2005 SUZUKI JIMNY ATE

Downloaded from www.Manualslib.com manuals search engine 1B-40 AIR CONDITIONING (OPTIONAL)
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.

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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

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3) Install magnet clutch.
a) Set magnet clutch squarely over clutch installation boss.
b) Place special tool onto clutch bearing.
Ensure that edge rests only on inner race of bearing.
Special tool
(A) : 09991-06010
4) Install snap ring (1) using special tool.
Special tool
(A) : 09900-06107
5) Adjust clearance between clutch plate (1) and magnet clutch
coil (2) by putting shim on compressor shaft.
Standard clearance between clutch plate and magnet
clutch coil
“a” : 0.3 – 0.6 mm (0.012 – 0.024 in.)
6) Tighten new clutch plate bolt (1) as specified torque.
Tightening torque
Clutch plate bolt
(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
Special tool
(A) : 09991-06020
CAUTION:
Be careful not to scratch bearing seal.

Downloaded from www.Manualslib.com manuals search engine 1B-46 AIR CONDITIONING (OPTIONAL)
2) Coat special tool surface with compressor oil and place it on
compressor shaft (1).
Special tool
(A) : 09991-06040
3) Install O-ring (1) to compressor body assembly (2).
4) Apply compressor oil to lip type seal and O-ring (1).
5) Install front head (3) to compressor body assembly (2).
Special tool
(A) : 09991-06040
6) Tighten new front head bolts to specified toque.
Tightening torque
Front heat bolts
(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
(b) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
Tightening Torque Specification
NOTE:
Tighten bolt (a) first, and next (b).
Fastening partTightening torque
Nm kg-m lb-ft
Tension pulley bolt (for vehicle with P/S) 25 2.5 18.0
Refrigerant 8 mm pipe (0.31 in.) 13 1.3 9.5
Refrigerant 12 mm pipe (0.47 in.) 23 2.3 16.6
Refrigerant 14.5 mm pipe (0.57 in.) 33 3.3 23.8
Dual pressure switch 10 1.0 7.0
Clutch plate bolt 14 1.4 10.5
Front head bolt (5 mm) 14 1.4 10.5
Front head bolt (8 mm) 23 2.3 16.6

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Required Service Materials
Special Tools
MaterialRecommended SUZUKI product
(Part Number)Use
Compressor oil
(Refrigerant oil)COMPRESSOR OIL RS20 (150 cc)
99000-99088-00D0O-ring
Each component
09900-06107 09991-06010 09991-06020 09991-06030
Snap ring pliers
(Open type)Magnet clutch pulley
installerArmature plate spanner Armature plate remover
09991-06040 09991-06050
Lip type seal protector Lip type seal installer

Downloaded from www.Manualslib.com manuals search engine 3-2 STEERING, SUSPENSION, WHEELS AND TIRES
General Diagnosis
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be consid-
ered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged
parts.
3) Spin front wheel. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and/or rough wheel
bearings.
Diagnosis Table
Condition Possible Cause Correction
Vehicle Pulls (Leads)
Mismatched or uneven tires Replace tire.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging springs Replace spring.
Radial tire lateral force Replace tire.
Disturbed front wheel alignment Check and adjust wheel alignment.
Disturbed rear wheel alignment Check and adjust wheel alignment.
Brake dragging in one road wheel Repair front brake.
Loose, bent or broken front or rear suspension
partsTighten or replace suspension part.
Abnormal or
Excessive Tire WearSagging or broken springs Replace spring.
Tire out of balance Adjust balance or replace tire.
Disturbed front wheel alignment Check wheel alignment.
Faulty shock absorber Replace shock absorber.
Hard driving Replace tire.
Overloaded vehicle Replace tire.
Not rotating tire Replace or rotate tire.
Worn or loose road wheel bearings Replace wheel bearing.
Wobbly wheel or tires Replace wheel or tire.
Tires not adequately inflated Adjust the pressure.
Wheel Tramp
Blister or bump on tire Replace tire.
Improper shock absorber action Replace shock absorber.

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Shimmy, Shake or
VibrationTire or wheel out of balance Balance wheels or replace tire
and/or wheel.
Loose wheel bearings Replace wheel bearing.
Loose wheel hub nuts Retighten.
Worn tie rod ends Replace tie rod end.
Worn king pin bearings or king pins Replace king pin bearing and/or
king pin.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire / wheel
assemblyReplace tire or wheel.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear box bolts Tighten box bolts.
Worn steering knuckle oil seal Replace.
Hard Steering
Bind in tie rod end ball studs or king pin bear-
ingsReplace tie rod end or king pin
bearing.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Steering gear box adjustment Check and adjust steering gear
box.
Tire not adequately inflated Inflate tires to proper pressure.
Bind in steering column Repair or replace.
Low fluid level, loose drive belt or malfunction of
power steering system (if equipped with P/S)Check and correct.
Too Much Play in
SteeringWheel bearings worn Replace wheel bearing.
Steering gear box attachments loose Tighten or repair.
Steering gear box adjustments Check and adjust steering gear
box.
Worn steering shaft joints Replace joint.
Worn tie rod ends drug rod ball joints Replace tie rod end.
Worn king pin bearings or king pin Replace king pin bearing and/or
king pin.
Poor Returnability
Bind in tie rod end ball studs Replace tie rod end.
Bind in king pin bearings Replace king pin bearing.
Bind in steering column Repair or replace.
Steering gear box needing lubricant Check, repair or lubricate steering
gear box.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Steering gear box not properly adjusted Check and adjust steering gear box
torque.
Tires not adequately inflated Adjust pressure.
Steering Noise
(Rattle or Chuckle)Loose bolts and nuts Retighten.
Broken or otherwise damaged wheel bearings Replace wheel bearing.
Worn or sticky tie rod ends Replace tire rod end.
Linkage joints needing grease Lubricate or replace. Condition Possible Cause Correction