oil SUZUKI JIMNY 2005 3.G Service Owner's Guide

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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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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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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.

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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.

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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.

Downloaded from www.Manualslib.com manuals search engine 1B-42 AIR CONDITIONING (OPTIONAL)
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