Suzuki Grand Vitara JB416 / JB420. Manual - part 293

7B-63 Air Conditioning System: 

5) Start engine and keep engine speed at 1,500 rpm. 

Then, operate A/C system.

6) Charge A/C system with refrigerant in vapor state. At 

this time, refrigerant container should be held 
upright.

7) When refrigerant container (3) is emptied, the use 

following procedure to replace it with a new 
refrigerant container (3).
a) Close low pressure valve.
b) Replace empty container (3) with a refrigerant 

container which has been charged with 
refrigerant. When using refrigerant container tap 
valve (4), use the following procedure for 
replacement.
i)

Retract needle (1) and remove refrigerant 
container tap valve (4) by loosening its plate 
nut (2).

ii) Install previously-removed refrigerant 

container tap valve (4) to a new refrigerant 
container (3).

c) Purge any air existing in center charging hose.

When using refrigerant container tap valve, use 
the following procedure to purge air.
i)

Once fully tighten refrigerant container tap 
valve and then loosen (open) plate nut 
slightly.

ii) Open low pressure valve of manifold gauge 

set a little.

iii) As soon as refrigerant comes out with a 

“hiss” (1) through a clearance between 
refrigerant container and tap valve, tighten 
plate nut as well as manifold gauge set low 
pressure valve.

iv) Turn handle of tap valve clockwise so that its 

needle is screwed into the new container to 
make a hole for refrigerant flow.

8) After the system has been charged with specified 

amount (570 

± 30 g) of refrigerant or when low 

pressure gauge and high pressure gauge have 
indicated the following specified value, close low 
pressure side valve on manifold gauge set.

IYSQ01720015-01

Low side and high side pressure example
Gauges should read as follows when ambient 
temperature is 30 

°C (86 °F)

Pressure
on high pressure gauge

M16 engine model:
1150 – 1410 kPa
11.5 – 14.1 kg/cm

2

164 – 201 psi
J20 engine model:
1300 – 1630 kPa
13.0 – 16.3 kg/cm

2

185 – 232 psi

Pressure
on low pressure gauge

M16 engine model:
280 – 410 kPa
2.8 – 4.1 kg/cm

2

40 – 58 psi
J20 engine model:
250 – 370 kPa
2.5 – 3.7 kg/cm

2

36 – 53 psi

IYSQ01720016-01

Air Conditioning System:  7B-64

Removal of Manifold Gauge Set

WARNING

!

 

High pressure side is under high pressure.
Therefore, be careful not to get injured 
especially on your eyes and skin.

 

For the A/C system charged with the specified amount of 
refrigerant, remove manifold gauge set as follows:

1) Close low pressure side valve of manifold gauge set. 

(The high pressure side valve is closed continuously 
during the process of charging.)

2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service 

valves. This operation must be performed quickly.

5) Put caps on service valves.

Check A/C System for Refrigerant Leaks
Whenever a refrigerant leak is suspected in the system 
or any service operation has been performed which may 
result in malfunction lines and/or connections, it is 
advisable to check for leaks.
Common sense should be used in performing any 
refrigerant leak test, since the need and extent of any 
such test will, in general, depend upon the nature of a 
complaint and the type of a service performed on the 
system.

Liquid leak detector

WARNING

!

 

• To prevent explosions or fires, make sure 

that there are no flammables in the vicinity.

• When exposed to fire, the refrigerant turns 

into a poisonous gas (phosgene). Do not 
inhale this gas.

 

There are a number of fittings and places throughout the 
air conditioning system where a liquid leak detector 
solution may be used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question 
with a swab, such as attached to the bubbles will form 
within seconds if there is a leak.
For confined areas, such as sections of the evaporator 
and condenser, an electronic (gas) leak detector (1) is 
more practical for determining leaks.

Special tool
(A):  09990–86011

A/C Condenser Assembly On-Vehicle 
Inspection

S5JB0A7206002

CAUTION

!

 

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 
condenser.

 

NOTE
Clogged condenser fins should be washed 
with water, and should be dried with 
compressed air.

 

Check the followings.
• Clog of condenser fins.

If any clog is found, condenser fins should be washed 
with water and should be dried with compressed air.

• Condenser fins for leakage and breakage If any 

defects are found, repair or replace condenser.

• Condenser fittings for leakage. If any defects are 

found, repair or replace condenser.

A/C Condenser Assembly Removal and 
Installation

S5JB0A7206003

CAUTION

!

 

Do not damage condenser fins. If condenser 
fin is bent, straighten it by using flat head 
screwdriver or pair of pliers.

 

I5JB0A720035-01

7B-65 Air Conditioning System: 

Removal

1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system referring to 

“Operation Procedure for Charging A/C with 
Refrigerant”.

NOTE
The amount of removed compressor oil must 
be measured for replenishing compressor 
oil.

 

3) Remove front bumper assembly referring to “Front 

Bumper Components in Section 9K”.

4) Remove front bumper upper member referring to 

“Front Bumper Components in Section 9K”.

5) Disconnect compressor discharge hose (1) and 

liquid pipe (2) from condenser assembly (4).

CAUTION

!

 

As soon as above hose and pipe are 
disconnected, cap opened fittings so that 
moisture and dust do not enter condenser.

 

6) Remove condenser assembly mounting bolts (3), 

and then remove condenser assembly.

NOTE
Be careful not to damage fins of condenser 
and radiator.

 

Installation
Reverse removal sequence to install condenser, noting 
the following point.
• Replenish specified amount of compressor oil to 

compressor suction side referring to “Precautions on 
Replenishing Compressor Oil”.

• Evacuate and charge the A/C system referring to 

“Evacuation” and “Charge” in “Operation Procedure 
for Charging A/C with Refrigerant”.

Desiccant Removal and Installation

S5JB0A7206007

Removal

1) Remove condenser assembly from vehicle referring 

to “A/C Condenser Assembly Removal and 
Installation”.

2) Remove circlip (4) using special tool.

Special tool
:  09900–06107 

3) Remove the filter (1) from the receiver / dryer tank 

(2).

4) Remove desiccant (3).

Installation
Reverse removal sequence to install desiccant, 
according to instruction manual with supply parts.

NOTE

• Replenish specified amount of compressor 

oil to compressor suction side referring to 
“Precautions on Replenishing Compressor 
Oil”.

• Install circlip (1) as shown in figure.

 

3

3

1

2

4

I5JB0A720036-02

3

2

1

4

I5JB0A720037-02

1

I5JB0A720038-01

Air Conditioning System:  7B-66

HVAC Air Filter Removal and Installation

S5JB0A7206009

Removal

1) Disconnect negative (–) cable at battery.
2) Remove glove box.
3) Remove filter cover (1).

4) Pull out filter element (1).

Installation
Reverse removal procedure for installation noting the 
followings:
• Install filter (1) into blower unit by paying attention to 

direction of arrow on filter.

• Enable air bag system after installation of filter.

Refer to “Enabling Air Bag System in Section 8B”.

HVAC Air Filter Inspection

S5JB0A7206010

Check that filter is not excessively dirty, damage or oily, 
clean filter with compressed air from air outlet side of 
filter. If abnormality is found, replace filter with new one.

1

I5JB0A720039-01

1

I5JB0A720040-03

1

I5JB0A720041-03

I5JB0A720092-02