Manual A/c (Type 1): Other Suzuki Equator I

Precautions for Working with HFC-134a (R-134a)

CONTAMINATED REFRIGERANT

If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are

1. Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere.
2. Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply.
3. Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred.
4. If you choose to perform the repair, recover the refrigerant using only dedicated equipment and containers. Do not recover contaminated refrigerant into your existing service equipment. If your facility does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended.
5. If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact SUZUKI Customer Affairs for further assistance.

MANIFOLD GAUGE SET

Be certain that the gauge face indicates R-134a or 134a. Make sure the gauge set has 1/2"-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) along with specified oil.

Scheme 68

SERVICE HOSES

Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut- off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.

Scheme 69

SERVICE COUPLERS

Never attempt to connect HFC-134a (R-134a) service couplers to a CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur.

Scheme 70

A/C SERVICE VALVE CHART

WORK FLOW

DIAGNOSIS PROCEDURES

TEMPERATURE CONTROL DIAL (TEMPERATURE CONTROL)

Increases or decreases the set temperature.

RECIRCULATION SWITCH

1. When REC switch is ON, REC switch indicator turns ON, and air inlet is set to REC.
2. When REC switch is turned OFF, or when compressor is turned from ON to OFF, REC switch is automatically turned OFF. REC mode can be re-entered by pressing REC switch again.
3. REC switch is not operated when DEF switch is turned ON, or at the D/F or FOOT position.

DEFROSTER SWITCH

Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.

REAR WINDOW DEFOGGER SWITCH

When switch is ON, rear window is defogged.

OFF SWITCH (BLOWER SPEED DIAL)

The compressor and blower are OFF.

A/C SWITCH (IF EQUIPPED)

The compressor is ON or OFF.

(Pressing the A/C switch will turn off the A/C switch and compressor.)

MODE SWITCHES

Controls the air discharge outlets.

FRONT BLOWER CONTROL DIAL

Manually controls the blower speed.

Scheme 71

When the A/C switch is pressed, or the mode switch is pressed to the DEF or D/F position, the front air control outputs a compressor ON signal to BCM.

The BCM then sends a compressor ON signal to ECM, via CAN communication line.

ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant pressure sensor signal, throttle angle sensor, etc.). If it judges compressor can be turned ON, it sends compressor ON signal to IPDM E/R, via CAN communication line.

Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate compressor.

Discharge Air Flow Table

DISCHARGE AIR FLOW CHART Mode door position Air outlet/distribution Vent Foot Defroster 95% 5% - 0% 40% - 20% 55% 25% 15% 50% 35% 7% 15% 78% Airflow always present at driver and passenger side demisters

Scheme 72

Scheme 73

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Scheme 78

Refrigerant Cycle

Refer to [ REFRIGERATION SYSTEM: REFRIGERANT CYCLE ]

CONTROL SYSTEM

The control system consists of input sensors, switches, the front air control (microcomputer) and outputs.

The relationship of these components is shown in the figure below

Scheme 79

Scheme 80

Scheme 81

CHECKING BLOWER

1. Turn blower control dial clockwise. Blower should operate on low speed.
2. Turn the blower control dial again, and continue checking each blower speed until all speeds are checked.
3. Leave blower on HI speed.

If NG, go to trouble diagnosis procedure for [ BLOWER MOTOR CIRCUIT CHECK ].

If OK, continue with next check.

CHECKING DISCHARGE AIR

Press each mode switch and confirm that discharge air comes out according to the air distribution table. Refer tot [ DISCHARGE AIR FLOW TABLE ].

Mode door position is checked in the next step.

If NG, go to trouble diagnosis procedure for [ MODE DOOR MOTOR CIRCUIT CHECK ].

If OK, continue with next check.

Note. Confirm that the A/C compressor clutch is engaged (sound or visual inspection) and intake door position is at fresh when the ( ) or ( ) is selected.

CHECKING RECIRCULATION

1. Press recirculation switch one time. Recirculation indicator should illuminate.
2. Press recirculation switch one more time. Recirculation indicator should go off.
3. Listen for intake door position change (blower sound should change slightly).

If NG, go to trouble diagnosis procedure for [ INTAKE DOOR MOTOR CIRCUIT CHECK ].

If OK, continue with next check.

Note. Confirm that the compressor clutch is engaged (sound or visual inspection) and intake door position is at fresh when the DEF or D/F is selected.

CHECKING TEMPERATURE DECREASE

1. Rotate temperature control dial counterclockwise.
2. Check for cold air at appropriate discharge air outlets.

If NG, listen for sound of air mix door motor operation if OK, go to trouble diagnosis procedure for [ INSUFFICIENT COOLING ]. If air mix door motor appears to be malfunctioning, go to [ AIR MIX DOOR MOTOR CIRCUIT CHECK ].

If OK, continue with next check.

CHECKING TEMPERATURE INCREASE

1. Rotate temperature control dial clockwise.
2. Check for hot air at appropriate discharge air outlets.

If NG, listen for sound of air mix door motor operation. If OK, go to trouble diagnosis procedure for [ INSUFFICIENT HEATING ]. If air mix door motor (front) appears to be malfunctioning, go to [ AIR MIX DOOR MOTOR CIRCUIT CHECK ].

If OK, continue with next check.

CHECK A/C SWITCH

1. Press A/C switch with the blower switch ON.
2. A/C switch indicator will turn ON. Confirm that the compressor clutch engages (sound or visual inspection).

If NG, go to trouble diagnosis procedure for [ MAGNET CLUTCH CIRCUIT CHECK ].

If OK, continue with next check.

Data List

DATA LIST

Front Air Control

The front air control has a built-in microcomputer which processes information sent from various sensors needed for air conditioner operation. The air mix door motor, mode door motor, intake door motor, blower motor and compressor are then controlled.

Scheme 82

The front air control is unitized with control mechanisms. When the various switches and temperature dials are operated, data is input to the front air control.

Potentio Temperature Control (PTC)

The PTC is built into the front air control. It can be set from cold to hot or any intermediate position by rotating the temperature dial.

Scheme 83

Front Air Control Component Function Check

SYMPTOM: A/C system does not come on.

TERMINALS AND REFERENCE VALUES FOR FRONT AIR CONTROL

VOLTAGE REFERENCE CHART Terminal No. Wire color Item Ignition switch Condition Voltage (V) (Approx.) 1 R/Y Power supply for BAT - - Battery voltage 3 P Ground for mode door motor and air mix door motor PBR ON - 0V 4 W Compressor ON signal ON A/C switch OFF 5V ON A/C switch ON 0V 5 R Front blower monitor ON Front blower motor OFF Battery voltage Front blower motor ON 0V 6 SB Air mix door motor feedback ON - 0 - 5V 7 V Mode door motor feedback ON - 0 - 5V 8 G Illumination + ON Park lamps ON Battery voltage 9 BR Illumination - - Park lamps ON 10 R Rear defrost request ON - Battery voltage 11 L Intake sensor ON - 0 - 5V 13 B Ground - - 0V 15 W/G Power supply for IGN ON - Battery voltage 16 Y Rear defroster request ON - Battery voltage 17 GR Air mix door motor CCW ON Counterclockwise rotation Battery voltage 18 O Air mix door motor CW ON Clockwise rotation Battery voltage 19 R Mode door motor CCW ON Counterclockwise rotation Battery voltage 20 BR Mode door motor CW ON Clockwise rotation Battery voltage 21 O Intake door motor CCW ON Counterclockwise rotation Battery voltage 22 Y Intake door motor CW ON Clockwise rotation Battery voltage 23 G Power supply for mode door motor and air mix door motor PBR ON - 5V 24 LG Variable blower control ON Blower speed (low) 1.7V Blower speed (hi) 4.5V 26 V Sensor ground ON - 0 - 5V

Scheme 84

Component Parts

Mode door control system components are

1. Front air control
2. Mode door motor
3. PBR (built into mode door motor)
4. Intake sensor

Mode Door Motor

The mode door motor is attached to the heater and cooling unit assembly. It rotates so that air is discharged from the outlet as indicated by the front air control. Motor rotation is conveyed to a link which activates the mode door.

Scheme 85

Mode Door Motor Component Function Check

SYMPTOM

1. Air outlet does not change.
2. Mode door motor does not operate normally.

Air mix door control system components are

1. Front air control
2. Air mix door motor
3. PBR (built into air mix door motor)
4. Intake sensor

Air Mix Door Motor

The air mix door motor is attached to the heater and cooling unit assembly. This motor rotates so that the air mix door is opened or closed to a position set by the front air control. Motor rotation is then conveyed through a shaft and the air mix door position is then fed back to the front air control by the PBR built into the air mix door motor.

Scheme 86

Intake door control system components are

1. Front air control
2. Intake door motor
3. Intake sensor

Intake door motor

The intake door motor is attached to the intake unit. It rotates so that air is drawn from inlets set by the front air control. Motor rotation is conveyed to a lever which activates the intake door.

Scheme 87

Intake Door Motor Component Function Check

SYMPTOM

1. Intake door does not change.
2. Intake door motor does not operate normally.

Blower speed control system components are

1. Front air control
2. Variable blower control
3. Front blower motor
4. Front blower motor relay

Scheme 88

Variable Blower Control

The variable blower control (1) is located on the heater and cooling unit assembly. The variable blower control receives a gate voltage from the front air control to steplessly maintain the blower motor voltage in the 0 to 5 volt range (approx.) ↓: front.

Scheme 89

Front Blower Motor Relay

Check continuity between terminals 3 and 5 and terminals 7 and 6 by supplying 12 volts and ground to coil side terminals 1 and 2 of the relay.

Scheme 90

Front Blower Motor

Confirm smooth rotation of the blower motor.

Scheme 91

1. Ensure that there are no foreign particles inside the blower unit.
2. Apply 12 volts to terminal 2 and ground to terminal 1 and verify that the motor operates freely and quietly.

Low Temperature Protection Control

The front air control will turn the compressor ON or OFF as determined by a signal detected by the intake sensor.

When intake air temperature is higher than 3.5°C (38.3°F), the compressor turns ON. The compressor turns OFF when intake air temperature is lower than 2.5°C (36.5°F).

Magnet Clutch Component Function Check

SYMPTOM: Magnet clutch does not engage.

Intake Sensor

The intake sensor is located on top of the heater and cooling unit assembly next to the A/C evaporator cover. It converts temperature of air after it passes through the evaporator into a resistance value which is then input to the front air control.

Scheme 92

After disconnecting intake sensor connector, measure resistance between terminals 1 and 2 at sensor harness side, using the table below.

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RESISTANCE AND TEMPERATURE CHART

If NG, replace intake sensor. Refer to [ INTAKE SENSOR: REMOVAL AND INSTALLATION ]

Component Function Check

SYMPTOM: Insufficient cooling

Recirculating-to-discharge Air Temperature Table

RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE CHART

Ambient Air Temperature-to-operating Pressure Table

Ambient air

AMBIENT AIR TEMPERATURE-TO-OPERATING PRESSURE CHART

Both High- and Low-pressure Sides are Too High

PROBABLE CAUSE CHART Gauge indication Refrigerant cycle Probable cause Corrective action [A] Both high- and low-pressure sides are too high. Pressure is reduced soon after water is splashed on condenser. Excessive refrigerant charge in refrigeration cycle Reduce refrigerant until specified pressure is obtained. Air suction by cooling fan is insufficient. Insufficient condenser cooling performance ↓ Condenser fins are clogged. Improper fan rotation of cooling fan Clean condenser. Check and repair cooling fan if necessary. Low-pressure pipe is not cold. When compressor is stopped high-pressure value quickly drops by approximately 196 kPa (2 kg/cm 2 , 28 psi). It then decreases gradually thereafter. Poor heat exchange in condenser (After compressor operation stops, high-pressure decreases too slowly.) ↓ Air in refrigeration cycle Evacuate and recharge system. Engine tends to overheat. Engine cooling systems malfunction. Check and repair engine cooling system. An area of the low-pressure pipe is colder than areas near the evaporator outlet. Plates are sometimes covered with frost. Excessive liquid refrigerant on low-pressure side Excessive refrigerant discharge flow Expansion valve is open a little compared with the specification. ↓ Improper expansion valve adjustment Replace expansion valve

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High-pressure Side is Too High and Low-pressure Side is Too Low

PROBABLE CAUSE CHART Gauge indication Refrigerant cycle Probable cause Corrective action [B] High-pressure side is too high and low-pressure side is too low. Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot. High-pressure tube or parts located between compressor and condenser are clogged or crushed. Check and repair or replace malfunctioning parts. Check oil for contamination

Scheme 95

High-pressure Side is Too Low and Low-pressure Side is Too High

PROBABLE CAUSE CHART Gauge indication Refrigerant cycle Probable cause Corrective action [C] High-pressure side is too low and low-pressure side is too high. High- and low-pressure sides become equal soon after compressor operation stops. Compressor pressure operation is improper. ↓ Damaged inside compressor packings. Replace compressor. No temperature difference between high- and low-pressure sides. Compressor pressure operation is improper. ↓ Damaged inside compressor packings. Replace compressor

Scheme 96

Both High- and Low-pressure Sides are Too Low

PROBABLE CAUSE CHART Gauge indication Refrigerant cycle Probable cause Corrective action [D] Both high- and low-pressure sides are too low. There is a big temperature difference between liquid tank outlet and inlet. Outlet temperature is extremely low. Liquid tank inlet and expansion valve are frosted. Liquid tank inside is slightly clogged. Replace liquid tank. Check oil for contamination. Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. Expansion valve inlet may be frosted. Temperature difference occurs somewhere in high-pressure side. High-pressure pipe located between liquid tank and expansion valve is clogged. Check and repair malfunctioning parts. Check oil for contamination. Expansion valve and liquid tank are warm or only cool when touched. Low refrigerant charge. ↓ Leaking fittings or components. Check refrigerant system for leaks. Refer to [ CHECKING OF REFRIGERANT LEAKS ] There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted. Expansion valve closes a little compared with the specification. ↓ Improper expansion valve adjustment. Malfunctioning expansion valve. Outlet and inlet may be clogged. Remove foreign particles by using compressed air. Check oil for contamination. An area of the low-pressure pipe is colder than areas near the evaporator outlet. Low-pressure pipe is clogged or crushed. Check and repair malfunctioning parts. Check oil for contamination. Air flow volume is too low. Evaporator is frozen. Check intake sensor circuit. Refer to [ INTAKE SENSOR CIRCUIT CHECK ]. Replace compressor. Repair evaporator fins. Replace evaporator. Refer to [ BLOWER MOTOR CIRCUIT CHECK ]

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Low-pressure Side Sometimes Becomes Negative

PROBABLE CAUSE CHART Gauge indication Refrigerant cycle Probable cause Corrective action [E] Low-pressure side sometimes becomes negative. Air conditioning system does not function and does not cyclically cool the compartment air. The system constantly functions for a certain period of time after compressor is stopped and restarted. Refrigerant does not discharge cyclically. ↓ Moisture is frozen at expansion valve outlet and inlet. ↓ Water is mixed with refrigerant. Drain water from refrigerant or replace refrigerant. Replace liquid tank

Scheme 98

Low-pressure Side Becomes Negative

PROBABLE CAUSE CHART Gauge indication Refrigerant cycle Probable cause Corrective action [F] Low-pressure side becomes negative. Liquid tank or front/rear side of expansion valve's pipe is frosted or dewed. High-pressure side is closed and refrigerant does not flow. ↓ Expansion valve or liquid tank is frosted. Leave the system at rest until no frost is present. Start it again to check whether or not the malfunction is caused by water or foreign particles. If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. If due to foreign particles, remove expansion valve and remove the particles with dry and compressed air (not shop air). If either of the above methods cannot correct the malfunction, replace expansion valve. Replace liquid tank. Check oil for contamination

Scheme 99

Insufficient Heating

SYMPTOM: Insufficient heating