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Author Topic: Samurai Complete Factory AC Manual  (Read 1015 times)

zorproducts

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Samurai Complete Factory AC Manual
« on: April 25, 2013, 02:50:10 PM »

I am not sure this manual explains the differences in the thermal cutoff switch from round to square dashes. If you need to know what I am taking about then you may need help installing or working on your Samurai AC.

For you engine swap guys, remember that AC only OR PS only from Sidekicks/Trackers is different than AC WITH power steering. If doing both you need the brackets and compressor* that fits the AC/PS setup. PS only and AC brackets only are not compatible to make AC with PS. A Sepentine (multible rib belt) compressor can be adapted to a Samurai existing AC system by using everything Samurai with the Kick compressor. You simply have the Samurai hoses recrimped onto the Kick barbed fittings.

*Narrower feet on the AC with PS compressor!


There are a lot of pages here so make sure you don't miss any. I am going to make 3 posts in a row with an average of 13 links. Enjoy and keep in mind I do not do complicated AC work, so asking me tech questions may dissapoint you.

http://www.zuksoffroad.net/ACS/ac.tif

http://www.zuksoffroad.net/ACS/ac001.tif

http://www.zuksoffroad.net/ACS/ac002.tif

http://www.zuksoffroad.net/ACS/ac003.tif

http://www.zuksoffroad.net/ACS/boltpg.tif

http://www.zuksoffroad.net/ACS/pg1.tif

http://www.zuksoffroad.net/ACS/pg2.tif

http://www.zuksoffroad.net/ACS/pg3.tif

http://www.zuksoffroad.net/ACS/pg4.tif

http://www.zuksoffroad.net/ACS/pg5.tif

http://www.zuksoffroad.net/ACS/pg6.tif

http://www.zuksoffroad.net/ACS/pg7.tif

http://www.zuksoffroad.net/ACS/pg8.tif

« Last Edit: April 27, 2013, 06:08:17 AM by zorproducts »
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Dakota77

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Re: Samurai Complete Factory AC Manual
« Reply #3 on: June 15, 2013, 06:02:38 PM »

I have a 1987 Tin Top that had a 1995 Sidekick (so I was told) 1.6 16V conversion in it but was a very sloppy job. The engine runs good but it is missing some things. I have AC in it but the compressor and the fan will not engage. I found the same AC manual that you posted but my tin top has only one relay for the fan control and the wires for the compressor goes directly to the AC amp. There is no high/low inline pressure switch. There is power to the fresh off switch and the AC switch lights up. I can bypass everything and go directly from the battery and the compressor will engages and do the same to the fan and it will run. I have a different AC amp part number than is on your post.  PN  Nippon Denso 077200-0341. My concern is that somewhere along the line they spliced into the hot wire to the fan relay and directly to the AC amp which might have burned out the amp. I was wondering if anyone has a wiring diagram for a 1987 Suzuki Samurai JX AC system so I can verify the wiring. I would appreciate any help!
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Still Zukin

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Re: Samurai Complete Factory AC Manual
« Reply #4 on: June 15, 2013, 08:00:24 PM »

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Dakota77

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Re: Samurai Complete Factory AC Manual
« Reply #5 on: June 16, 2013, 12:32:08 PM »

This wiring diagram has the two relays, one for the compressor and one for the condenser fan, mine only has one for the condenser fan and the wires for the compressor go directly to the AC amp. This wiring diagram above is the same for the PN 077200-1230 amp and mine is the PN 077200-0341 amp. Either something changed from 1987 to 1988 or I must have some strange system.
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Still Zukin

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Re: Samurai Complete Factory AC Manual
« Reply #6 on: June 16, 2013, 08:16:49 PM »

Since A/C was a dealer item there may be different ones out there.
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Dakota77

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Re: Samurai Complete Factory AC Manual
« Reply #7 on: June 17, 2013, 09:40:24 PM »

Well I thank you for your help. I decided to open the wire bundle and see where everything goes. I have quite a birds nest but I traced most of the wires to the switches and controls that should be in the system. I did find a black wire that came out of the AC amp up to the area where the heater/AC controls are and has a single plug connector on it. The best I can come up with is it hooks into the blower fan control but I am not sure. I have three different wiring diagrams that have different color coded wires all have the two relays and years from 89, 92, 95 and a Tracker thrown in just to check it out. I am going to pull the heater/AC control panel out this weekend and see what I can find.
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Still Zukin

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Re: Samurai Complete Factory AC Manual
« Reply #8 on: June 18, 2013, 04:15:41 AM »

I replaced the relay in mine and that did not help so I have a toggle switch under the dash to turn it on then use the button in the heater control and now have A/C in my 87 tintop. It has been converted to the newer stuff. It works but when I was in AZ the engine ran pretty warm in traffic.
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Dakota77

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Re: Samurai Complete Factory AC Manual
« Reply #9 on: June 23, 2013, 05:14:40 PM »

Well I traced all the wires to the switches and I still can not find where the single black wire goes. It goes back to the AC amp but the only way I can find where it is supposed to be attached to is to get a wiring diagram for the single relay system. I might just bypass the AC amp and put another relay and a hi/low pressure switch in line so I will have some protection. It worked back in the 60s and 70s without one and seemed to work alright. I have one more place to check for a wiring diagram and then I am out of options. Last chance.
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jbwilli

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Re: Samurai Complete Factory AC Manual
« Reply #10 on: April 29, 2018, 05:55:42 AM »

I am responded to this older 2013 dated post, in hopes it will reach some of you in this thread that discusses Samurai AC AMP PN's.

I am searching for information of Suzuki Samurai AC AMP PNS vs which model Samurai they are compatible with. I have see 3 different AC AMP PNS quoted (077200 0341, 077200 1230 and 077200 0970). There may be more?

I am adding AC to my 1990 1.3L TBI (NO CARB) JL 4x4 model. My ultimate goal is to ID the correct AC AMP PN for this model.
FYI: MEGAZIP Samurai parts on line catalogue shows only 1 SUZUKI AC AMP PN for all Samurai models from 1988 thru 1995, for both R12 and R134 systems???....I doubt that, and they could not answer my question as to why?

Any help would be greatly appreciated!
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zorproducts

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Re: Samurai Complete Factory AC Manual
« Reply #11 on: May 04, 2018, 09:48:10 PM »

The AC AMP connectors were the same. I assume like many Samurai items they made changes in productions and this was identified by the different part numbers. Good luck in your quest to obtain one. I only buy them and hide away.
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jbwilli

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Re: Samurai Complete Factory AC Manual
« Reply #12 on: May 05, 2018, 06:20:11 AM »

*** UPDATE *** The first AC harness I purchased was from a 1988 1/2 Samurai. It had a 13 pin AC AMP connector.
The second AC harness I purchased was from a 1990 Samurai. It has a 12 pin AC AMP connector!
I have confirmed the AC AMP connectors changed in 1990 and they are not interchangeable.

I now believe there was only one AC AMP pn for the 1990 thru 1995 Samurai.(I assume for all the newer TBI models, no carb???).

That Suzuki Samurai AC AMP PN is 95572 80C50. The 1990 Suzuki Sidekick AC AMP pn is 95510 78E40 (not the same?).
Both are 12 pin!
The problem is no one uses the Suzuki PN to ID the different AC AMPS, but instead use the DENSO PN which is ink stamped on the outside of the AC AMP cover. The Suzuki PN cannot be found on the part as DENSO/NIPPON DENSO made them all!

I am searching for the correct DENSO PN for a 1990 Suzuki Samurai AC AMP. MEGAZIP parts in Japan cannot tell me what the DENSO is for their PN 95572 80C50 as they cannot "see" the items in stock. (ARGH!). At $167 plus expensive shipping, I am not ready to take that gamble in hopes of finding a used one here in the US. I may have to take that gamble in the end!
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zorproducts

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Re: Samurai Complete Factory AC Manual
« Reply #13 on: May 12, 2018, 09:17:46 PM »

Call me we finished the second story and I am finally sorting through 10 years of saving AC parts. I have amplifiers maybe I have a spare
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jbwilli

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Re: Samurai Complete Factory AC Manual
« Reply #14 on: May 18, 2018, 07:38:58 AM »

Call me we finished the second story and I am finally sorting through 10 years of saving AC parts. I have amplifiers maybe I have a spare
YES PLEASE HELP!...I have confirmed via DENSO TECH GROUP the correct 12 pin AC AMP for my 1990 Samurai 1.3L TBI is DENSO PN 077200 1230. If you have one, please contact me! THX!
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