Switch SUZUKI JIMNY 2005 3.G Service Owner's Manual

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A/C System Inspection of ECM and ITS Cir-
cuits
ECM and its circuits can be checked at ECM wiring couplers by
measuring voltage.
Voltage Check
1) Remove ECM from vehicle by referring to “Engine Control
Module” in Section 6E.
2) Connect ECM couplers (1) to ECM (2).
3) Check voltage at each terminal of couplers connected.CAUTION:
ECM cannot be checked by itself. It is strictly prohibited
to connect voltmeter or ohmmeter to ECM with couplers
disconnected from ECM.
NOTE:
Because each terminal voltage is affected by the battery
voltage, confirm that the battery voltage is 11 V or more
when ignition switch is ON.
[A] : Fig. A
[B] : Fig. B
3. E19-3

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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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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

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On-Vehicle Service
Service Precaution
When servicing air conditioning system, note the following instructions.
Refrigerant line
Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.
Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system,
install a blind plug or cap to the fitting immediately.
When connecting hoses and pipes, apply a few drops of compressor oil to seats of coupling nuts and O-ring.
When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
Tighten flared nuts by the following specified torque.
Tightening torque (Flared Nut Used for)
8 mm pipe : 13 N·m (1.3 kg-m, 9.5 lb-ft)
12 mm pipe : 23 N·m (2.3 kg-m, 16.6 lb-ft)
14.5 mm pipe : 33 N·m (3.3 kg-m, 23.8 lb-ft)
Route drain hose so that drained water does not make any contact to vehicle components.
Before evacuating and charging refrigerant, replenish specified amount of compressor oil to compressor
suction side by referring to “Replenishing Compressor Oil” in this section.
1. Suction hose:
Apply compressor oil to O-ring.4. Condenser outlet pipe:
Apply compressor oil to O-ring.
2. Discharge hose:
Apply compressor oil to O-ring.5. Expansion valve:
Apply compressor oil to O-ring.
3. Receiver / dryer outlet pipe:
Apply compressor oil to O-ring.6. Dual pressure switch:
Apply compressor oil to O-ring.

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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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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.

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4) Remove compressor drive belt (1) as follows.
For vehicle with P/S
Loosen tension pulley bolts (2).
For vehicle without P/S
Loosen tension pulley tightening nut (3) and adjusting bolt
(4).
5) Disconnect thermal switch connector.
6) Disconnect suction and discharge hoses from compressor.
7) Remove compressor (1) from its bracket (2).
INSTALLATION
Reverse removal procedure for installation, 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 system by referring to “Recovery” in
this section.
Adjust drive belt tension by referring to “Compressor Drive
Belt” in this section.
[A] : Vehicle with P/S
[B] : Vehicle without P/S
NOTE:
Cap open fittings immediately to keep moisture out of
system.
NOTE:
If compressor is replaced, drain oil from removed com-
pressor. And then, measure its amount.

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Magnet Clutch
1. Thermal switch 6. Magnet clutch coil a. Front head bolt
: Tighten bolt “a” first, and next “b”.
2. Compressor body assembly 7. Compressor pulley b. Front head bolt
: Tighten bolt “a” first, and next “b”.
3. O-ring 8. Circlip c. Clutch plate bolt
4. Lip seal 9. Shim Tightening torque
5. Front head 10. Clutch plate Do not reuse.

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INSPECTION
Check clutch plate and clutch pulley for leaks of compressor
oil.
Check clutch bearing of compressor pulley for noise, wear
and grease leakage.
Measure resistance of magnet clutch coil (1) between mag-
net clutch lead wire (2) and compressor body assembly.
If measured resistance is not within tolerance, replace mag-
net clutch coil.
Magnet Clutch coil resistance
: 3.4 – 4.1
Ω at 20 °C (68 °F)
Check thermal switch (1) for continuity using ohmmeter.
If it is no continuity, replace thermal switch.
REMOVAL
1) Remove compressor from vehicle referring to “Compressor”
in this section.
2) Fix clutch plate (1) with special tool, and remove clutch plate
bolt (2) and washer (3).
Special tool
(A) : 09991-06020
3) Remove clutch plate (1) using special tool.
Special tool
(A) : 09991-06030