Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual — part 91

7B-8 Air Conditioning System:

Charge proper amount of refrigerant accurately in
accordance with the following procedure.

Specified amount of refrigerant
570

± 30 g (20.1 ± 1.0 oz)

The initial charging of the A/C system is performed from
the high-pressure side with the engine stopped.
And next, this method must be followed by charging from
the low-pressure side with the engine running.

1) Check to make sure that hoses are routed properly

after evacuating the system.

2) Connect low charging hose (1) and high charging

hose (2) of the manifold gauge set (3) in position.
Thus open refrigerant container valve (4) to purge
the charging line.

3) Open the high-pressure side valve (6) and charge

refrigerant to system.

4) After a while, open the low-pressure side valve (5)

and close the high-pressure side valve (6).

WARNING

!

Make sure that high pressure-side valve is
closed securely.

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.

5

6

1

2

3

4

I5JB0A720034-01

IYSQ01720015-01

IYSQ01720016-01

Air Conditioning System: 7B-9

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.

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): 09990–86012

Relief Valve On-Vehicle Inspection for M16
Engine Model

S5JB0E7206044

Using special tool, check is there is refrigerant leakage.
If there is refrigerant leakage, replace relief valve (1).

Special tool
(A): 09990–86012

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

(A)

I5RW0A721054-01

1

(A)

I5JB0D720005-01

7B-10 Air Conditioning System:

Relief Valve On-Vehicle Inspection For J20
Engine Model

S5JB0E7206045

Using special tool (A), check is there is refrigerant
leakage.
If there is refrigerant leakage, replace compressor body.

Special tool
(A): 09990–86012

Special Tools and Equipment

Special Tool

S5JB0E7208001

(A)

I5JB0D720006-01

09990–86012
Gas leak detector
This kit includes following
items. 1. Gas leak detector,
2. Instruction manual, 3.
Filter, 4. Sensor, 5. Dri-sell
battery (size D)) / ) / )

1

2

3

4

5

Table of Contents 9- i

9

Section 9

CONTENTS

Body, Cab and Accessories

Precautions . . . . . . . . . . . . .9-1

Precautions. . . . . . . . . . . . . . . . 9-1

Precautions on Body, Cab and Accessories. . . 9-1
Precautions for Body Service. . . . . . . . 9-1
Fastener Caution for Body Service . . . . . ... 9-1

Wiring Systems. . . . . . . . . . .9A-*

Precautions. . . . . . . . . . . . . . ... 9A-*

Cautions in Body Electrical System Servicing. ..9A-*
Precautions for Wiring System. . . . . . . .9A-*

General Description . . . . . . . . . . . . 9A-*

Abbreviations . . . . . . . . . . . . . ...9A-*
Wire / Connector Color Symbols. . . . . . ..9A-*
Symbols and Marks . . . . . . . . . . . .9A-*
How to Read Connector Layout Diagram . . . 9A-*
How to Read Connector Codes and Terminal

Nos. . . . . . . . . . . . . . . . . .9A-*

How to Read Ground Point . . . . . . . . ..9A-*
How to Read Power Supply Diagram. . . . ...9A-*
How to Read System Circuit Diagram. . . . ..9A-*

Connector Layout Diagram . . . . . . . . . 9A-*

Connector Layout Diagram . . . . . . . . ..9A-*
Engine Compartment . . . . . . . . . . ...9A-*
Instrument Panel. . . . . . . . . . . . ..9A-*
Door, Roof. . . . . . . . . . . . . . . 9A-*
Floor. . . . . . . . . . . . . . . . . .9A-*
Rear . . . . . . . . . . . . . . . . . .9A-*

Ground Point . . . . . . . . . . . . . . 9A-*

Ground (earth) Point . . . . . . . . . . . 9A-*

Power Supply Diagram . . . . . . . . . . 9A-*

Power Supply Diagram . . . . . . . . . . 9A-*
Fuses and the Protected Parts . . . . . . . 9A-*
Fuses in Battery Fuse Box, Fuse Box No.1 . . .9A-*
Fuse Box No.2 (In Power Integration No.1,

Power Integration No.2), Relay Box. . . . ...9A-*

Fuse Box No.3 (In J/B). . . . . . . . . . .9A-*
Junction Block (J/B) Connector / Fuse Layout . .9A-*
Junction Block Inner Circuit (Overview) . . . ...9A-*
Junction Block Inner Circuit (Detail) . . . . . .9A-*

System Circuit Diagram. . . . . . . . . ... 9A-*

System Circuit Diagram . . . . . . . . . ...9A-*
A-1 Cranking System Circuit Diagram . . . . .9A-*
A-2 Charging System Circuit Diagram . . . . .9A-*
A-3 Ignition System Circuit Diagram (M16A) . ...9A-*

A-3 Ignition System Circuit Diagram (J20A). . 9A-*
A-4 Cooling System Circuit Diagram. . . . ... 9A-*
A-5 Engine and A/C Control System Circuit

Diagram (M16A). . . . . . . . . . . . 9A-*

A-5 Engine and A/C Control System Circuit

Diagram (J20A) . . . . . . . . . . . . . 9A-*

A-6 A/T Control System Circuit Diagram. . . . 9A-*
A-7 Immobilizer System Circuit Diagram . . . 9A-*
A-8 Body Control System Circuit Diagram . . .. 9A-*
A-10 4WD Control System Circuit Diagram . . 9A-*
B-1 Windshield Wiper and Washer Circuit

Diagram. . . . . . . . . . . . . . . . 9A-*

B-2 Rear Wiper and Washer Circuit Diagram . . 9A-*
B-3 Rear Defogger Circuit Diagram . . . . . 9A-*
B-4 Power Window Circuit Diagram. . . . . 9A-*
B-5 Power Door Lock Circuit Diagram . . . . 9A-*
B-6 Power Mirror Circuit Diagram . . . . . ... 9A-*
B-7 Horn Circuit Diagram . . . . . . . . . 9A-*
B-8 Seat Heater Circuit Diagram. . . . . . . 9A-*
B-9 Keyless Start Circuit Diagram. . . . . ... 9A-*
B-10 Sliding Roof Circuit Diagram . . . . . .. 9A-*
B-11 Headlight Cleaner Circuit Diagram . . . . 9A-*
C-1 Combination Meter Circuit Diagram . . . . 9A-*
D-1 Headlight System Circuit Diagram (One

bulb type) . . . . . . . . . . . . . . .. 9A-*

D-1 Headlight System Circuit Diagram (With

Projector light) . . . . . . . . . . . . ... 9A-*

D-1 Headlight System Circuit Diagram (With

Discharge bulb) . . . . . . . . . . . . . 9A-*

D-2 Position, Tail and Licence Plate Light

System Circuit Diagram . . . . . . . . . 9A-*

D-3 Front Fog Light System Circuit Diagram . .. 9A-*
D-4 Illumination Light System Circuit Diagram . 9A-*
D-5 Interior Light System Circuit Diagram. . ... 9A-*
D-6 Turn Signal and Hazard Warning Light

System Circuit Diagram . . . . . . . . . 9A-*

D-7 Brake Light System Circuit Diagram . . . 9A-*
D-8 Back-Up Light System Circuit Diagram . . 9A-*
D-9 Headlight Beam Leveling System Circuit

Diagram (Manual Leveling) . . . . . . . ... 9A-*

D-9 Headlight Beam Leveling System Circuit

Diagram (Auto Leveling) . . . . . . . . ... 9A-*

D-10 Rear Fog Light Circuit Diagram. . . . .. 9A-*
E-2 Auto A/C System Circuit Diagram . . . . 9A-*
F-1 Air-Bag System Circuit Diagram (4ch). . .. 9A-*

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.