sensor SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 0A-12 GENERAL INFORMATION
 Never connect any tester (voltmeter, ohmmeter, or what-
ever) to electronic control unit when its coupler is dis-
connected. Attempt to do it may cause damage to it.
 Never connect an ohmmeter to electronic control unit
with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.
 Be sure to use a specified voltmeter / ohmmeter. Other-
wise, accurate measurements may not be obtained or
personal injury may result.
 When taking measurements at electrical connectors
using a tester probe (2), be sure to insert the probe from
the wire harness side (backside) of the connector (1).
 When connecting meter probe (2) from terminal side of
coupler (1) because it can’t be connected from harness
side, use extra care not to bend male terminal of coupler
of force its female terminal open for connection.
In case of such coupler as shown connect probe as
shown to avoid opening female terminal.
Never connect probe where male terminal is supposed
to fit.
 When checking connection of terminals, check its male
half for bend and female half for excessive opening and
both for locking (looseness), corrosion, dust, etc.
 Before measuring voltage to check for electrical system,
check to make sure that battery voltage is 11V or higher.
Such terminal voltage check at low battery voltage will
lead to erroneous diagnosis.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-21
Abbreviations May Be Used In This Manual
Abbreviations
AABC
ATDC
API
ATF
ALR
AC
A/T
A/C
ABDC
A/F
A-ELRAnti-lock Brake System
After Top Dead Center
American Petroleum Institute
Automatic Transmission Fluid
Automatic Locking Retractor
Alternating Current
Automatic Transmission
Air Conditioning
After Bottom Dead Center
Air Fuel Mixture Ratio
Automatic-Emergency
Locking RetractorEEBCM
ECM
ECT Sensor
EGR
EGRT Sensor
EFE Heater
ELR
EPS
EVAP
EVAP CanisterElectronic Brake Control Module,
ABS Control Module
Engine Control Module
Engine Coolant Temperature
Sensor (Water Temp. Sensor,
WTS)
Exhaust Gas Recirculation
EGR Temperature Sensor
(Recirculated Exhaust Gas Temp.
Sensor, REGTS)
Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
Emergency Locking Retractor
Electronic Power Steering
Evaporative Emission
Evaporative Emission Canister
(Charcoal Canister) BB+
BTDC
BBDCBattery Positive Voltage
Before Top Dead Center
Before Bottom Dead Center
CCKT
CMP Sensor
CO
CPP Switch
CPU
CRSCircuit
Camshaft Position Sensor
(Crank Angle Sensor, CAS)
Carbon Monoxide
Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
Central Processing Unit
Child Restraint SystemF 4WD 4 Wheel Drive
GGEN
GNDGenerator
Ground
HHC
HO2SHydrocarbons
Heated Oxygen Sensor
DDC
DLC
DOHC
DOJ
DRL
DTCDirect Current
Data Link Connector
(Assembly Line Diag. Link, ALDL,
Serial Data Link, SDL)
Double Over Head Camshaft
Double Offset Joint
Daytime Running Light
Diagnostic Trouble Code
(Diagnostic Code)IIAC Valve
IAT Sensor
ICM
IG
ISC ActuatorIdle Air Control Valve (Idle Speed
Control Solenoid Valve, ISC
Solenoid Valve)
Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
Immobilizer Control Module
Ignition
Idle Speed Control Actuator
(Motor)

Downloaded from www.Manualslib.com manuals search engine 0A-22 GENERAL INFORMATION
LLH
LSPVLeft Hand
Load Sensing Proportioning Valve
TTBI
TCC
TCM
TP Sensor
TVV
TWC
2WDThrottle Body Fuel Injection
(Single-Point Fuel Injection, SPI)
Torque Converter Clutch
Transmission Control Module
(A/T Controller, A/T Control Mod-
ule)
Throttle Position Sensor
Thermal Vacuum Valve
(Thermal Vacuum Switching Valve,
TVSV, Bimetal Vacuum Switching
Valve, BVSV)
Three Way Catalytic Converter
(Three Way Catalyst)
2 Wheel Drive MMAF Sensor
MAP Sensor
Max
MFI
Min
MIL
M/TMass Air Flow Sensor
(Air Flow Sensor, AFS, Air Flow
Meter, AFM)
Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Maximum
Multiport Fuel Injection
(Multipoint Fuel Injection)
Minimum
Malfunction Indicator Lamp
(“CHECK ENGINE” Light)
Manual Transmission
N NOx Nitrogen Oxides VVIN
VSSVehicle Identification Number
Vehicle Speed Sensor
OOBD
O/D
OHCOn-Board Diagnostic System
(Self-Diagnosis Function)
Overdrive
Over Head CamshaftWWU-OC
WU-TWCWarm Up Oxidation Catalytic
Converter
Warm Up Three Way Catalytic
Converter
PPNP
P/S
PSP Switch
PCM
PCVPark/Neutral Position
Power Steering
Power Steering Pressure Switch
(P/S Pressure Switch)
Powertrain Control Module
Positive Crankcase Ventilation
R RH Right Hand
SSAE
SDM
SFI
SOHCSociety of Automotive Engineers
Sensing and Diagnostic Module
(Air bag controller, Air bag control
module)
Sequential Multiport Fuel Injection
Single Over Head Camshaft

Downloaded from www.Manualslib.com manuals search engine 1B-2 AIR CONDITIONING (OPTIONAL)
Evacuating ................................................. 1B-23
Evacuating procedure ............................ 1B-23
Charging .................................................... 1B-25
Charging procedure ............................... 1B-25
Removing Manifold Gauge Set .................. 1B-28
Leak Test ................................................... 1B-28
On-Vehicle Service ...................................... 1B-29
Service Precaution ..................................... 1B-29
Refrigerant line ....................................... 1B-29
Handling refrigerant HFC-134a
(R-134a) ................................................. 1B-30
Condenser Assembly ................................. 1B-31
Receiver / Dryer ......................................... 1B-32
Condenser Cooling Fan Assembly ............ 1B-33Cooling Unit (Evaporator) .......................... 1B-34
A/C Evaporator Thermistor (A/C Evaporator
Temperature Sensor)................................. 1B-37
Expansion Valve ........................................ 1B-37
Dual Pressure Switch ................................ 1B-38
A/C Switch ................................................. 1B-39
Condenser Cooling Fan Motor Relay ........ 1B-39
Compressor ............................................... 1B-39
Magnet Clutch............................................ 1B-41
Lip Type Seal ............................................. 1B-45
Tightening Torque Specification................ 1B-46
Required Service Materials ......................... 1B-47
Special Tools ............................................... 1B-47

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-5
Diagnosis
General Diagnosis Table
Condition Possible Cause Correction
Cool air won’t come
out (A/C system won’t
operative)No refrigerant Perform recover, evacuation and charging.
Fuse blown Check fuses in main and circuit fuse
boxes, and check short circuit to ground.
A/C switch faulty Check A/C switch.
Blower fan switch faulty Check blower fan switch referring to Sec-
tion 1A.
A/C evaporator thermistor faulty Check A/C evaporator thermistor.
Dual pressure switch faulty Check dual pressure switch.
Wiring or grounding faulty Repair as necessary.
ECT sensor faulty Check ECT sensor referring to Section 6E.
ECM and its circuit faulty Check ECM and its circuit referring to Sec-
tion 6E.
4WD controller faulty Check 4WD controller referring to Section
3D.
Cool air won’t come
out (A/C compressor
won't operative)ECM faulty Check ECM and its circuit referring to Sec-
tion 6E.
Magnet clutch faulty Check magnet clutch.
Compressor drive belt loosen or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air won’t come
out (A/C condenser
cooling fan motor
won’t operative)Fuse blown Check “A/C” fuse in main fuse box, and
check short circuit to ground.
Wiring or grounding faulty Repair as necessary.
Condenser cooling fan motor relay
faultyCheck condenser cooling fan motor relay.
Condenser cooling fan motor faulty Check condenser cooling fan motor.
Cool air won’t come
out (Blower fan motor
won’t operative)Fuse blown Check fuses in main and circuit fuse
boxes, and check short circuit to ground.
Blower fan motor resistor faulty Check blower fan motor resistor referring
to Section 1A.
Blower fan switch faulty Check blower fan switch referring to Sec-
tion 1A.
Wiring or grounding faulty Repair as necessary.
Blower fan motor faulty Check blower fan motor referring to Sec-
tion 1A.

Downloaded from www.Manualslib.com manuals search engine 1B-16 AIR CONDITIONING (OPTIONAL)
Electronical Diagnosis
Wiring Diagram
[A]: 4WD model 4. Dual pressure switch 9. Thermal switch 14. Circuit fuse box
[B]: 2WD model 5. 4WD controller 10. Ignition switch 15. Main fuse box
1. Blower fan motor 6. Condenser cooling fan motor relay 11. A/C evaporator thermistor 16. Generator
2. Blower fan motor resistor 7. Condenser cooling fan motor 12. ECT sensor 17. ECM
3. Blower fan motor switch and A/C switch 8. Compressor 13. Lighting switch

Downloaded from www.Manualslib.com manuals search engine 1B-18 AIR CONDITIONING (OPTIONAL)
Terminal arrangement of ECM coupler (Viewed from harness side)
1. Blower fan motor 8. Compressor [A]: To “A/C” fuse (25A) in main fuse box
2. Dual pressure switch 9. Thermal switch [B]: To “HEATER” fuse (20A) in circuit fuse box
3. A/C switch 10. Main relay [C]: To “FI” fuse (15A) in main fuse box
4. A/C evaporator thermistor 11. Engine earth [D]: 4WD model
5. ECT sensor 12. Blower fan motor switch [E]: 2WD model
6. Condenser cooling fan motor relay 13. 4WD controller
7. Condenser cooling fan motor 14. ECM

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-19
ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL
Terminal Wire CircuitMeasurement
groundNormal value Condition
E18-1 PCompressor
magnet clutch
outputGround to
engine (Fig B)10 – 14 voltBlower fan motor switch and A/C
switch ON with engine running
0 – 1 voltsExcept the above-mentioned condi-
tion with engine running
E18-5 Bl/BMain power sup-
ply for ECMGround to
engine (Fig B)10 – 14 voltsIgnition switch ON with engine
stopped
E18-6 Bl/BMain power sup-
ply for ECMGround to
engine (Fig B)10 – 14 voltsIgnition switch ON with engine
stopped
E18-10 Bl Main relay driveGround to
engine (Fig B)0.5 – 1.2 voltIgnition switch ON with engine
stopped
0 volts Ignition switch OFF
E18-16 G/W A/C switch inputGround to
engine (Fig B)12 – 15 voltsBlower fan motor switch or A/C switch
OFF with engine running
0 – 1 voltBlower fan motor switch and A/C
switch ON with engine running
12 – 15 voltsWithin several seconds after operate
transfer lever between 2WD and 4WD
with above condition
E18-18 P/BCompressor
cooling fan relay
outputGround to
engine (Fig B)0 – 1 voltBlower fan motor switch and A/C
switch ON or engine coolant tempera-
ture at more than 110 °C (230 °F) with
engine running.
12 – 15 voltsExcept the above-mentioned condi-
tion with engine running
E18-20 B/BlSensor ground
for A/C evapora-
torGround to
body (Fig A)–0.5 – 0 volt Engine running
E18-24 Bl/YBlower fan
speed inputGround to
engine (Fig B)0 – 1 voltBlower fan motor switch 2nd or 3rd
with engine running
4 – 7 voltsBlower fan motor switch 1st with
engine running
12 – 15 voltsBlower fan motor switch and A/C
switch OFF with engine running
E19-1 BMain ground for
ECMGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-2 B/RECM ground for
power circuitGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-3 B/RECM ground for
power circuitGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-10 B/BlSensor ground
for ECT sensorGround to
body (Fig A)–0.5 – 1 volt Engine running

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

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.