Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Air Conditioning System



See Figures 1 and 2

It is recommended that the A/C system be serviced by an EPA Section 609 certified automotive technician utilizing a refrigerant recovery/recycling machine.

The do-it-yourselfer should not service his/her own vehicle's A/C system for many reasons, including legal concerns, personal injury, environmental damage and cost. The following are some of the reasons why you may decide not to service your own vehicle's A/C system.

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Fig. Fig. 1: A label in the engine compartment warns that the A/C system should only be serviced by qualified personnel

According to the U.S. Clean Air Act, it is a federal crime to service or repair (involving the refrigerant) a Motor Vehicle Air Conditioning (MVAC) system for money without being EPA certified. It is also illegal to vent R-12 and R-134a refrigerants into the atmosphere. Selling or distributing A/C system refrigerant (in a container which contains less than 20 pounds of refrigerant) to any person who is not EPA 609 certified is also not allowed by law.

State and/or local laws may be more strict than the federal regulations, so be sure to check with your state and/or local authorities for further information. For further federal information on the legality of servicing your A/C system, call the EPA Stratospheric Ozone Hotline.

Federal law dictates that a fine of up to $25,000 may be leveled on people convicted of venting refrigerant into the atmosphere. Additionally, the EPA may pay up to $10,000 for information or services leading to a criminal conviction of the violation of these laws.

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Fig. Fig. 2: Your A/C system should be serviced only by qualified MVAC technician, one reason being the extreme toxicity of air conditioning refrigerant

When servicing an A/C system you run the risk of handling or coming in contact with refrigerant, which may result in skin or eye irritation or frostbite. Although low in toxicity (due to chemical stability), inhalation of concentrated refrigerant fumes is dangerous and can result in death; cases of fatal cardiac arrhythmia have been reported in people accidentally subjected to high levels of refrigerant. Some early symptoms include loss of concentration and drowsiness (zzzzzzzz).

Generally, the limit for exposure is lower for R-134a than it is for R-12. Exceptional care must be practiced when handling R-134a.

Also, refrigerants can decompose at high temperatures (near gas heaters or open flame), which may result in hydrofluoric acid, hydrochloric acid and phosgene (a fatal nerve gas).

R-12 refrigerant can damage the environment because it is a Chlorofluorocarbon (CFC), which has been proven to add to ozone layer depletion, leading to increasing levels of UV radiation. UV radiation has been linked with an increase in skin cancer, suppression of the human immune system, an increase in cataracts, damage to crops, damage to aquatic organisms, an increase in ground-level ozone, and increased global warming.

R-134a refrigerant is a greenhouse gas which, if allowed to vent into the atmosphere, will contribute to global warming (the Greenhouse Effect).

It is usually more economically feasible to have a certified MVAC automotive technician perform A/C system service on your vehicle. Some possible reasons for this are as follows:

While it is illegal to service an A/C system without the proper equipment, the home mechanic would have to purchase an expensive refrigerant recovery/recycling machine to service his/her own vehicle.
Since only a certified person may purchase refrigerant-according to the Clean Air Act, there are specific restrictions on selling or distributing A/C system refrigerant-it is legally impossible (unless certified) for the home mechanic to service his/her own vehicle. Procuring refrigerant in an illegal fashion exposes one to the risk of paying a $25,000 fine to the EPA.

R-12 Refrigerant Conversion

If your vehicle still uses R-12 refrigerant, one way to save A/C system costs down the road is to investigate the possibility of having your system converted to R-134a. The older R-12 systems can be easily converted to R-134a refrigerant by a certified automotive technician by installing a few new components and changing the system oil.

The cost of R-12 is steadily rising and will continue to increase, because it is no longer imported or manufactured in the United States. Therefore, it is often possible to have an R-12 system converted to R-134a and recharged for less than it would cost to just charge the system with R-12.

If you are interested in having your system converted, contact local automotive service stations for more details and information.


See Figures 3 and 4

Although the A/C system should not be serviced by the do-it-yourselfer, preventive maintenance can be practiced and A/C system inspections can be performed to help maintain the efficiency of the vehicle's A/C system. For preventive maintenance, perform the following:

The easiest and most important preventive maintenance for your A/C system is to be sure that it is used on a regular basis. Running the system for five minutes each month (no matter what the season) will help ensure that the seals and all internal components remain lubricated.

Some newer vehicles automatically operate the A/C system compressor whenever the windshield defroster is activated. When running, the compressor lubricates the A/C system components; therefore, the A/C system would not need to be operated each month.

In order to prevent heater core freeze-up during A/C operation, it is necessary to maintain proper antifreeze protection. Use a hand-held coolant tester (hydrometer) to periodically check the condition of the antifreeze in your engine's cooling system.

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Fig. Fig. 3: A coolant tester can be used to determine the freezing and boiling levels of the coolant in your vehicle

Antifreeze should not be used longer than the manufacturer specifies.

For efficient operation of an air conditioned vehicle's cooling system, the radiator cap should have a holding pressure which meets manufacturer's specifications. A cap which fails to hold these pressures should be replaced.

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Fig. Fig. 4: To ensure efficient cooling system operation, inspect the radiator cap gasket and seal

Any obstruction of or damage to the condenser configuration will restrict air flow which is essential to its efficient operation. It is, therefore, a good rule to keep this unit clean and in proper physical shape.

Bug screens which are mounted in front of the condenser (unless they are original equipment) are regarded as obstructions.

The condensation drain tube expels any water which accumulates on the bottom of the evaporator housing into the engine compartment. If this tube is obstructed, the air conditioning performance can be restricted and condensation buildup can spill over onto the vehicle's floor.


See Figure 5

Although the A/C system should not be serviced by the do-it-yourselfer, preventive maintenance can be practiced and A/C system inspections can be performed to help maintain the efficiency of the vehicle's A/C system. For A/C system inspection, perform the following:

The easiest and often most important check for the air conditioning system consists of a visual inspection of the system components. Visually inspect the air conditioning system for refrigerant leaks, damaged compressor clutch, abnormal compressor drive belt tension and/or condition, plugged evaporator drain tube, blocked condenser fins, disconnected or broken wires, blown fuses, corroded connections and poor insulation.

A refrigerant leak will usually appear as an oily residue at the leakage point in the system. The oily residue soon picks up dust or dirt particles from the surrounding air and appears greasy. Through time, this will build up and appear to be a heavy dirt impregnated grease.

For a thorough visual and operational inspection, check the following:

Check the surface of the radiator and condenser for dirt, leaves or other material which might block air flow.

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Fig. Fig. 5: Periodically remove any debris from the condenser and radiator fins

Check for kinks in hoses and lines. Check the system for leaks.
Make sure the drive belt is properly tensioned. When the air conditioning is operating, make sure the drive belt is free of noise or slippage.
Make sure the blower motor operates at all appropriate positions, then check for distribution of the air from all outlets with the blower on HIGH or MAX .

Keep in mind that under conditions of high humidity, air discharged from the A/C vents may not feel as cold as expected, even if the system is working properly. This is because vaporized moisture in humid air retains heat more effectively than dry air, thereby making humid air more difficult to cool.

Make sure the air passage selection lever is operating correctly. Start the engine and warm it to normal operating temperature, then make sure the temperature selection lever is operating correctly.