Suzuki Aerio, Verona 2002-06

Removal & Installation

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  1. Run engine at idle speed with A/C ON for 10 minutes.
  2.  
  3. Stop the engine.
  4.  
  5. Disconnect negative (-) cable at battery.
  6.  
  7. Recover refrigerant from A/C system.
    NOTE
    The amount of removed compressor oil must be measured for replenishing compressor oil.

  8.  
  9. Disconnect magnet clutch lead wire coupler (1).
  10.  
  11. Remove condenser cooling fan (2).

    Click image to see an enlarged view

    Fig. Disconnect the magnetic clutch lead wire coupler and remove condenser cooling fan

  12.  
  13. Remove heated oxygen sensor-2 and magnet clutch lead wire clamp.
  14.  
  15. Disconnect discharge pipe and suction pipe from compressor.
    NOTE
    Cap all of the refrigerant line opening immediately to keep moisture out of the system.

  16.  
  17. Remove compressor mounting bolts (2), and then remove compressor (3) from its bracket.
    CAUTION
    When removing compressor, be careful not to damage heated oxygen sensor-2 wire (4).



    Click image to see an enlarged view

    Fig. Remove compressor mounting bolts and compressor

  18.  

To install:

  1. Reverse removal procedure to install compressor noting the following instructions.

    If compressor is replaced, add new compressor oil by referring to Refrigerant Charging: Manual Type.
     
    Evacuate and charge system.
     

  2.  

5- & 6-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery lead.
  4.  
  5. Properly discharge the air conditioning system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Position the front lift arms so that they do not obstruct the sub-frame support plates.



    The accessory drive belt. Refer to Accessory Drive Belts removal and installation.
     
    The bolts for the low and high pressure hoses for the compressor
     

  8.  
  9. Raise the vehicle.
  10.  
  11. Remove or disconnect the following:

    The protective cover under the engine
     
    The 2 bolts for the front splash guard. Press in the cover by pressing in the catches at the front edge. Pull the cover backwards
     
    The bolt for the cable conduit
     
    Remove the conduit from the sub-frame
     
    Detach the air duct for the control module box from the sub-frame
     

  12.  
  13. Unscrew the low and high pressure hoses from the compressor and bend them to one side.
  14.  
  15. Disconnect the connector from the magnetic clutch for the compressor.
  16.  
  17. Remove the 4 bolts from the compressor.
  18.  
  19. Hold the cable conduit to one side and remove the A/C compressor from between the sub-frame and the body.

    Click image to see an enlarged view

    Fig. Removing the compressor from between the sub-frame and the body-5- and 6-Cylinder Engines

  20.  

To install:

  1. The installation is the reverse of the removal procedure.
  2.  
  3. Install or connect the following:
    NOTE
    Always use new O-rings lubricated with compressor oil.



    The A/C compressor between the sub-frame and the body
     
    Install the mounting screws, Tighten to 18 ft. lbs. (24 Nm)
     



    The low and high pressure hoses
     
    The magnetic clutch connector
     
    The cable conduit on the sub-frame
     
    The air duct on the control module box on the sub-frame
     
    The protective cover under the engine
     
    The front splash guard
     

  4.  
  5. Lower the vehicle.
  6.  
  7. Install or connect the following:

    The accessory drive belt
     
    The battery negative lead to battery
     

  8.  
  9. Vacuum pump and properly recharge refrigerant system.
  10.  

8-Cylinder Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery lead.
  4.  
  5. Properly discharge the air conditioning system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Plug the terminals of the compressor using the transport plugs from the new compressor.



    The accessory drive belt. Refer to Accessory Drive Belts removal and installation
     
    The engine cooling fan. Refer to Engine Fan removal and installation
     
    Hang the lower coolant hose (1) to one side.
     
    Remove the 2 connectors (2)
     
    The hose/pipe connections to the compressor and push them to one side

    Click image to see an enlarged view

    Fig. Location of coolant hose and electrical connectors-8-Cylinder Engine

     

  8.  
  9. Remove the lower mounting screw (1) at the pulley. The screw can be reached from underneath after the splashguard for the engine has been removed. The screw is in the right-hand corner of the sub-frame.
    NOTE
    The screw cannot be removed from this position.

  10.  
  11. Remove the screw (2) underneath the compressor hose/pipe terminals.
  12.  
  13. Remove the upper mounting screw (3) at the pulley.
    NOTE
    This screw (3) is longer than the other two screws.



    Click image to see an enlarged view

    Fig. Location of lower and upper mounting bolts A/C compressor-8-Cylinder Engine

  14.  
  15. Withdraw the compressor slightly. Remove the lower left-hand mounting bolt.
  16.  
  17. Remove the compressor with the connectors turned outwards (as illustrated).

    Click image to see an enlarged view

    Fig. Removing A/C compressor-8-Cylinder Engine

  18.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Install or connect the following:
    CAUTION
    Ensure that the electrical cables are not trapped behind the compressor. The electrical cables must be pulled in tight to the compressor under the pipe/hose connectors.



    The A/C compressor with the connectors turned outwards
     
    The compressor in the sub-frame
     
    The lower, left-hand mounting bolt
     

  4.  
  5. Install or connect the following:
    NOTE
    Do not install the skid plate yet.



    The compressor with 3 x M8 bolts. Tighten to 18 ft. lbs. (24 Nm)
     
    The pipes/hoses to the compressor
     
    The connectors
     
    The lower coolant hose
     
    The accessory drive belt. Refer to Accessory Drive Belts removal and installation
     



    The engine cooling fan. Refer to Engine Fan removal and installation
     
    The negative battery lead.
     

  6.  
  7. Vacuum pump the air conditioning (A/C) system.
  8.  
  9. Properly fill the air conditioning (A/C) system with refrigerant.
  10.  

 
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