Lever SUZUKI JIMNY 2005 3.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine HEATER AND VENTILATION 1A-7
Heater Blower Fan Switch
INSPECTION
Check blower fan switch for each terminal-to-terminal continuity.
For the detail refer to “Wiring Circuit” earlier in this section.
Heater Unit/Boost Ventilation
REMOVAL
1) Disconnect negative (–) cable at battery.
2) If equipped with air bag system disable air bag system.
Refer to “Disabling Air Bag System” in Section 10B.
3) Drain engine coolant and disconnect water hoses (1) from
heater unit.
4) Remove instrument panel.
5) Remove bolts, nuts and screws as shown figure.
6) Remove heater unit (1).
INSTALLATION
Install heater unit by reversing removal procedure, noting the fol-
lowing items.
When installing each part, be careful not to catch any cable
or wiring harness.
Adjust control cable (refer to heater control lever assembly in
this section).
Fill engine coolant to radiator.
If equipped with air bag system, enable air bag system,
Refer to “Enabling Air Bag System” in Section 10B.
TERMINAL
POSITIONBEI L MH
OFF
Lo
M
Hi

Downloaded from www.Manualslib.com manuals search engine 1B-6 AIR CONDITIONING (OPTIONAL)
Cool air won’t come
out or insufficient
cooling (A/C system
normal operative)Insufficient or excessive charge of
refrigerantCheck charge of refrigerant and system for
leaks.
Condenser clogged Check condenser.
A/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator
thermistor.
A/C evaporator thermistor faulty Check A/C evaporator thermistor.
Expansion valve faulty Check expansion valve.
Receiver / dryer clogged Check receiver / dryer.
Compressor drive belt loosen or broken Adjust or replace drive belt.
Magnetic clutch faulty Check magnetic clutch.
Compressor faulty Check compressor.
Air in A/C system Replace receiver / dryer, and perform
evacuation and charging.
Air leaking from cooling unit or air duct Repair as necessary.
Heater and ventilation system faulty Check air inlet box (cooling unit), heater
control lever assembly and heater unit
referring to Section 1A.
Blower fan motor faulty Check blower fan motor referring to Sec-
tion 1A.
Excessive compressor oil existing in
A/C systemPull out compressor oil in A/C system cir-
cuit, and replace compressor.
Cool air won’t come
out only intermittentlyWiring connection faulty Repair as necessary.
Expansion valve faulty Check expansion valve.
Excessive moisture in A/C system Replace receiver / dryer, and perform
evacuation and charging.
Magnetic clutch faulty Check magnetic clutch.
Excessive charge of refrigerant Check charge of refrigerant.
Thermal switch faulty Check thermal switch.
Cool air comes out
only at high speedCondenser clogged Check A/C condenser.
Insufficient charge of refrigerant Check charge of refrigerant.
Air in A/C system Replace receiver / dryer, and perform
evacuation and charging.
Compressor drive belt loosen or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air won’t come
out only at high speedExcessive charge of refrigerant Check charge refrigerant.
A/C evaporator frosted Check A/C evaporator and A/C evaporator
thermistor.
Insufficient velocity of
cooled airA/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator
thermistor.
Air leaking from cooling unit or air duct Repair as necessary.
Blower fan motor faulty Check blower fan motor referring to Sec-
tion 1A.
Wiring or grounding faulty Repair as necessary. Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-19
ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL
Terminal Wire CircuitMeasurement
groundNormal value Condition
E18-1 PCompressor
magnet clutch
outputGround to
engine (Fig B)10 – 14 voltBlower fan motor switch and A/C
switch ON with engine running
0 – 1 voltsExcept the above-mentioned condi-
tion with engine running
E18-5 Bl/BMain power sup-
ply for ECMGround to
engine (Fig B)10 – 14 voltsIgnition switch ON with engine
stopped
E18-6 Bl/BMain power sup-
ply for ECMGround to
engine (Fig B)10 – 14 voltsIgnition switch ON with engine
stopped
E18-10 Bl Main relay driveGround to
engine (Fig B)0.5 – 1.2 voltIgnition switch ON with engine
stopped
0 volts Ignition switch OFF
E18-16 G/W A/C switch inputGround to
engine (Fig B)12 – 15 voltsBlower fan motor switch or A/C switch
OFF with engine running
0 – 1 voltBlower fan motor switch and A/C
switch ON with engine running
12 – 15 voltsWithin several seconds after operate
transfer lever between 2WD and 4WD
with above condition
E18-18 P/BCompressor
cooling fan relay
outputGround to
engine (Fig B)0 – 1 voltBlower fan motor switch and A/C
switch ON or engine coolant tempera-
ture at more than 110 °C (230 °F) with
engine running.
12 – 15 voltsExcept the above-mentioned condi-
tion with engine running
E18-20 B/BlSensor ground
for A/C evapora-
torGround to
body (Fig A)–0.5 – 0 volt Engine running
E18-24 Bl/YBlower fan
speed inputGround to
engine (Fig B)0 – 1 voltBlower fan motor switch 2nd or 3rd
with engine running
4 – 7 voltsBlower fan motor switch 1st with
engine running
12 – 15 voltsBlower fan motor switch and A/C
switch OFF with engine running
E19-1 BMain ground for
ECMGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-2 B/RECM ground for
power circuitGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-3 B/RECM ground for
power circuitGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-10 B/BlSensor ground
for ECT sensorGround to
body (Fig A)–0.5 – 1 volt Engine running

Downloaded from www.Manualslib.com manuals search engine 1B-36 AIR CONDITIONING (OPTIONAL)
INSTALLATION
Reverse removal procedure to install cooling unit, and then noting
the following instructions.
If A/C evaporator thermistor removed, its should be rein-
stalled in original position.
Install uniformly the packing (1) to installation hole.
Replenish specified amount of compressor oil to compressor
suction side by referring to “Replenishing Compressor Oil” in
this section.
Evacuate and charge refrigerant by referring to “Evacuating”
and “Charging” in this section.
Adjust mode control cable, temperature control cable and
fresh air control cable by referring to “Heater Control Lever
Assembly” in Section 1A.
Enable air bag system referring to “Enable Air Bag System”
in Section 10B. (if equipped)
Fill engine coolant to radiator, referring to “Cooling System
Flush and Refill” in Section 6B.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-39
A/C Switch
REMOVAL AND INSTALLATION
Refer to “Heater Control Lever Assembly” in Section 1A.
INSPECTION
Press A/C switch button and check if there is continuity
between terminals “A” and “B”.
With battery voltage (+) connected to terminal “C” and (–) to
terminal “A”, press A/C Switch button and blower fan switch
to “Hi” (3rd position).
Check if indicator lamp lights.
Condenser Cooling Fan Motor Relay
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove condenser cooling fan motor relay (1) from vehicle.
3) Check that there is no continuity between terminal “a” and
“b”. If there is continuity, replace relay.
4) Check that there is continuity between terminals “a” and “b”
when battery is connected to terminal “c” and “d”.
If there is no continuity, replace relay.
Compressor
REMOVAL
1) Run engine at idle speed with air conditioning ON for 10 min-
utes. After that stop the engine.
2) Disconnect negative (–) cable at battery.
3) Recover refrigerant from refrigeration system by referring to
“Recovery” in this section.
1. Blower fan and A/C switch
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

Downloaded from www.Manualslib.com manuals search engine 3C-8 STEERING WHEEL AND COLUMN
3) Tighten steering shaft nut to specified torque.
Tightening torque
Steering shaft nut (a) : 33 N·m (3.3 kg-m, 23.5 lb-ft)
4) Install steering wheel pad (for vehicle without air bag system)
or driver air bag (inflator) module (for vehicle with air bag
system) as follows.
For vehicle without air bag system
–For TYPE A
a) Connect horn connector.
b) Install steering wheel pad.
–For TYPE B
a) To install the pad, hook (1) the upper part of the pad to the
pawl of the steering wheel and push in the lower part of the
pad until it fits to the set spring securely.
For vehicle with air bag system
a) Install driver air bag (inflator) module to steering wheel.
Refer to “Driver Air Bag (Inflator) Module” in this section.
Centering contact coil (for vehicle with air bag sys-
tem)
1) Check that vehicle’s wheels (front tires) are set at straight-
ahead position.
2) Check that ignition switch is at “LOCK” position.
3) Turn contact coil counterclockwise slowly with a light force till
contact coil will not turn any further. NOTE:
After installing the steering wheel, turn the steering
wheel about 1 full rotation so that the cancel cam pin fits
into the pin hole in the steering wheel and then check the
turn signal lever for proper function.
NOTE:
Contact coil can turn about 5 turns at maximum, that is, if
it is at the center position, can turn about two and a half
turns both clockwise and counterclockwise.

Downloaded from www.Manualslib.com manuals search engine 3D-2 FRONT SUSPENSION
General Description
4WD Control System
The 4WD control system consists of a 4WD switch, a vacuum switch, a vacuum tank, two vacuum switching
valves (VSV1 and VSV2) and air locking hub assemblies.
The 4WD controller controls locking or unlocking of the air locking hub according to operation of the transfer shift
control lever.
Vacuum generated in the intake manifold passes through the check valve and stored in the vacuum tank.
According to signals from the 4WD switch, the 4WD controller activates VSV1 (for unlocking) or VSV2 (for lock-
ing) to apply vacuum from the vacuum tank so that the front axle and the wheel hub are disengaged or engaged.
1. Front axle housing 3. Steering knuckle 5. Wheel spindle 7. Wheel bearing
2. Shock absorber 4. Kingpin 6. Wheel hub 8. Front axle shaft (4WD)

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-5
Components and Functions
Component Function
4WD switch When the transfer shift lever is shifted to 4L or 4H position from 2H, this switch
turns ON and cause the 4WD control system to turn ON.
4WD controller When the 4WD switch turns on, the 4WD controller activates VSV2 to lock the
air locking hubs and when it receives an “ON” signal from the vacuum switch, it
makes VSV2 to complete operation within 5 seconds and causes the 4WD indi-
cator light to light up.
If vacuum in the vacuum circuit fails to reach the specified level due to a leakage
in the vacuum circuit (when no “ON” signal is inputted from the vacuum switch),
the 4WD controller stops operation of VSV2 in 15 seconds and makes the 4WD
indicator light to flash to warn occurrence of a trouble.
When the 4WD switch turns off, the 4WD controller activates VSV1 for 10 sec-
onds to unlock the hubs and at the same time makes the 4WD indicator light
turn off.
VSV1 VSV1 operates according to the signal from the 4WD controller. When it is acti-
vated, the port opens and vacuum in the intake manifold is applied through the
vacuum circuit to unlock to the slide gear in the air locking hub. As a result, the
air locking hubs are unlocked.
VSV2 VSV2 operates according to the signal from the 4WD controller. When it is acti-
vated, the port opens and vacuum in the intake manifold is applied through the
vacuum circuit to lock to the slide gear in the air locking hub. As a result, the air
locking hubs are locked.
Vacuum switch When VSV2 receives the “ON” signal from 4WD switch, vacuum is applied
through its circuit to the vacuum switch. The vacuum switch turns on when it
detects vacuum exceeding 260 mmHg.
“4WD” indicator lamp It lights up when 4WD control system is in the 4WD mode.
It flashes to warn that locking hub operation has not completed (4WD control
system fails to shift 4WD).

Downloaded from www.Manualslib.com manuals search engine 3D-6 FRONT SUSPENSION
OPERATION
2WD
→ 4WD
When the transfer shift control lever is shifted from the 2WD (2H) position to the 4WD (4H or 4L) position, a 4WD
“ON” signal is transmitted to the 4WD controller which then activates VSV2 to apply vacuum in the intake mani-
fold to the chamber “B” in the hub housing.
When vacuum is applied, the slide gear is separated from the magnet, moves toward the center of the vehicle
body and gets engaged with the outer gear. In this way, the front axle shaft and the front wheel hub rotate as one
unit.
If vacuum in the circuit fails to reach 260 mmHg within 15 seconds after operation of VSV2 due to such trouble
as a hole in the vacuum pipe, the slide gear does not operate and the 4WD indicator light flashes to warn that
the hub is unlocked.
1. ECM 8. Engine speed signal 15. Chamber B 22. Slide gear
2. 4WD controller 9. Intake manifold 16. Piston A 23. Wheel hub
3. 4WD indicator lamp 10. Check valve 17. Magnet 24. Spindle
4.4WD switch 11. Vacuum tank 18. Housing 25. Front axle shaft
5. A/C switch (if equipped) 12. VSV1 19. Spring 26. To opposite side
6. Vacuum switch 13. VSV2 20. Diaphragm 27. A/C controller
7. A/C cut signal (if equipped) 14. Outer gear 21. Sleeve A: Vacuum circuit

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-7
4WD
→ 2WD
When the transfer shift control lever is shifted from the 4WD (4H or 4L) to the 2WD (2H) position, the 4WD con-
troller activates VSV1 and the intake manifold vacuum is applied to the chamber “A” in the hub housing. As the
slide gear is shifted to the wheel side by the vacuum force and disengaged from the outer gear, rotation of the
front wheel hub is not transmitted to the front axle shaft.
1. EPI & A/C controller 8. Engine speed signal 15. Chamber A 22. Slide gear
2. 4WD controller 9. Intake manifold 16. Piston A 23. Wheel hub
3. 4WD indicator lamp 10. Check valve 17. Magnet 24. Spindle
4.4WD switch 11. Vacuum tank 18. Housing 25. Front axle shaft
5. A/C switch (if equipped) 12. VSV1 19. Spring 26. To opposite side
6. Vacuum switch 13. VSV2 20. Diaphragm 27. A/C controller
7. A/C cut signal (if equipped) 14. Outer gear 21. Sleeve A: Vacuum circuit