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I recently had the AC compressor relay fail on a 2003 XL7. Fortunately there was a spare relay in the fuse box marked as 'Other' so I was able to swap them and verify that the AC does indeed work. I have not been able to find a replacement relay however except for a few used ones on EBay.

The relay is a Denso 156700-2480 (from memory) and when trying to cross reference it I found that the Omron G8HL series is the same type of relay called a 'Micro ISO' relay. I find it kind of strange though that if these relays are made to an ISO spec that they are not very, very common. It looks like about every Japanese vehicle of similar vintage uses the same type of relays but of course they all have their own part number on them to make it hard to cross reference.

So, question is: Anyone know of a source, other than dealership for these relays? I guess if I can't find them I'll hit the local salvage yards and pull some spares to have on hand.

Also, WTF was Suzuki thinking when they used that Torx head bolt on the alternator pivot?? (Changed belts t yesterday too.) I see from the forum here that it is a constant source of grief.

EDIT: Almost forgot! All four plastic clips that hold the radiator fan shroud in were in bad shape. The generic plastic panel clips at the auto parts store (1/4" diameter) sort of fit but are not a good fix. Any source for these plastic clips?
 

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Thanks Max, I can get the parts from a local dealer but was hoping to discover an aftermarket source. Small parts like these are typically sourced from component suppliers (like Denso) and are used in many makes/models. Seems silly to have to pay dealer prices but that is often the only choice.

Several years ago the end positive battery cable on my wife's Escort Wagon was in bad shape (it was the metal clamp style not older lead style). I could not find a replacement so I went to the Ford dealer who said they could not just get the positive battery cable and could only sell me a section of the wiring harness for $120! I later found a replacement clamp for a couple of bucks. After crimping it on (and then soldering) it outlasted the rest of the car.

I'm not anti-dealer but like to have choices :)
 

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It just dawned on me to search for "micro iso relay".

This first link explains the three basic types of relays based on weather they have a resistor or diode or no suppressor built in (if not built in it to the relay it will be in the ECU). The other difference is if the relay is SPST or SPDT.

12 Volt Car Relays Used In Automotive Industry

This link is about the same form factor relay used in motor cycles but it has a lot of cross reference information:

Micro-ISO Relays

And finally here is a place selling the relays:

Micro Relays - Iso Footprint - 4 Terminal

I'm not sure is the Suzuki's relay has an y suppression built in so I will take apart the bad one and see. I also found that Mouser Electronics (who I need to place an order with this week anyhow) carries these relays made by Panasonic. Either from Mouser or the place above the relays are on the order of $6 not the $30 the dealer wants.

I still have not found a source for the clips but I bet the body shop guys can get them :)
 

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A few more notes...

The relays marked as 'other' actually powers the heaters in the oxygen sensors. I found that out when the check engine light came on today. I stopped by the auto parts store and asked them to plug the code scanner in and it came back with: P0031, P0051, P0037, P0057 which are all low voltage to the O2 sensors. I pulled the relay back out of the AC compressor position and popped it back in the 'Other' position where it came from. My wife is not happy to not have AC but...

I took apart the bad AC compressor relay and found it had badly pitted contacts. It was also the type with the suppression resistor across the coil, the resistor is 10K if anyone is interested. I ordered two relays with suppression resistors from 'relays are us'. With the $15 shipping charge it was about $28 for two relays (one spare). So, about half the price of one from the dealer. If your thinking of going the same rout with a relay for your vehicle make sure to pull the old one apart and see if it has a resistor or diode and make sure you get the correct type, if you don't you risk damaging the ECU.
 

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Thought I'd add a bit onto this thread.

My 2004 XL-7 A/C seemed a bit lacking last Summer and this Spring had been woeful- actually cutting out randomly. :(

I figured it was low on gas (being 11yo and never been regassed) and verified this by bypassing the High/ Low pressure cut out. But when the guy came to regas it he said the pressure was fine and it wasn't a gas problem :mad:. I was 100% sure it was the problem, but after some fault finding it was discovered the compressor relay was cutting out :huh:. It must have coincidentally decided to work when I bypassed the pressure switch. The relay was swapped with the horn relay and the A/C worked fine, but so did the horn..... :huh:....

Anyway, about two weeks later the A/C has been working perfectly (and the horn :D). I sourced some new relays to replace the dodgy one plus the others associated with the A/C- there are actually four of them: "Compressor Relay", "Condenser Fan Relay", "Condenser HI Fan Relay No.1" and "Condenser HI Fan Relay No.2". All located in the engine bay. I'd recommend anyone with an XL-7 of a similar vintage consider replacing them as preventative maintenance.

The OEM Denso 156700-2480 relay which (as previously mentioned) is a Micro ISO relay footprint. However, it's roughly 15.5 x 23 x 14mm (H x L x W) - which is lower than a "standard" micro ISO relay's 25mm height. The good news is there is sufficient space in the relay/ fuse box to fit the higher standard micro ISO four pin N/O relays which have the same pin out.

I sourced some Britax RM4-1235R relays (which are sealed, resistor suppressed and rated at 35 Amp). http://www.britaxae.com.au/products.php?categoryname=Relays&subcategoryid=59&page=5 I believe the standard Denso is rated at 20 Amps and finding them new is very hard.

I cut the dodgy relay apart and like Jeff Birt's it smells smoky with the contacts worn/ pitted and black looking. The outer casing of the relay also shows some signs of heat discolouration.
 

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Carefully there. He has a different model. ;) Your GV may be different.
 

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Hello murcod,

Did the Britax RM4-1235R relays work? Also, what was the cost? Thanks
Hi, yes they're working perfectly. I got mine off Ebay.com.au - so not much use to anyone outside Australia.

They are a "standard size" relay- not Suzuki specific. So you should be able to find an equivalent where ever you live. Just make sure you get the type which has a resistor across the coil- it protects the electronic circuitry that drives the relay.
 
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