPERATION


A/C AMPLFER
The A/C amplifier (located on lower evaporator case) controls
operation of the Vacuum Switching Valve (VSV), A/C compressor clutch
and condenser fan motor based on signals from different sensors.
COMPRESSOR & CONDENSER FAN RELAYS
Relays operate condenser fan motor and magnetic clutch on A/C
compressor. Fan motor operates as long as the A/C compressor is under
operation.
CONDENSER
The condenser assembly, located in front of the radiator,
consists of coils and cooling fins. Air passing through the condenser
cools the high pressure refrigerant vapor, causing it to condense into
liquid.
DUAL-PRESSURE SWTCH
The dual-pressure switch stops A/C compressor operation when
refrigerant pressure drops or reaches too great a level. Switch is
installed on the high pressure line, behind receiver-drier.
EVAPORATOR
The evaporator cools and dehumidifies the air before it
enters the vehicle. Heat in the air passing through the evaporator
core is lost to the cooler surface of the core, thereby cooling and
conditioning the air. As the air loses its heat to the evaporator core
surface, any moisture (humidity) in the air condenses on the outside
surface of the evaporator core and is drained off as water.
EXPANSON VALVE
High pressure liquid refrigerant enters the expansion valve
through inlet screen and passes through the valve seat and orifice.
Upon passing through the orifice, the high pressure liquid becomes a
low pressure liquid. The low pressure liquid leaves the expansion
valve, flowing into the evaporator core, where it absorbs heat and
changes to a low pressure vapor.
MAGNETC CLUTCH
A/C-HEATER SYSTEM - MANUAL ArticIe Text (p. 2)
1994 Suzuki SwiftFor Xeon
Copyright 1998 Mitchell Repair nformation Company, LLC
A/C switch, coolant temperature switch and dual-pressure
switch control magnetic clutch on A/C compressor. When engine is
running, magnetic clutch allows compressor to run according to signals
sent by A/C amplifier.
RECEVER-DRER
Receiver-drier temporarily stores condensed liquid
refrigerant. It also removes dirt and moisture in refrigerant by means
of a filter and desiccant bag. A sight glass, installed on top of
receiver-drier, indicates refrigerant flow.
THERMSTOR
If evaporative temperature of refrigerant drops to 32F (0C)
or less, the evaporator fins develop frost or ice. This reduces
evaporator core airflow, lowering cooling capacity. A thermistor,
installed on the evaporator, prevents this frost or ice from forming
on the evaporator core.
VACUUM SWTCHNG VALVE (VSV)
To prevent engine from overheating or stalling, the VSV
increases engine speed a little more than the specified idle speed by
opening or closing according to A/C amplifier signal. When VSV is
open, intake manifold receives air through VSV and through idle port
and ISC solenoid valve.
TESTING
A/C SYSTEM PERFORMANCE
1) Connect manifold gauge set to A/C system. Start engine and
allow it to idle at 2000 RPM. Turn A/C on. Set blower lever to maximum
speed, and temperature lever to cool position. Open all windows and
doors.
2) Insert thermometer in cool air outlet. Thermometer should
read 77-95F (25-35C). On R-12 systems, high pressure gauge reading
should be 200-220 psi (14-15.5 kg/cm). On R-134a systems, high
pressure gauge reading should be 256-313 psi (18-22 kg/cm).
A/C AMPLFER
1) Ensure A/C amplifier control functions, with A/C on, are
as follows: idle speed increase (if equipped with vacuum switching
valve), A/C compressor clutch operation is delayed 0.8 of a second
after vacuum switching valve is on or outputting A/C on signal to
Engine Control Module (ECM).
2) The A/C system operation should be as indicated in A/C
AMPLIFIER TESTING table. The A/C system should be off while cranking
engine. The A/C system should come off within 10 seconds of full
throttle opening (90 percent open).
NOTE: Additional A/C amplifier testing is not available from
manufacturer.
A/C AMPLIFIER TESTING TABLE

Condition A/C System Operation


R-12 Pressures
High Side
Above 383 psi (27.0 kg/cm) ................................. Off
Below 299 psi (21.0 kg/cm) .................................. On
Low Side
Below 29.9 psi (2.1 kg/cm) ................................. Off
Above 34.1 psi (2.4 kg/cm) .................................. On
R-134a Pressures
High Side
Above 455 psi (32.0 kg/cm) ................................. Off
Below 370 psi (26.0 kg/cm) .................................. On
Low Side
Below 28.4 psi (2.0 kg/cm) ................................. Off
Above 37.0 psi (2.6 kg/cm) .................................. On
Engine Coolant Temperature
Above 230F (110C) .......................................... Off
Below 217F (103C) ........................................... On
Evaporator Temperature
Below 34F (1C) ............................................. Off
Above 35F (2C) .............................................. On

A/C-HEATER SYSTEM - MANUAL ArticIe Text (p. 3)


1994 Suzuki SwiftFor Xeon
Copyright 1998 Mitchell Repair nformation Company, LLC
A/C SWTCH
1) Disconnect negative battery cable. Remove A/C-heater
control knob and panel to access A/C switch. Disconnect A/C switch
electrical connector.
2) With A/C switch off, continuity should not be present
between any terminals. With A/C switch on, continuity should exist
between Blue and Pink/Black wire terminals. If continuity is not as
specified, replace A/C switch.
CLUTCH COL
If compressor clutch is oil-soaked, check front shaft seal
for leak. Replace shaft seal if necessary. Check pulley bearing for
roughness and noise. Replace bearing if necessary. Ensure clutch coil
resistance is 3.0-3.4 ohms at 77F (25C). If resistance is not as
specified, replace clutch coil.
COMPRESSOR & CONDENSER FAN RELAYS
1) Disconnect negative battery cable. Disconnect relay
electrical connectors, and remove relay. Apply battery voltage to
relay terminals No. 1 and 2. See Fig. 1.
2) Attach ohmmeter leads to relay terminals No. 3 and 4.
Continuity should be present with battery voltage applied. If
continuity is not present, replace relay.
Fig. 1: Testing Compressor & Condenser Fan Relays (Swift)
Courtesy of Suzuki of America Corp.
COOLANT TEMPERATURE SWTCH
Heat temperature switch in boiling water until temperature
reaches 226F (108C). Continuity should exist between switch terminal
and switch body. If continuity does not exist, replace coolant
temperature switch.
DUAL-PRESSURE SWTCH
1) Check dual-pressure switch operation at 77F (25C), with
A/C system properly charged, and A/C system (compressor) under
operation.
2) On R-12 systems, low pressure switch should not show
continuity if pressure is 30 psi (2.1 kg/cm) or less. If pressure is
383 psi (26.9 kg/cm) or more, high pressure switch should not show
continuity. If continuity is not as specified, replace dual-pressure
switch.
3) On R-134a systems, low pressure switch should not show
continuity if pressure is 28 psi (2.0 kg/cm) or less. If pressure is
455 psi (32.0 kg/cm) or more, high pressure switch should not show
continuity. If continuity is not as specified, replace dual-pressure
switch.
EXPANSON VALVE
On-Vehicle Testing
1) Connect manifold gauge set to compressor. Run engine at
fast idle with A/C on. Ensure low pressure gauge shows a reading of 7-
A/C-HEATER SYSTEM - MANUAL
71 psi (0.5-5.0 kg/cm).
2) If reading is less than 7 psi (0.5 kg/cm), check
expansion valve and receiver-drier. Replace components as necessary.
If reading is more than 71 psi (5.0 kg/cm), tighten remote bulb
holder or replace expansion valve.
Bench Testing
1) Connect manifold gauge set to expansion valve. Connect
manifold gauge charge hose to R-134a source. See Fig. 2. Ensure
manifold gauge set valves are closed. Put expansion valve bulb in
container of water with thermometer.
2) Slowly open high side of manifold gauge set to 70 psi (4.9
kg/cm). Read low side pressure. Pressure should correspond to bulb
temperature as indicated in EXPANSION VALVE PRESSURE table. If
pressure values are incorrect, replace expansion valve.
EXPANSION VALVE PRESSURE TABLE

Temperature F (C) psi (kg/cm)


32 (0) ............................................. 20-28 (1.5-2.0)
50 (10) ............................................ 32-42 (2.2-2.8)
75 (24) ............................................ 62-72 (4.1-4.5)

Fig. 2: Testing Expansion Valve On Bench (Swift)


Courtesy of Suzuki of America Corp.
THERMSTOR
Disconnect thermistor electrical connector. Connect ohmmeter
leads to thermistor terminals. Ensure resistance is within
specifications. See THERMISTOR RESISTANCE table. If continuity is not
as specified, replace thermistor.
THERMISTOR RESISTANCE TABLE

Temperature F (C) (1) Ohms


32 (0) ................................................... 4200-5000
50 (10) .................................................. 2800-3200
70 (20) .................................................. 1800-2000
(1) - Resistance values are approximate.

VACUUM SWTCHNG VALVE (VSV)


1) Disconnect vacuum hose and connector from VSV. Check VSV
solenoid by applying battery voltage to valve terminals. Air should
flow from port "A" to port "B". See Fig. 3.
2) Using an ohmmeter, check continuity between VSV body and
each valve terminal. Continuity should not be present. Connect
ohmmeter leads to VSV terminals. Ohmmeter reading should be 24-30
ohms. Replace VSV if readings are not as specified.
A/C-HEATER SYSTEM - MANUAL ArticIe Text (p. 5)
1994 Suzuki SwiftFor Xeon
Copyright 1998 Mitchell Repair nformation Company, LLC
Fig. 3: Testing Vacuum Switching Valve Operation (Swift)
Courtesy of Suzuki of America Corp.
REMOVAL & INSTALLATION
NOTE: For removal and installation procedures not covered in this
article, see HEATER SYSTEM article in the AIR
CONDITIONING & HEAT section.
CONDENSER
Removal & Installation
1) Discharge A/C system using approved refrigerant
recovery/recycling equipment. Remove front bumper.
2) Disconnect refrigerant hose(s) from condenser fittings.
3) Disconnect and plug receiver-drier outlet pipe above
condenser cooling fan. Remove hood latch and lock assembly. Disconnect
fan motor wiring harness. Remove condenser, cooling fan and receiver-
drier as an assembly. Remove cooling fan and receiver-drier from
condenser.
4) Reverse removal procedure to install. When installing a
new condenser, add 0.7-1 ounce of refrigerant oil. Evacuate and
recharge system, and check it for leaks.
EVAPORATOR, EXPANSON VALVE & THERMSTOR
Removal & Installation
1) Disconnect negative battery cable. Discharge A/C system
using approved refrigerant recovery/recycling equipment. Disconnect
blower motor and blower motor resistor wires. Disconnect fresh air
control cable from blower motor housing.
2) Remove glove box. Remove blower motor unit. Disconnect A/C
amplifier and thermistor wires. See Fig. 4. Disconnect refrigerant
lines and remove evaporator unit.
3) Remove clamps, and separate evaporator housing. Remove
evaporator core, expansion valve or thermistor as required. To
install, reverse removal procedure. Evacuate and recharge system, and
check it for leaks.
A/C-HEATER SYSTEM - MANUAL ArticIe Text (p. 6)
1994 Suzuki SwiftFor Xeon
Copyright 1998 Mitchell Repair nformation Company, LLC
Fig. 4: Removing Evaporator Unit (Swift)
Courtesy of Suzuki of America Corp.
RECEVER-DRER
Removal & Installation
1) Discharge A/C system using approved refrigerant
recovery/recycling equipment. Disconnect liquid lines from inlet and
outlet fittings. Remove receiver-drier from holder.
2) To install, reverse removal procedure. If installing a new
receiver-drier, add 0.4 ounce of refrigerant oil. Evacuate and
recharge system, and check it for leaks.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE

Application Ft. Lbs. (N.m)


Compressor Bolts
8-mm ............................................... 18-22 (25-30)
10-mm .............................................. 30-37 (40-50)
Refrigerant Hoses
8-mm ................................................. 10.1 (13.7)
13-mm ................................................ 16.6 (22.5)
16-mm ................................................ 23.8 (32.3)
INCH Lbs. (N.m)
Coolant Temperature Switch ................................ 106 (12)

A/C-HEATER SYSTEM - MANUAL


WIRING DIAGRAMS
Fig. 5: Manual A/C-Heater System Wiring Diagram (Swift)
END OF ARTICLE