ect SUZUKI JIMNY 2005 3.G Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine 1B-24 AIR CONDITIONING (OPTIONAL)
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.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-25
Charging
Charging procedure
The initial charging of the A/C system is performed from the high
pressure side with the engine stopped.
And next, this method must be followed by charging from the low
pressure side with the engine running.
1) Check to make sure that hoses are routed properly after
evacuating the system. CAUTION:
 Always charge through low pressure side of A/C sys-
tem at after the initial charging is performed from the
high pressure side with the engine stopped.
 Never charge to high pressure side of A/C system with
engine running.
 Do not charge while compressor is hot.
 When installing tap valve to refrigerant container to
make a hole there through, carefully follow directions
given by manufacturer.
 A pressure gauge should always be used before and
during charging.
 The refrigerant container should be emptied of refrig-
erant when discarding it.
 The refrigerant container should not be heated up to
40 °C (104 °F) or over.
 Refrigerant container should not be reversed in direc-
tion during charging. Reversing in direction causes liq-
uid refrigerant to enter compressor, causing troubles,
such as compression of liquid refrigerant and the like.
NOTE:
The air conditioning system contains HFC-134a (R-134a).
Described here is a method to charge the air conditioning
system with refrigerant from the refrigerant service con-
tainer.
When charging refrigerant recovered by using the refrig-
erant and recycling equipment (when recycling refriger-
ant), follow the procedure described in the equipment
manufacturer’s instruction manual.

Downloaded from www.Manualslib.com manuals search engine 1B-26 AIR CONDITIONING (OPTIONAL)
2) Connect Low charging hose (1) and High charging hose (2)
of the manifold gauge set (3) in position. Thus open refriger-
ant container valve (4) to purge the charging line.
3) Open the high pressure side valve (5) and charge refrigerant
to system.
4) After a while, open the low pressure side valve (6) and close
the high pressure side valve (5).
5) Start engine and keep engine speed at 1500 r/min. Then,
operate air conditioning.
6) Charge A/C system with refrigerant in vapor state. At this
time, refrigerant container should be held upright.
7) When refrigerant container (3) is emptied, use the following
procedure to replace refrigerant container with a new refrig-
erant container (3).
a) Close low pressure valve.
b) Replace empty container (3) with a refrigerant container
which has been charged with refrigerant. When using
refrigerant container tap valve (4), use the following proce-
dure for replacement.
i) Retract needle (1) and remove refrigerant container tap
valve (4) by loosening its plate nut (2).
ii) Install previously-removed refrigerant container tap valve
(4) to a new refrigerant container (3).
c) Purge any air existing in center charging hose
When using refrigerant container tap valve, use the follow-
ing procedure to purge air.
i) Once fully tighten refrigerant container tap valve (1), and
then loosen (open) plate nut (2) slightly.
ii) Open low pressure side valve (3) of manifold gauge set
(4) a little.
iii) As soon as refrigerant comes out with a “hiss” through a
clearance between refrigerant container and tap valve,
tighten plate nut (2) as well as low pressure side valve (3).
iv) Turn handle of tap valve (1) clockwise so that its needle is
screwed into the new container to make a hole for refriger-
ant flow. WARNING:
Make sure that high pressure side valve is closed
securely.

Downloaded from www.Manualslib.com manuals search engine 1B-28 AIR CONDITIONING (OPTIONAL)
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.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-29
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.

Downloaded from www.Manualslib.com manuals search engine 1B-30 AIR CONDITIONING (OPTIONAL)
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.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-31
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.

Downloaded from www.Manualslib.com manuals search engine 1B-32 AIR CONDITIONING (OPTIONAL)
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.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-33
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.

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.