I am leaving the procedure in the order from the Suzuki AC install manual for others installing while the motor is in.
As I didn't start with a Suzuki Air Conditioning Install Kit, I did not have all the "little" parts... mostly plastic and rubber like parts that fell apart while picking the parts from the yard.
My comments are in BLUE.
First collect the parts:
-- Cooling unit (evaporator)
-- Interior Harness
-- Amplifier
-- Control switch and harness
-- Engine bay AC Harness
-- Condenser Fan Compressor Clutch Harness
-- Water temperature switch
-- Receiver bracket
-- Compressor with brackets/bolts
-- New (longer) Drive belt
-- Suction Tube
-- Suction Hose
-- Discharge Hose
-- Liquid Tube (condenser/receiver)
-- Liquid Tube (receiver/cooling unit)
-- Condenser
-- Condenser fan
-- Something to use as side seals and foam packing seal around radiator
Other things to collect:
AC service gauges
A vacuum pump
AC flush kit (if needed)
New receiver (drier/accumulator)
New O-rings
O-ring lube (You can use PAG oil, but there are better sealing solutions)
PAG 46 Oil (100ml)
--
If not new parts, clean and flush with proper solvent.
Blow dry with clean dry air.
This is my "Flush Kit."
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Remove Glove box
Remove Air duct (discard)
You might want to clean out the heater
This was BEFORE I vacuumed out the heater box
Remove Blower AssemblyCut out template of silencer pad (not needed on 1994)
Remove caps from firewall (Suction Line, Liquid Tube, Drain Hose)
Temporarily connect cooling unit band to heater unit. Ensure screw head is down.
Install drain hose to cooling unit
Install cooling unit to firewall. Fasten with two bolts (interior) and one nut (engine bay)
Loosen and move cooling unit band over cooling unit/heater unit connection
Tighten the band
Install the grommets for the cooling unit tubes and hoses
Connect 10 pin connector to vehicle harness connector
Connect 2 pin connector to the thermistor
Connect 12 pin connector to the amplifier
Connect 3 pin connector to the A/C switch (w/lever controls only)
Cut out cap in heater control, install AC switch (w/lever controls only)
Remove cover in heater control, install AC switch knob (w/button controls only)
Note:
There are two major kinds of wiring harnesses.
The earlier (up to 1995) has an in-line fuse and the on/off switch attaches
to the harness.
The later Harness (96 and up) has only three connectors and no fuse.
Secure the A/C harness clip to the harness bolt.
Reinstall Blower Assembly
Reinstall Glove box
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Remove Headlight covers (Sport)
Remove Front Grille
Remove Bumper
Remove Horn
Remove Air Cleaner and duct (if on right side)
Remove Battery
Remove Evap Canister
Remove Washer Tank (if on right side)
Remove Cruise Control (if on right side)
Remove Radiator Overflow tank (if on right side)
Remove Drive belt (P/S belt on 1.6l) & discard
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Install Compressor J18, M8 bolts, torque 18.1 ft/lbs
Ensure the compressor is filled with the proper amount and type
compressor oil. My research says ND-Oil 8 is PAG 46.
The manual says the system should have 100ml.
Install New Drive belt (P/S belt on 1.6l)
The lower bracket bolts to the power steering bracket
With AC compressor installed, the power steering pump uses the "fixed" lower bolt position
See the bolt hidden in the pump pulley?
The problem is these nice blue bracket I collected where the wrong size. I THINK they are for an early R-12compressor.
Complete "test fit" with the proper AC compressor brackets
and a spare PS pump.
bottom right use original bolt on tubing clamp (J18)
Fasten ( R ) Side Seal to Radiator support using a bolt
This is what I came up with for the side seal. (x2)
It is to keep hot air from inside the engine compartment from going back around and back though the condenser and radiator.
I cut holes for the headlights and blinkers
I installed the tubes, covered with foam and zip tied to the body. Other parts are being test fitted.
Fasten Receiver bracket and ( R ) Side Seal to Radiator support using a bolt, but do not tighten.
Fasten ( R ) Side Seal to Body using two plastic pins
bottom left use original bolt on tubing clamp (J18)
Fasten ( L ) Side Seal to Radiator support using two bolts
Fasten Discharge Hose Clamp Bracket (J18) and ( L ) Side Seal to Radiator support using a bolt, but do not tighten.
--
Fasten ( L ) Side Seal to Body using two plastic pins
Install Relays to Discharge Hose Clamp Bracket (J18)
Insert the condenser from the bottom side up.
Fasten the condenser to radiator supports with 4 bolts.
I installed the condenser and fan after the motor was in but before the radiator. I could not install it from below as the towing brackets (another post) were in the way.
Loosely install Receiver to receiver bracket
Connect Liquid Tube between the receiver and the condenser with 2 bolts torque to 4.0 ft lbs (receiver)
torque to 7.2 ft lbs (condenser)
Install condenser fan to the condenser with 4 bolts (M6)
Install suction tube clamp bracket to ( R ) radiator support with original bolt and plastic bolt to side seal.
Install suction tube clamp bracket to ( L ) radiator support with original bolt and plastic bolt to side seal. J18?
Install Liquid tube between receiver and cooling unit torque to 4.0 ft lbs (receiver)
Route the suction tube from cooling unit to left side of radiator.
Connect the suction and liquid tubes to the cooling unit.
Fasten tubes to body with clamps
Connect the discharge hose between the compressor and the condenser inlet fitting with two bolts torque to 7.2 ft lbs
Connect the suction hose between the compressor and the suction tube torque to 7.2 ft lbs
Fasten the discharge hose to the bracket using a clamp and a bolt.
Fasten the suction hose to the bracket using a clamp and a bolt.
Fasten the suction tube to the bracket using a clamp and a bolt.
Remove original bolt (plug) from thermostat/water housing and discard.
Install water temperature switch to the thermostat/water housing torque to 8.7 ft lbs
Clean above radiator with IPA and install label
Install foam packing seal to top of radiator
My "foam packing seal" that has the same function as the sides shields. I might need to zip tie in place... but may not need it.
Route the A/C harness along the vehicle wire harness
Fasten the A/C harness to the vehicle wire harness with original clamps and tyes.
Connect the A/C harness to power at fuse box.
Connect the A/C harness to original harness (control)
Connect the A/C harness to pressure switch at receiver
Connect the A/C harness to condenser fan
Connect the A/C harness to compressor clutch
Connect the A/C harness to relays (by battery (1.6) or left radiator support (1.8)
Connect the A/C harness to body ground
Connect the A/C harness to water temperature switch
I connected AC power, with a 25 amp fuse, to the alternator side of the main fuse rather than the positive terminal of the battery. I dislike extra connections right at the battery. I also found I do not have the correct engine (over) temperature switch. Grounding the wire allows the system to work until I get the proper switch.
--
Inspect the install for parts install and fastening
Inspect the install for pinched electrical harness
Inspect the install for pinched, bent or constricted hoses and tubes
Inspect the install for safety gaps
--
Reinstall Radiator Overflow tank (if removed)
Reinstall Cruise Control (if removed)
Reinstall Washer Tank (if removed)
Reinstall Evap Canister
Reinstall Battery
Reinstall Air Cleaner and duct (if removed)
Reinstall Horn
--
Pull vacuum (Sorry no pictures)
Check for leaks
Charge system – J18, HFC-134a standard charge 1.32 to 1.43 lbs (600 to 650g)
I charged the system with HC-12a. My calculations said I should have needed almost two cans for proper operation. (1.375lbs = 22oz HFC-134a) or 1.57cans/9.43oz HC-12a
But I had higher pressure than a normally operating HC-12a system at just above idle. (28lbs) So I only installed a single can.
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Inspect the install. There should be _NO_ abnormal sounds during operation
Inspect the install. On/off compressor clutch
Inspect the install. Blower motor speed changes
Inspect the install. Air inlet (rec/fresh) change with lever
Inspect the install. Air outlet change with lever
Inspect the install. Temperature (hot/cold adjustment)
--
Reinstall headlight covers
Reinstall Bumper
Reinstall Front Grille
Works Good.
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