pressure SUZUKI JIMNY 2005 3.G Service User Guide

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Abnormal noise from crankshaft pulley
Abnormal noise from tension pulley
Abnormal noise from A/C evaporator
Abnormal noise from blower fan motor
Condition Possible Cause Correction
A large rattling noise
is heard at idle or sud-
den acceleration.Loosen crankshaft pulley bolt. Retighten bolt.
Condition Possible Cause Correction
Clattering noise is
heard from pulley.Worn or damaged bearing. Replace tension pulley.
Pulley cranks upon
contact.Cracked or loose bracket. Replace or retighten bracket.
Condition Possible Cause Correction
Whistling sound is
heard from A/C evapo-
rator.Depending on the combination of the interior /
exterior temperatures, engine rpm and refriger-
ant pressure, the refrigerant flowing out of the
expansion valve may, under certain conditions,
make a whistling sound.At times, slightly decreasing refrig-
erant volume may stop this noise.
Inspect expansion valve and
replace if faulty.
Condition Possible Cause Correction
Blower fan motor
emits a chirping
sound in proportion to
its speed of rotation.Worn or damaged motor brushes or commuta-
tor.Repair or replace blower fan motor.
Fluttering noise or
large droning noise is
heard from blower fan
motor.Leaves or other debris introduced from fresh air
inlet to blower fan motor.Remove debris and make sure that
the screen at fresh air inlet is intact.

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Performance Diagnosis
1) Confirm that vehicle and environmental conditions are as fol-
lows.
Vehicle is not exposed to direct sun.
Ambient temperature is within 15 – 35 °C (59 – 95 °F).
2) Make sure that high pressure valve (1) and low pressure
valve (2) of manifold gauge set (3) are firmly closed.
3) Connect high pressure charging hose (4) to high pressure
service valve (5), and connect low pressure charging hose
(6) to low pressure service valve (7).
4) Bleed the air in charging hoses (4), (6) by loosening their
respective nuts on manifold gauge set (3), utilizing the refrig-
erant pressure. When a hissing sound is heard, immediately
tighten nut.
5) Warm up engine to normal operating temperature (engine
coolant temperature at 80 – 90 °C (176 – 194 °F)) and keep
it at specified idle speed. (Radiator cooling fan should not be
working when checking pressure and temperature.)
6) Turn A/C switch ON, and set blower switch at “HI” (3rd posi-
tion), temperature knob at “COOL” air outlet control knob at
“FACE” and fresh / circulation control knob at “CIRCULA-
TION”. (Confirm that A/C compressor and radiator / con-
denser cooling fan are working.)
Keep all windows, doors and engine food open.
Performance diagnosis condition
7) With dry bulb thermometer (1) inserted into center duct air
outlet and another one set near evaporator air inlet, read
temperature indicated on each thermometer. CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.
Ambient temperature 15 – 35 °C (59 – 95 °F)
Engine rpm Keep to 1,500 rpm.
Blower fan motor switch “H” (3rd position)
Temperature control “Cool”
Air outlet control “Face”
Vehicle doors All open
Air inlet door position Recirculation

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8) Check if each pressure on low side and on high side is within
shaded range of the graph.
If each gauge reading is out of specified pressure, correct
defective part referring to “Performance Diagnosis Table” in
this section.
Low side and high side pressure example :
9) Check inlet port temperature-to-outlet port temperature rela-
tionship using graph.
For example, if evaporator inlet port temperature is 25 °C
(77 °F) and center duct air outlet temperature is 8 °C
(46.4 °F), their crossing point is within acceptable range as
shown in the graph.
If crossing point is out of acceptable range, diagnose trouble
referring to “Performance Diagnosis Table” in this section. NOTE:
Pressure registered on gauge varies with ambient tem-
perature. Therefore, use graph when determining if pres-
sures are normal or not.
Gauges should read as follows when ambient tempera-
ture is 30 °C (86 °F).
Pressure on high pres-
sure gauge1400 – 1750 kPa
14.0 – 17.5 kg/cm
2
199.1 – 248.9 psi
Pressure on low pressure
gauge230 – 350 kPa
2.3 – 3.5 kg/cm
2
32.7 – 49.8 psi

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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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CROSSING POINT OF CENTER VENTILATION LOUVER TEMPERATURE AND RECIRCULATION AIR
INLET TEMPERATURE
Detail diagnosis table (Ambient temperature at 30°C (86°F))
Condition Possible Cause Correction
Crossing point is
higher than accept-
able range
(“E” area)Insufficient or excessive charge of refrigerant Check refrigerant pressure
Dirty or bent A/C evaporator fins Clean or repair
Air leakage from cooling (heater) unit or air duct Repair or replace
Malfunctioning, switch over function of door in
cooling (heater) unitRepair or replace
Compressor malfunction Check compressor
Crossing point is
lower than acceptable
range
(“F” area)Insufficient air volume from center duct (Heater
blower malfunction)Check blower motor and fan
Compressor malfunction Check compressor
Condition
Possible Cause Correction MANIFOLD
GAUGEMPa
(kg/cm
2)
(psi)Detail
Lo Hi
0.23 – 0.35
(2.3 – 3.5)
(33 – 50)1.4 – 1.75
(14 – 17.5)
(200 – 249)Normal condition
––
Negative
pressure0.5 – 0.6
(5 – 6)
(71.2 – 85.3)The low pressure side
reads a negative pres-
sure, and the high pres-
sure side reads an
extremely low pressure.
Presence of frost
around tubing to and
from receiver / dryer
and expansion valve.Dust particles or water
droplets are either stuck
or frozen inside expan-
sion valve, preventing the
refrigerant from flowing.Clean expansion valve.
Replace it if it cannot be
cleaned.
Replace receiver / dryer.
Evacuate the A/C sys-
tem and recharge with
fresh refrigerant.
Normal :
0.23 – 0.35
(2.3 – 3.5)
(33 – 50)
↑
↑ ↑ ↑ ↓
↓↓ ↓
Abnormal :
Negative
pressureNormal :
1.4 – 1.75
(14 – 17.5)
(200 – 249)
↑
↑ ↑ ↑ ↓
↓↓ ↓
Abnormal :
0.69 – 0.98
(7 – 10)
(100 – 142)During A/C operation,
the low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.Expansion valve is frozen
due to moisture in the
system, and temporarily
shuts off the refrigeration
cycle.Replace expansion valve.
Replace receiver / dryer.
Evacuate A/C system
and recharge with fresh
refrigerant.

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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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Electronical Diagnosis
Wiring Diagram
[A]: 4WD model 4. Dual pressure switch 9. Thermal switch 14. Circuit fuse box
[B]: 2WD model 5. 4WD controller 10. Ignition switch 15. Main fuse box
1. Blower fan motor 6. Condenser cooling fan motor relay 11. A/C evaporator thermistor 16. Generator
2. Blower fan motor resistor 7. Condenser cooling fan motor 12. ECT sensor 17. ECM
3. Blower fan motor switch and A/C switch 8. Compressor 13. Lighting switch

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Terminal arrangement of ECM coupler (Viewed from harness side)
1. Blower fan motor 8. Compressor [A]: To “A/C” fuse (25A) in main fuse box
2. Dual pressure switch 9. Thermal switch [B]: To “HEATER” fuse (20A) in circuit fuse box
3. A/C switch 10. Main relay [C]: To “FI” fuse (15A) in main fuse box
4. A/C evaporator thermistor 11. Engine earth [D]: 4WD model
5. ECT sensor 12. Blower fan motor switch [E]: 2WD model
6. Condenser cooling fan motor relay 13. 4WD controller
7. Condenser cooling fan motor 14. ECM

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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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1) Connect high charging hose (1) and low charging hose (2) of
manifold gauge set (3) respectively as follows:
High charging hose (1) → High pressure charging valve (4)
on discharge hose
Low charging hose (2) → Low pressure charging valve (5) on
suction hose
2) Attach center charging hose (6) of manifold gauge set (3) to
vacuum pump (7).
3) Operate vacuum pump (7), and then open discharge side
valve (Hi) (8) of manifold gauge set (3).
If there is no blockage in the system, there will be an indica-
tion on high pressure gauge (9).
In this case, open the other side valve (Lo) (10) of the set
and repair the system.
4) Approximately 10 minutes later, low pressure gauge (11)
should show a vacuum lower than –760 mmHg providing no
leakage exists.
5) Evacuation should be carried out for a total of at least 15
minutes.
6) Continue evacuation until low pressure gauge (9) indicates a
vacuum less than –760 mmHg, and then close both valves
(8), (10).
7) Stop vacuum pump (7). Disconnect center charging hose (6)
from pump inlet. Now, the system is ready for charging refrig-
erant. NOTE:
 If the system does not show a vacuum below –760
mmHg, close both valves, stop vacuum pump and
watch movement of low pressure gauge.
 Increase in the gauge reading suggests existence of
leakage. In this case, repair the system before continu-
ing its evacuation.
 If the gauge shows a stable reading (suggesting no
leakage), continue evacuation.