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Air Conditioning System: Removal & Installation Suzuki Aerio I

Automatic HVAC System 23 illustrations ~2013 words

Replacement of refrigerant container in charging procedure

When refrigerant container (1) is emptied, use the following procedure to replace it with a new refrigerant container (1).

Scheme 100

Scheme 100: Replacement of refrigerant container in charging procedure
Scheme 100: Replacement of refrigerant container in charging procedure

Scheme 101

Scheme 101
Scheme 101
  1. Close low pressure valve.
  2. Replace empty container (1) with a refrigerant container which has been charged with refrigerant. When using refrigerant container tap valve (2), use the following procedure for replacement. Retract needle (3) and remove refrigerant container tap valve (2) by loosening its plate nut (4). Install the refrigerant container tap valve (2) to a new refrigerant container (1).
  3. Purge any air existing in center charging hose When using refrigerant container tap valve, use the following procedure to purge air. Once fully tighten refrigerant container tap valve (1), and then loosen (open) plate nut (2) slightly. Open low pressure side valve (3) of manifold gauge set (4) a little. As soon as refrigerant comes out with a "hiss" through a clearance between refrigerant container and tap valve, tighten plate nut (2) as well as low pressure side valve (3). Turn handle of tap valve (1) clockwise so that its needle is screwed into the new container to make a hole for refrigerant flow.

Heater and Cooling Unit Removal and Installation

Reference: HEATER AND COOLING UNIT COMPONENTS: MANUAL TYPE

CAUTIONBe careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten it by using flat head screwdriver or pair of pliers.

Scheme 102

Scheme 102: Removal
Scheme 102: Removal

Scheme 103

Scheme 103
Scheme 103

Scheme 104

Scheme 104
Scheme 104

Scheme 105

Scheme 105
Scheme 105
  1. Disconnect negative (-) cable at battery.
  2. Recover refrigerant from A/C system by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) . NOTE: The amount of removed compressor oil must be measured for replenishing compressor oil.
  3. Remove suction pipe mounting bolts (1).
  4. Disconnect suction pipe (1) and condenser outlet pipe (2) using special tools. Special Tool 09991-15410 For condenser outlet pipe 09991-15420 For suction pipe CAUTION: Keep internal parts of air conditioning system free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.
  5. Drain engine coolant and disconnect heater hoses (1) from heater unit.
  6. Remove heater unit mounting nuts (2).
  7. Remove instrument panel referring to «INSTRUMENT PANEL REMOVAL AND INSTALLATION»(ref-251100-S22921662052007032000000) .
  8. Remove blower unit (1) referring to Step 5 ) to 7 ) of «BLOWER UNIT REMOVAL AND INSTALLATION»(ref-251093-S09637279612007032000000) .
  9. Disconnect couplers from the following parts. Temperature control actuator Air flow control actuator A/C evaporator inlet air temperature sensor (2) A/C evaporator outlet air temperature sensor (3) Blower motor controller
  10. Remove heater and cooling unit drain hose (4).
  11. Remove heater and cooling unit (5) from vehicle body.

Installation

Reverse removal procedure to install heater and cooling unit noting the following instructions.

  1. When installing each part, be careful not to catch any cable or wiring harness.
  2. Fill engine coolant to radiator.
  3. Replenish specified amount of compressor oil to compressor suction side by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  4. Evacuate and charge refrigerant by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  5. Sufficiently apply compressor oil to fitting surface of O-ring and pipe.

Condenser Assembly Removal and Installation

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

Scheme 106

Scheme 106: Removal
Scheme 106: Removal
  1. Disconnect negative (-) cable at battery.
  2. Recover refrigerant from A/C system by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) . NOTE: The amount of removed compressor oil must be measured for replenishing compressor oil.
  3. Remove front bumper referring to «FRONT BUMPER AND REAR BUMPER COMPONENTS»(ref-251107-S10961227522007032000000) .
  4. Remove hood lock cross member (1) and radiator stay bolts (2).
  5. Disconnect discharge hose (3) and condenser outlet pipe (4) from condenser (5). CAUTION: Keep internal parts of air conditioning system free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.
  6. Remove condenser mounting bolts (6).
  7. Remove condenser (5).

Reference: CONDENSER ASSEMBLY INSPECTION: MANUAL TYPE

Reverse removal procedure to install condenser noting the following instructions.

  1. Replenish specified amount of compressor oil to compressor suction side by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  2. Evacuate and charge refrigerant by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  3. Sufficiently apply compressor oil to fitting surface of O-ring and pipe.

Reverse removal procedure to install desiccant noting the following instructions.

  1. Do not remove desiccant from the plastic bag until just before inserting it into the receiver.
  2. Tighten receiver/dryer cap to specified torque. Tightening torque Receiver/dryer cap: 13 N.m (1.3 kg-m, 9.5 lb-ft)
  3. Replenish specified amount of compressor oil to compressor suction side by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .

Scheme 107

Scheme 107: Removal
Scheme 107: Removal

Scheme 108

Scheme 108
Scheme 108
  1. Remove condenser assembly referring to «CONDENSER ASSEMBLY REMOVAL AND INSTALLATION: MANUAL TYPE»(ref-251094-S02474329662007032000000) .
  2. Remove circlip (1) and filter cap (2) from receiver/dryer (3). CAUTION: Keep internal parts of air conditioning system free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.
  3. Remove desiccant (1) using a plier.

Reverse removal procedure to install desiccant noting the following instructions.

  1. Do not remove desiccant from the plastic bag until just before inserting it into the receiver.
  2. Replenish specified amount of compressor oil to compressor suction side by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .

Condenser Cooling Fan Removal and Installation

CAUTIONBe careful not to damage fins of radiator. If radiator fin is bent, straighten it by using flat head screwdriver or pair of pliers.

Scheme 109

Scheme 109: Removal
Scheme 109: Removal
  1. Disconnect negative (-) cable at battery.
  2. Disconnect condenser cooling fan motor coupler.
  3. Remove condenser cooling fan (1) from radiator (2).

Reference: CONDENSER COOLING FAN INSPECTION: MANUAL TYPE

Reverse removal procedure to install condenser cooling fan.

A/C Evaporator Removal and Installation

Reference: HEATER AND COOLING UNIT COMPONENTS: MANUAL TYPE

CAUTIONBe careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten it by using flat head screwdriver or pair of pliers.

Scheme 110

Scheme 110: Removal
Scheme 110: Removal

Scheme 111

Scheme 111
Scheme 111

Scheme 112

Scheme 112
Scheme 112
  1. Disconnect negative (-) cable at battery.
  2. Recover refrigerant from A/C system by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) . NOTE: The amount of removed compressor oil must be measured for replenishing compressor oil.
  3. Remove blower unit referring to «BLOWER UNIT REMOVAL AND INSTALLATION»(ref-251093-S09637279612007032000000) .
  4. Disconnect suction pipe (1) and condenser outlet pipe (2) using special tools. Special Tool 09991-15410 For condenser outlet pipe 09991-15420 For suction pipe CAUTION: Keep internal parts of air conditioning system free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.
  5. Fully remove packing from expansion valve.
  6. Remove expansion valve pipe (1) from expansion valve (2). CAUTION: Keep internal parts of air conditioning system free from moisture and dirt. When disconnecting any line from system, install a blind plug or cap to the fitting immediately.
  7. Remove expansion valve (2) from evaporator.
  8. Disconnect A/C evaporator inlet and outlet air temperature sensor couplers (1).
  9. Remove A/C evaporator outlet air temperature sensor (2).
  10. Remove air joint duct (3).
  11. Pull out A/C evaporator from heater and cooling unit (4).

Reference: A/C EVAPORATOR INSPECTION: MANUAL TYPE

Reference: A/C EVAPORATOR INLET AND OUTLET AIR TEMPERATURE SENSORS INSPECTION: MANUAL TYPE

Reverse removal procedure to install A/C evaporator noting the following instructions.

  1. Replenish specified amount of compressor oil to compressor suction side by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  2. Evacuate and charge refrigerant by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  3. Stick packing to expansion valve and expansion valve pipe after installation.
  4. Sufficiently apply compressor oil to fitting surface of O-ring and pipe.

Reference: A/C EVAPORATOR INLET AND OUTLET AIR TEMPERATURE SENSORS INSPECTION: MANUAL TYPE

Reverse the removal procedure to install A/C evaporator inlet and outlet air temperature sensors.

Removal

Refer to A/C EVAPORATOR REMOVAL AND INSTALLATION: MANUAL TYPE .

Reference: EXPANSION VALVE INSPECTION: MANUAL TYPE

Reverse removal procedure to install expansion valve noting the following instructions.

  1. Replenish specified amount of compressor oil to compressor suction side by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  2. Evacuate and charge refrigerant by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  3. Sufficiently apply compressor oil to fitting surface of O-ring and pipe.

Reference: A/C REFRIGERANT PRESSURE SWITCH INSPECTION: MANUAL TYPE

Reverse removal procedure to install A/C refrigerant pressure switch noting the following instruction.

Scheme 113

Scheme 113: Installation
Scheme 113: Installation
  1. Tighten A/C refrigerant pressure switch as specified torque.
  2. Sufficiently apply compressor oil to fitting surface of O-ring. Tightening torque A/C refrigerant pressure switch a: 11 N.m (1.1 kg-m, 8.0 lb-ft)

Compressor Drive Belt Removal and Installation

Reference: COMPRESSOR DRIVE BELT INSPECTION: MANUAL TYPE

Refer to GENERATOR DRIVE BELT REMOVAL AND INSTALLATION .

Reference: COMPRESSOR INSPECTION: MANUAL TYPE

Reverse removal procedure to install compressor noting the following instructions.

  1. If compressor is replaced, pour new compressor oil by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .
  2. Evacuate and charge system by referring to «OPERATION PROCEDURE FOR REFRIGERANT CHARGING: MANUAL TYPE»(ref-251094-S01938675342007032000000) .

Magnet Clutch Removal and Installation

Reference: MAGNET CLUTCH COMPONENTS: MANUAL TYPE

Scheme 114

Scheme 114: Removal
Scheme 114: Removal

Scheme 115

Scheme 115
Scheme 115

Scheme 116

Scheme 116
Scheme 116

Scheme 117

Scheme 117
Scheme 117
  1. Remove compressor from vehicle referring to «COMPRESSOR REMOVAL AND INSTALLATION: MANUAL TYPE»(ref-251094-S39548467602007032000000) .
  2. Fix armature plate (1) with special tool, and then remove armature plate bolt. Special Tool 09920-53710 NOTE: Do not reuse armature plate bolt.
  3. Remove armature plate.
  4. Remove shims from shaft.
  5. Using special tool, remove circlip. Special Tool 09900-06107
  6. Remove magnet clutch lead wire clamp and magnet clutch lead wire ground terminal.
  7. Remove magnet clutch pulley with puller (1). NOTE: Be careful not to damage magnet clutch pulley.
  8. Remove circlip using special tool. Special Tool 09900-06107
  9. Remove magnet clutch coil (1).

Scheme 118

Scheme 118: Installation
Scheme 118: Installation

Scheme 119

Scheme 119
Scheme 119

Scheme 120

Scheme 120
Scheme 120

Scheme 121

Scheme 121
Scheme 121
  1. Install magnet clutch coil (2). NOTE: Protrusion on under side of magnet clutch coil (2) must match hole in compressor assembly (3) to prevent movement and to locate lead wire correctly.
  2. Using special tool, install new circlip (1) as shown. Special Tool 09900-06107
  3. Install magnet clutch lead wire clamp and magnet clutch lead wire ground terminal.
  4. Install magnet clutch pulley (1). Set magnet clutch pulley squarely over clutch installation boss. Place special tool onto magnet clutch pulley bearing. Ensure that edge rests only on inner race of bearing. Special Tool 09991-06010 Install new circlip. CAUTION: Be careful not to scratch bearing seal.
  5. Adjust clearance between armature plate (1) and magnet clutch pulley (2) by putting shim(s) on compressor shaft. Standard clearance between armature plate and magnet clutch pulley "a" 0.35 - 0.6 mm (0.014 - 0.023 in.)
  6. Tighten new armature plate bolt (1) to specified torque. Tightening torque Armature plate bolt a: 18 N.m (1.8 kg-m, 13.0 lb-ft) Special Tool 09920-53710
  7. Install compressor to vehicle referring to «COMPRESSOR REMOVAL AND INSTALLATION: MANUAL TYPE»(ref-251094-S39548467602007032000000) .

Reference: HEATER AND COOLING UNIT COMPONENTS: AUTOMATIC TYPE

Refer to HEATER AND COOLING UNIT REMOVAL AND INSTALLATION: MANUAL TYPE .

Scheme 122

Scheme 122: Removal
Scheme 122: Removal
  1. Disconnect negative (-) cable at battery.
  2. Remove sunload sensor (1) from instrument panel by depressing tab and pushing sensor upward from underneath.
  3. Disconnect sunload sensor connector (2).

Reference: SUNLOAD SENSOR INSPECTION: AUTOMATIC TYPE

Reverse removal procedure for installation.

Reference: OUTSIDE AIR TEMPERATURE SENSOR INSPECTION: AUTOMATIC TYPE

Reverse removal procedure for installation.

Note. During installation, make sure that aspirator hose is securely connected to inside air temperature sensor.

Reverse removal procedure to install inside air temperature sensor.

Reference: CONDENSER ASSEMBLY INSPECTION: AUTOMATIC TYPE

Refer to CONDENSER ASSEMBLY REMOVAL AND INSTALLATION: MANUAL TYPE .

Desiccant Removal and Installation For Sedan Model

Refer to DESICCANT REMOVAL AND INSTALLATION FOR SEDAN MODEL: MANUAL TYPE .

Desiccant Removal and Installation For Wagon Model

Refer to DESICCANT REMOVAL AND INSTALLATION FOR WAGON MODEL: MANUAL TYPE .

Reference: CONDENSER COOLING FAN INSPECTION: AUTOMATIC TYPE

Refer to CONDENSER COOLING FAN REMOVAL AND INSTALLATION: MANUAL TYPE .

Reference: A/C EVAPORATOR INSPECTION: AUTOMATIC TYPE

Refer to A/C EVAPORATOR REMOVAL AND INSTALLATION: MANUAL TYPE .

A/C Evaporator Outlet Air Temperature Sensor Removal and Installation

Reference: A/C EVAPORATOR OUTLET AIR TEMPERATURE SENSOR INSPECTION: AUTOMATIC TYPE

Refer to A/C EVAPORATOR INLET AND OUTLET AIR TEMPERATURE SENSOR REMOVAL AND INSTALLATION: MANUAL TYPE .

Expansion Valve Removal and Installation

Reference: EXPANSION VALVE INSPECTION: AUTOMATIC TYPE

Refer to EXPANSION VALVE REMOVAL AND INSTALLATION: MANUAL TYPE .

A/C Refrigerant Pressure Switch Removal and Installation

Reference: A/C REFRIGERANT PRESSURE SWITCH INSPECTION: AUTOMATIC TYPE

Refer to A/C REFRIGERANT PRESSURE SWITCH REMOVAL AND INSTALLATION: MANUAL TYPE .

Reference: COMPRESSOR DRIVE BELT INSPECTION: AUTOMATIC TYPE

Refer to COMPRESSOR DRIVE BELT REMOVAL AND INSTALLATION: MANUAL TYPE .

Compressor Removal and Installation

Reference: Compressor Inspection: Automatic Type

Refer to COMPRESSOR REMOVAL AND INSTALLATION: MANUAL TYPE .

Reference: MAGNET CLUTCH COMPONENTS: AUTOMATIC TYPE

Refer to MAGNET CLUTCH REMOVAL AND INSTALLATION: MANUAL TYPE .

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