check oil SUZUKI JIMNY 2005 3.G Service User Guide

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SECTION 1B
AIR CONDITIONING (OPTIONAL)
CONTENTS
General Description ....................................... 1B-3
Major Components and Location ................. 1B-3
Refrigerant Circulation ................................. 1B-4
Refrigerant Type .......................................... 1B-4
Diagnosis ........................................................ 1B-5
General Diagnosis Table .............................. 1B-5
Abnormal Noise Diagnosis ........................... 1B-7
Abnormal noise from compressor ............ 1B-7
Abnormal noise from magnetic clutch ...... 1B-7
Abnormal noise from tubing ..................... 1B-7
Abnormal noise from condenser .............. 1B-7
Abnormal noise from crankshaft pulley .... 1B-8
Abnormal noise from tension pulley ......... 1B-8
Abnormal noise from A/C evaporator ....... 1B-8
Abnormal noise from blower fan motor .... 1B-8
Quick Checking of Refrigerant Charge......... 1B-9Performance Diagnosis.............................. 1B-10
Performance diagnosis table.................. 1B-12
Detail diagnosis table (Ambient
temperature at 30°C (86°F)) .................. 1B-13
Compressor Drive Belt ............................... 1B-15
Electronical Diagnosis ................................ 1B-16
Wiring Diagram .......................................... 1B-16
A/C System Inspection of ECM and ITS
Circuits ....................................................... 1B-17
Refrigerant Recovery, Evacuating and
Charging ....................................................... 1B-21
Operation Procedure for Refrigerant
Charging .................................................... 1B-21
Recovery .................................................... 1B-22
Replenishing Compressor Oil .................... 1B-22 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to “Refrigerant Type” in this section.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
NOTE:
For basic servicing method of the air conditioning system that is not described in this section, refer to
AIR CONDITIONING BASIC MANUAL (Part number: 99520-02130).

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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

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Performance diagnosis table
HIGH PRESSURE GAUGE
LOW PRESSURE GAUGE
NOTE:
If ambient temperature is approximately 30 °C (86 °F), it is possible to diagnose A/C system in detail
referring to “Detail Diagnosis Table (Ambient Temperature At 30 °C (86 °F))” under “Performance
Diagnosis” in this section.
Condition Possible Cause Correction
Pressure in higher
than acceptable range
(“A” area)Refrigerant overcharged Recharge
Expansion valve frozen or clogged Check expansion valve
Clogged refrigerant passage of high side Clean or replace
Condenser cooling fan malfunction (Insufficient
cooling of condenser)Check condenser cooling fan
Dirty or bent condenser fins (Insufficient cooling
of condenser)Clean or repair
Compressor malfunction (Insufficient oil etc.) Check compressor
Engine overheat Check engine cooling system refer-
ring to Section 6B.
Pressure is lower than
acceptable range
(“B” area)Insufficient refrigerant (Insufficient charge or
leakage)Check for leakage, repair if neces-
sary and recharge
Expansion valve malfunction (valve opens too
wide)Check expansion valve
Compressor malfunction (Insufficient compres-
sion)Check compressor
Condition Possible Cause Correction
Pressure is higher
than acceptable range
(“C” area)Expansion valve malfunction (valve opens too
wide)Check expansion valve
Compressor malfunction (Insufficient compres-
sion)Check compressor
Pressure is lower than
acceptable range
(“D” area)Insufficient refrigerant (Insufficient charge or
leakage)Check for leakage, repair if neces-
sary and recharge
Expansion valve malfunction (valve opens too
narrow)Check expansion valve
Clogged refrigerant passage (crashed pipe) Repair or replace

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0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3)
0.69 – 0.98
(7 – 10)
(100 – 142)Both low and high pres-
sure sides indicate low
readings.
Continuous air bub-
bles are visible through
sight glass.
Output air is slightly
cold.Insufficient refrigerant in
system.
(Refrigerant leaking)Using leak detector,
check for leaks and repair
as necessary.
Recharge refrigerant to a
specified amount.
If the pressure reading is
almost 0 when the mani-
fold gauges are attached,
check for any leaks,
repair them, and evacu-
ate the system.
0.4 – 0.6
(4 – 6)
(56.9 – 85.3)Pressure on low pres-
sure side is high.
Pressure on high pres-
sure side is low.
Both pressure becom-
ing equal right after A/C
is turned OFF.Internal leak in compres-
sor.Inspect compressor and
repair or replace as nec-
essary.
0.35 – 0.45
(3.5 – 4.5)
(50 – 64)
1.96 – 2.45
(20 – 25)
(285 – 355)Pressure on both low
and high pressure
sides is high.
Air bubbles are not visi-
ble even when engine
rpm is lowered.Overcharged A/C sys-
tem.Adjust refrigerant to
specified amount.
Faulty condenser cooling
operation.Clean condenser.
Faulty condenser cooling
fan operation.Inspect and repair con-
denser cooling fan.
Pressure on both low
and high pressure
sides is high.
Low pressure side tub-
ing is not cold when
touched.
Air bubbles are visible
through sight glass.Presence of air in A/C
system.
(Improperly evacuated)Replace receiver / dryer.
Inspect quantity of com-
pressor oil and presence
of contaminants in oil.
Evacuate system and
recharge with fresh
refrigerant.
0.45 – 0.55
(4.5 – 5.5)
(64 – 78)Pressure on both low
and high pressure
sides is high.
Large amount of frost
or dew on the low pres-
sure side tubing.Faulty expansion valve.
Refrigerant flow is not
regulated properly.Replace expansion valve. Condition
Possible Cause Correction MANIFOLD
GAUGEMPa
(kg/cm
2)
(psi)Detail
Lo Hi

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Refrigerant Recovery, Evacuating and Charging
Operation Procedure for Refrigerant Charging
WARNING:
 Your eyes should not be exposed to refrigerant (liquid).
Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately
–6 °C (21 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause
a serious injury. To protect your eyes against such accident, it is necessary to always wear gog-
gles. Should it occur that HFC-134a (R-134a) strikes your eyes(s), consult a doctor immediately.
– Do not use your hand to rub the affected eye(s). Instead, use quantities of fresh cold water to
splash it over the affected area to gradually raise temperature of such area above freezing point.
– Obtain proper treatment as soon as possible from a doctor or eye specialist.
 Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.
 Refrigerant must not be handled near where welding or steam cleaning is performed.
 Refrigerant should be kept at a cold and dark place. It should never be stored where a high temper-
ature is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).
 Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazardous
to health.
Replenish compressor oil
Start evacuating
Inspect and repair connections
Charge 550 50 g of
refrigerant in gas form Stop evacuating 15 minutes (–760 mmHg)
Wait 10 mintues
If gauge shows
abnormal conditions Check system for
pressure tightness
Check A/C system
With refrigerant
Check system for refrigerant
leaks and refrigerant
charging quantity
Performance test

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Handling refrigerant HFC-134a (R-134a)
Always wear goggles to protect your eyes.
Avoid you direct contact to liquid refrigerant.
Do not heat refrigerant container higher than 40 °C (104 °F).
Do not discharge refrigerant into atmosphere.
Do not allow liquid refrigerant to touch bright metals. Refrigerant combined with moisture is corrosive and
will tarnish surfaces of bright metals including chrome. WARNING:
Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately.
 Do not use your hand to rub affected eye(s). Instead, use quantities of fresh cold water to splash it
over affected area to thus gradually raise its temperature above the freezing point.
 Obtain proper treatment as soon as possible from a doctor or eye specialist.
Should liquid refrigerant HFC-134a (R-134a) get on your skin, such affected part should be treated
in the same manner as when skin is frostbitten or frozen.
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to “Refrigerant Type” in this section. When
replenishing or changing refrigerant and compressor oil and when replacing parts, make sure that the
material or the part to be used is appropriate to the A/C installed in the vehicle being service.Use of
incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.

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Condenser Assembly
INSPECTION
Check the following.
Check clog of condenser fins.
If, any clogs are found, condenser fins should be washed
with water, and should be dried with compressed air.
Check condenser fins for leakage and breakage.
If any defects are found, repair or replace condenser.
Check condenser fittings for leakage.
If any defects are found, repair or replace condenser.
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to “Recov-
ery” in this section.
3) Remove front bumper referring to “Front Bumper” in Section
8.
4) Disconnect A/C condenser cooling fan motor and dual pres-
sure switch connectors.
5) Remove radiator mounting bolts.
6) Disconnect discharge hose (1) from condenser (2).
7) Disconnect receiver / dryer outlet hose (3) and condenser
outlet pipe (4) from receiver / dryer (5).
8) Remove condenser cooling fan assembly (6) from con-
denser (2).
9) Remove receiver / dryer (5) with its bracket (7) from con-
denser (2).
10) Remove condenser (2) from radiator.
INSTALLATION
Reverse removal procedure to install condenser, and then noting
the following instructions.
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. CAUTION:
Be careful not to damage condenser fins. If condenser fin
is bent, straighten it by using flat head screwdriver or
pair of pliers.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

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A/C Evaporator Thermistor (A/C Evaporator
Temperature Sensor)
INSPECTION
Check resistance between terminals for A/C evaporator ther-
mistor (1).
If check results are as not specified, replace thermistor.
A/C evaporator temperature sensor resistance
Expansion Valve
INSPECTION
Refer to “Performance Diagnosis” in this section.
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“Recover” in this section.
3) Remove attaching bolt (1).
4) Remove suction hose (2) and receiver dryer outlet pipe (3)
from expansion valve (4).
5) Remove expansion valve (4).Sensor Temperature (°C (°F)) Resistance (k
Ω)
0 (32) 6.4 – 7.0
25 (77) 1.8 – 2.2
NOTE:
When A/C evaporator thermistor (1) removed, its should
be reinstalled in original position.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

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INSTALLATION
Reverse removal procedure for installation, and then note the fol-
lowing instructions.
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 “Evacuation”
and “Charging” in this section.
Dual Pressure Switch
INSPECTION
1) Check dual pressure switch (1) for continuity at normal tem-
perature (approximately 25 °C (77 °F)) when A/C system has
a proper charge of refrigerant and A/C system (compressor)
is under operation. In each of these cases, switch should
show proper continuity.
2) Check switch for continuity at specified pressure as shown.
A : Approximately 195 kPa (1.95 kg/cm
2, 27.5 psi)
B : Approximately 3140 kPa (31.4 kg/cm
2, 446.5 psi)
C : Approximately 225 kPa (2.25 kg/cm
2, 32.0 psi)
D : Approximately 2550 kPa (25.5 kg/cm
2, 362.5 psi)
Tightening torque
Dual pressure switch
(a) : 10 N·m (1.0 kg-m, 7.0 lb-ft)

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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.