Suzuki Grand Vitara JB419. Manual — part 128

Air Conditioning System: 7B-18

Repair Instructions

Operation Procedure for Charging A/C with Refrigerant

S5JB0B7206001

WARNING

!

• Your eyes should not be exposed to refrigerant (liquid).

Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6

°C (21.2

°F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a serious
injury. To protect your eyes against such accident, it is necessary to always wear goggles. Should it
occur that HFC-134a (R-134a) strikes your eye(s), consult a doctor immediately.
– Do not use your hand to rub the affected eye(s). Instead, use quantities of fresh cold water to

splash it over the affected area to gradually raise temperature of such area above freezing point.

– Obtain proper treatment as soon as possible from a doctor or eye specialist.

• Should the liquid refrigerant HFC-134a (R-134a) is exposed to your skin, the affected area should be

treated in the same manner as when skin is frostbitten or frozen.

• Do not handle refrigerant near any place where welding or steam cleaning is performed.
• Refrigerant should be kept in a cold and dark place. It should never be stored in any place where

temperature is high, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).

• Avoid breathing fume produced when HFC-134a (R-134a) is burned. Such fume may be hazardous to

your health.

Star

Start e

t evacuation.

acuation.

Stop e

Stop evacuation.

acuation.

20 min

20 minutes (abo

utes (above 760 mmHg)

e 760 mmHg)

Wait 10 min

ait 10 minutes

utes

Chec

Check A/C system f

k A/C system for

or

pressure tighteness

pressure tighteness.

Recharge A/C system with

Recharge A/C system with
refr

refriger

igerant.

ant.

Chec

Check A/C system f

k A/C system for refr

or refriger

igerant

ant

leaks and amount of refr

leaks and amount of refriger

igerant

ant

charged.

charged.

Perf

erfor

ormance test

mance test

Inspect and repair connections

Inspect and repair connections.

If gauge sho

If gauge shows

ws

abnor

abnormal conditions

mal conditions

Recharge 570 30 g of

Recharge 570 30 g of
refr

refriger

igerant.

ant.

I5JB0A720031-02

7B-19 Air Conditioning System:

Recovery
When discharging refrigerant out of A/C system, always
recover it by using refrigerant recovery and recycling
equipment (1). Discharging refrigerant HFC-134a
(R134a) into atmosphere would cause adverse effect to
environments.

NOTE

• After recovering refrigerant from system

the amount of removed compressor oil
must be measured for replenishing
compressor oil. Refer to “Precautions on
Replenishing Compressor Oil”.

• When handling recovery and recycling

equipment, be sure to follow the
instruction manual for the equipment.

Evacuation

CAUTION

!

Do not evacuate before recovering
refrigerant in system.

NOTE
Once A/C system circuit is opened (exposed
to atmospheric air) air conditioning system
must be evacuated by using a vacuum pump.
The A/C system should be attached with a
manifold gauge set, and should be evacuated
for approx. 20 minutes.

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

hose (2) of manifold gauge set (3) respectively as
follows:
High charging hose (1)

→ High pressure charging

valve (4) on discharge hose
Low charging hose (2)

→ Low pressure charging

valve (5) on suction pipe

2) Attach center charging hose (6) of manifold gauge

set (3) to vacuum pump (7).

3) Operate vacuum pump (7), and then open

discharge-side valve (9) (Hi) of manifold gauge set
(3).
If there is no blockage in the system, there will be an
indication on high pressure gauge (10).
In this case, open the other-side valve (8) (Lo) of the
set and repair the system.

4) Approx. 10 minutes later, low pressure gauge (11)

should show a vacuum lower than –100 kPa (–1.0
kg/cm

2

, –760 mmHg, –14.2 psi) providing no

leakage exists.

NOTE

• If the system does not show a vacuum

below –100 kPa (–1.0 kg/cm

2

, –760 mmHg,

–14.2 psi), close both valves, stop vacuum
pump and watch movement of low
pressure gauge.

• Increase in the gauge reading suggests

existence of leakage. In this case, repair
the system before continuing its
evacuation.

• If the gauge shows a stable reading

(suggesting no leakage), continue
evacuation.

5) Evacuation should be carried out for a total of at

least 20 minutes.

6) Continue evacuation until low pressure gauge

indicates a vacuum less than –100 kPa (–1.0 kg/cm

2

,

–760 mmHg, –14.2 psi), and then close both valves
(8), (9).

7) Stop vacuum pump (7). Disconnect center charging

hose (6) from pump inlet. Now, the system is ready
for charging refrigerant.

1

I5JB0B720008-01

6

10

9

7

3

11

1

4

5

8

2

I5JB0B720009-02

Air Conditioning System: 7B-20

Checking of A/C System for Pressure Leaks
After completing the evacuation, close manifold gauge
high pressure valve (Hi) and low-pressure valve (Lo) and
wait 10 minutes. Verify that low-pressure gauge reading
has not changed.

CAUTION

!

If the gauge reading moves closer to “0”,
there is a leak somewhere. Inspect the tubing
connections, make necessary corrections.
And then evacuate system once again and
make sure that there are no leaks.

Charge

CAUTION

!

• Because the sight glass is not used for this

A/C system, do not perform an additional
charge to the A/C system. To charge the
proper amount of refrigerant, recover and
evacuate the A/C system first. And then,
charge the proper amount of refrigerant
into the A/C system.

• Always charge through low pressure-side

of A/C system at after the initial charging is
performed from the high-pressure side
with the engine stopped.

• Never charge to high pressure-side of A/C

system with engine running.

• Do not charge while compressor is hot.
• When installing tap valve to refrigerant

container to make a hole there through,
carefully follow directions given by
manufacturer.

• A pressure gauge should always be used

before and during charging.

• The refrigerant container should be

emptied of refrigerant when discarding it.

• The refrigerant container should not be

heated up to 40

°C (104 °F) or over.

• Refrigerant container should not be

reversed in direction during charging.
Reversing in direction causes liquid
refrigerant to enter compressor, causing
troubles, such as compression of liquid
refrigerant and the like.

NOTE
The A/C system contains HFC-134a (R-134a).
Described here is a method to charge the A/C
system with refrigerant from the refrigerant
service container.
When charging refrigerant recovered by
using the refrigerant and recycling
equipment (when recycling refrigerant),
follow the procedure described in the
equipment manufacturer’s instruction
manual.

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.

1

6

2

4

3

5

I5JB0B720010-02

7B-21 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.

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.

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

1570 – 1970 kPa
15.7 – 19.7 kg/cm

2

223 – 282 psi

Pressure
on low pressure gauge

230 – 330 kPa
2.3 – 3.3 kg/cm

2

33 – 47 psi

IYSQ01720016-01