SUZUKI JIMNY 2005 3.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine 1B-20 AIR CONDITIONING (OPTIONAL)
E19-14 G/BECT sensor
inputGround to
engine (Fig B)0.73 – 0.83 volts
(315 – 355 Ω)Engine coolant temperature at
approximately 80 °C (176 °F) with
engine running
0.35 – 0.45 volts
(145 – 165 Ω)Engine coolant temperature at
approximately 110 °C (230 °F) with
engine running
*If the temperature is more than
113 °C (235 °F), compressor should
be stop (come back at less than
111 °C (232 °F)
E19-27 W/RA/C evaporator
thermistor tem-
perature inputGround to
engine (Fig B)2.0 – 2.3 volts
(1800 – 2200 Ω)Evaporator thermistor temperature at
approximately 25 °C (77 °F) with
engine running
3.5 – 3.6 volts
(6300 – 7000 Ω)Evaporator thermistor temperature at
approximately 0 °C (32 °F) with
engine running
*If the temperature is less than
approximately 2.5 °C (36.5 °F), com-
pressor cooling fan should be stop
(come back at less than approxi-
mately 4 °C (39.2 °F) Terminal Wire CircuitMeasurement
groundNormal value Condition

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Refrigerant Recovery, Evacuating and Charging
Operation Procedure for Refrigerant Charging
WARNING:
 Your eyes should not be exposed to refrigerant (liquid).
Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately
–6 °C (21 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause
a serious injury. To protect your eyes against such accident, it is necessary to always wear gog-
gles. Should it occur that HFC-134a (R-134a) strikes your eyes(s), consult a doctor immediately.
– Do not use your hand to rub the affected eye(s). Instead, use quantities of fresh cold water to
splash it over the affected area to gradually raise temperature of such area above freezing point.
– Obtain proper treatment as soon as possible from a doctor or eye specialist.
 Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.
 Refrigerant must not be handled near where welding or steam cleaning is performed.
 Refrigerant should be kept at a cold and dark place. It should never be stored where a high temper-
ature is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).
 Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazardous
to health.
Replenish compressor oil
Start evacuating
Inspect and repair connections
Charge 550 50 g of
refrigerant in gas form Stop evacuating 15 minutes (–760 mmHg)
Wait 10 mintues
If gauge shows
abnormal conditions Check system for
pressure tightness
Check A/C system
With refrigerant
Check system for refrigerant
leaks and refrigerant
charging quantity
Performance test

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Recovery
REFRIGERANT RECOVERY
When evacuating A/C system, always recover refrigerant by using
equipment (1) for refrigerant recovery and recycling. Discharging
refrigerant HFC-134a (R-134a) into atmosphere would cause
adverse effect to environments.
Replenishing Compressor Oil
It is necessary to replenishing specified amount of compressor oil
to compressor (1) from compressor suction side hole (2) before
evacuating and charging refrigerant.
Compressor oil
99000-99088-00D0
WHEN CHARGING REFRIGERANT ONLY
When charging refrigerant without replacing any component part,
replenish the same amount of measured oil when recover refrig-
erant (if not measure, replenish 30 cc oil).NOTE:
 After recover refrigerant from system, the amount of
removed compressor oil must be measured for replen-
ishing compressor oil.
 When handling recovery and recycling equipment, be
sure to follow the instruction manual for the equip-
ment.

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WHEN REPLACING COMPRESSOR
Compressor oil is sealed in each new compressor by the amount
required for A/C system. Therefore, when using a new compres-
sor for replacement, drain oil from new compressor by the amount
calculated as follows.
“C” = “A” – “B”
“C” : Amount of oil to be drained
“A” : Amount of oil sealed in a new compressor
“B” : Amount of oil remaining in removed compressor
WHEN REPLACING OTHER PART
Replenish the following amount of oil to compressor.
Amount of compressor oil to be replenished
Evacuating
Evacuating procedure
Whenever opened (exposed to atmospheric air), A/C system
must be evacuated by using a vacuum pump.
1. New compressor
2. Removed compressor
Replaced part Amount of compressor oil to be
replenished
Evaporator
30 cm
3 (30 cc, 1.83 cu-in)
Condenser
30 cm
3 (30 cc, 1.83 cu-in)
Receiver / dryer
20 cm
3 (20 cc, 1.22 cu-in)
Hoses
10 cm
3 (10 cc, 0.61 cu-in) each
Pipes
10 cm
3 (10 cc, 0.61 cu-in) each
NOTE:
Do not evacuate before recovering refrigerant and replen-
ishing compressor oil.

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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.

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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.

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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.

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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.