Air conditioning SUZUKI JIMNY 2005 3.G Service Owner's Guide

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8) After the system has been charged with specified amount
(500 – 600 g) of refrigerant or when low pressure gauge (1)
and high pressure gauge (2) have indicated the following
specified amount, close low pressure side valve (3) on mani-
fold gauge set (4). At this time, look into the sight glass (5) of
receiver / dryer (6) and check that there are no bubbles (7) in
the sight glass, which means that the system is fully
charged.
Gauges should read as follows when ambient tempera-
ture is 30 °C (86 °F).
Pressure
on high pressure 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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Removing Manifold Gauge Set
When A/C system has been charged with a specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set. (The
high pressure side valve is closed continuously during the
process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service valves.
This operation must be performed rapidly.
5) Put caps on service valves.
Leak Test
Whenever a refrigerant leak is suspected in the system or any
service operation has been performed which may result in dis-
turbing lines or connections, it is advisable to test for leaks.
Common sense should be used in performing any refrigerant leak
test, since the need and extent of any such test will, in general,
depend upon the nature of a complaint and the type of a service
performed on the system.
LIQUID LEAK DETECTOR
There are a number of fittings and places throughout the air con-
ditioning system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question with a
swab, such as attached to the cap of a vial, bubbles will form
within seconds if there is a leak.
For confined areas, such as sections of the evaporator and con-
denser, an electronic (refrigerant) leak detector (1) is more practi-
cal for determining leaks.WARNING:
High pressure side is naturally under high pressure. So,
care must be used to protect your eyes and skin.

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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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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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Receiver / Dryer
REMOVAL
1) Recover refrigerant from A/C system by referring to “Recov-
ery” in this section.
2) Remove front bumper referring to “Front Bumper” in Section
8.
3) Disconnect receiver / dryer outlet hose (1) and condenser
outlet pipe (2) from receiver / dryer (3).
4) Remove receiver / dryer (3) with its bracket (4).
INSTALLATION
Reverse removal procedure to install receiver / dryer, 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. NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

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Condenser Cooling Fan Assembly
ASSEMBLY
INSPECTION
1) Check continuity between each two terminals about the con-
denser cooling fan motor (1).
If check results are no continuity, replace condenser cooling
fan motor.
2) Connect battery to condenser cooling fan motor as shown in
figure, then check that the condenser cooling fan motor
operates smoothly.
Reference current of condenser cooling fan motor
approximately 7.5 A at 12 V
REMOVAL
1) Remove front bumper.
2) Disconnect condenser cooling fan motor connector (1).
3) Remove radiator mounting bolts.
4) Remove condenser cooling fan assembly (2) from con-
denser (3).
INSTALLATION
Reverse removal procedure for installation.CAUTION:
Be careful not to damage condenser fins. If condenser fin
is bent, straighten condenser fin by using flat head
screwdriver or pair of pliers.

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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.

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3) Drain engine coolant and disconnect heater hoses (1) from
heater unit.
4) Disable air bag system referring to “Disabling Air Bag Sys-
tem” in Section 10B (if equipped).
5) Remove attaching bolt (1).
6) Disconnect suction hose (2) and receiver / dryer outlet pipe
(3) from expansion valve (4).
7) Remove instrument panel referring to “Instrument Panel” in
Section 9.
8) Remove cooling unit (1) with heater unit (2) from vehicle
body.
9) Remove cooling unit (1) from heater unit (2).
INSPECTION
Check the following.
Check clog of A/C evaporator fins.
If any clogs are found, A/C evaporator fins should be
washed with water, and should be dried with compressed
air.
Check A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace A/C evaporator.
Check A/C evaporator fittings for leakage.
If any defects are found, repair or replace A/C evaporator.

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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.