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

Downloaded from www.Manualslib.com manuals search engine 0B-20 MAINTENANCE AND LUBRICATION
Final Inspection
SEATS
Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front
seat back allows it to be locked at any angle.
SEAT BELT
Inspect belt system including webbing, buckles, latch plates, retractors and anchors for damage or wear.
If “REPLACE BELT” label on front seat belt is visible, replace belt. Check that seat belt is securely locked.
BATTERY ELECTROLYTE LEVEL CHECK
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If bat-
tery is equipped with built-in indicator, check battery condition by the indicator.
ACCELERATOR PEDAL OPERATION
Check that pedal operates smoothly without getting caught or interfered by any other part.
ENGINE START
Check engine start for readiness.
On automatic transmission vehicles, try to start the engine in each select lever position. The starting motor
should crank only in “P” (Park) or “N” (Neutral).
On manual transmission vehicles, place the shift lever in “Neutral,” depress clutch pedal fully any try to start.
EXHAUST SYSTEM CHECK
Check for leakage, cracks or loose supports.
CLUTCH (FOR MANUAL TRANSMISSION)
Check for the following.
Clutch is completely released when depressing clutch pedal,
No slipping clutch occurs when releasing pedal and accelerating.
Clutch itself is free from any abnormal condition. WARNING:
When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to
prevent any accident.
WARNING:
Before performing the following check, be sure to have enough room around the vehicle. Then, firmly
apply both the parking brake and the regular brakes. Do not use the accelerator pedal. If the engine
starts, be ready to turn off the ignition promptly. Take these precautions because the vehicle could
move without warning and possibly cause personal injury or property damage.

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-21
GEARSHIFT OR SELECTOR LEVER (TRANSMISSION)
Check gear shift or selector lever for smooth shifting to all positions and for good performance of transmission in
any position.
With automatic transmission equipped vehicle, also check that shift indicator indicates properly according to
which position selector lever is shifted to.
With automatic transmission equipped vehicle, make sure that vehicle is at complete stop when shifting selector
lever to “P” range position and release all brakes.
BRAKE
Foot Brake
Check the following:
that brake pedal has proper travel,
that brake works properly,
that it is free from noise,
that braking force is applied equally on all wheels,
and that brake do not drag.
Parking Brake
Check that lever has proper travel.
Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
STEERING
Check to ensure that steering wheel is free from instability, or abnormally heavy feeling.
Check that the vehicle does not wander or pull to one side.
ENGINE
Check that engine responds readily at all speeds.
Check that engine is free from abnormal noise and abnormal vibration.
BODY, WHEELS AND POWER TRANSMITTING SYSTEM
Check that body, wheels and power transmitting system are free from abnormal noise and abnormal vibration or
any other abnormal condition.
METERS AND GAUGE
Check that speedometer, odometer, fuel meter, temperature gauge, etc. are operating accurately.
LIGHTS
Check that all lights operate properly.
WINDSHIELD DEFROSTER
Periodically check that air comes out from defroster outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan switch lever to “HI” position for this check. WARNING:
With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any per-
sonal injury or property damage. Be prepared to apply regular brake quickly even if vehicle should
start to move.

Downloaded from www.Manualslib.com manuals search engine HEATER AND VENTILATION 1A-3
Diagnosis
Diagnosis Table
Wiring Circuit
Condition Possible Cause Correction
Heater blower won’t
work even when its
switch is ON.Blower fuse blown Replace fuse to check for short.
Blower resistor faulty Check resistor.
Blower fan switch faulty Check blower fan switch.
Blower motor faulty Replace motor.
Wiring or grounding faulty Repair as necessary.
Incorrect temperature
output.Control cables broken or binding Check cables.
Temperature control lever faulty Check control lever.
Control cable clamp position is faulty Check and adjustment.
Air damper broken Repair damper.
Air ducts clogged Repair air ducts.
Heater radiator leaking or clogged Replace radiator.
Heater hoses leaking or clogged Replace hoses.
When mode control
lever is changed, air
outlet port is not
changed.Control cable broken or binding Check cable.
Mode control lever faulty Check control lever.
Control cable clamp position is faulty Check and adjustment.
Air damper broken Repair damper.
Air ducts leaking on clogged Repair air ducts.
1. Heater motor 3. Heater blower motor switch 5. To ECM 7. To 4WD controller or A/C controller
(if equipped)
2. Fuse box 4. Heater resister 6. To combination switch

Downloaded from www.Manualslib.com manuals search engine 1A-8 HEATER AND VENTILATION
CAUTION:
When the heater unit is disassembled and reassembled,
locking force of the heater case lock may reduce. In such
a case, tighten the heater case with a tapping screw of
M4
×L16 (1) as shown in the figure, or air may leak from its
joint section.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-1
6F1
6F2
1B
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
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).

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-9
Quick Checking of Refrigerant Charge
The following procedure can be used for quickly checking whether
the A/C system has a proper charge of refrigerant or not.
Run engine at fast idle, and operate A/C at its maximum cooling
capacity for a few minutes. Then, look at the sight glass (1) on
receiver / dryer (2) and compare what is observed with the symp-
toms listed in below.
CHECKING REFRIGERANT CHARGE
3. Bubbles
Symptom Charge of refrigerant condition Correction
Bubbles observed in sight glass Insufficient charge of refrigerant in
systemCheck system for leaks with a
leak tester.
No bubbles observed in sight glass No or insufficient charge of refrig-
erant in systemRefer to the items 3 and 4.
No temperature difference between
compressor inlet and outletEmpty or nearly empty system Evacuate and charge system and
then check it for leaks with a leak
tester.
Noticeable temperature difference
between compressor inlet and outletProper or too much charge of
refrigerant in systemRefer to the items 5 and 6.
When A/C is turned OFF, refrigerant in
sight glass clears immediately and
remains clearToo much charge of refrigerant in
systemDischarge excess refrigerant in
order to obtain a specified charge.
When A/C is turned OFF, refrigerant in
sight glass once produces bubbles and
then clearsProper charge of refrigerant in
systemNo correction needed because
charge of refrigerant is normal.

Downloaded from www.Manualslib.com manuals search engine 1B-10 AIR CONDITIONING (OPTIONAL)
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

Downloaded from www.Manualslib.com manuals search engine 1B-14 AIR CONDITIONING (OPTIONAL)
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

Downloaded from www.Manualslib.com manuals search engine 1B-34 AIR CONDITIONING (OPTIONAL)
Cooling Unit (Evaporator)
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to “Recov-
ery” in this section. CAUTION:
Be careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten A/C evaporator
fin by using flat head screwdriver or pair of pliers.
1. A/C evaporator 3. Expansion valve 5. Packing 7. O-ring
2. A/C evaporator thermistor
(A/C evaporator temperature sensor)4. Evaporator case 6. Air inlet door 8. Door link
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.