2005 SUZUKI JIMNY Lever

Downloaded from www.Manualslib.com manuals search engine HEATER AND VENTILATION 1A-5
Heater Blower Resistor
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disable air bag system, if equipped.
Refer to “Disabling Air Bag System” in Section 10B.
3) Disconnect resistor coupler.
4) Remove blower motor resistor (3) as shown figure.
INSPECTION
Measure each terminal-to-terminal resistance on resistor
If measured resistance is incorrect, replace heater blower motor
resistor.
Heater blower resistor resistance
Me-Lo: approx. 2.4
Ω
Me-Hi: approx. 1.2
Ω
INSTALLATION
1) Reverse removal procedure for installation.
2) Enable air bag system, if equipped.
Refer to “Enabling Air Bag System” in Section 10B.
Heater Control Lever Assembly
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disable air bag system, if equipped.
Refer to “Disabling Air Bag System” in Section 10B.
3) Remove meter cluster hood, ashtray, center garnish, instru-
ment glove box and radio or accessory case (if equipped),
Then remove mounting screws (2) from heater control lever
assembly (1).
1. Heater unit
2. Blower motor

Downloaded from www.Manualslib.com manuals search engine 1A-6 HEATER AND VENTILATION
4) Disconnect blower fan switch coupler and A/C switch coupler
(if equipped)
5) Disconnect each heater control cables.
6) Remove heater control lever assembly (1).
7) Remove blower fan switch screw (3).
8) Remove blower fan switch (2) as shown figure.
INSTALLATION
1) Install in reverse order of removal procedure, adjustment the
following items.
Move control lever fully in arrow direction
Push heater lever and air inlet box lever fully in arrow direc-
tion and fix cable with clamp in position as shown figure.
2) If equipped with air bag, enable air bag system. Refer to
“Enabling Air Bag System” in Section 10B.
1. Heater control lever assembly
NOTE:
After installing control cables, be sure that control levers
move smoothly and stop at proper position.
1. Heater unit
2. Air inlet box
3. Mode control cable
4. Temperature control cable
5. Fresh air control cable

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Heater Blower Fan Switch
INSPECTION
Check blower fan switch for each terminal-to-terminal continuity.
For the detail refer to “Wiring Circuit” earlier in this section.
Heater Unit/Boost Ventilation
REMOVAL
1) Disconnect negative (–) cable at battery.
2) If equipped with air bag system disable air bag system.
Refer to “Disabling Air Bag System” in Section 10B.
3) Drain engine coolant and disconnect water hoses (1) from
heater unit.
4) Remove instrument panel.
5) Remove bolts, nuts and screws as shown figure.
6) Remove heater unit (1).
INSTALLATION
Install heater unit by reversing removal procedure, noting the fol-
lowing items.
When installing each part, be careful not to catch any cable
or wiring harness.
Adjust control cable (refer to heater control lever assembly in
this section).
Fill engine coolant to radiator.
If equipped with air bag system, enable air bag system,
Refer to “Enabling Air Bag System” in Section 10B.
TERMINAL
POSITIONBEI L MH
OFF
Lo
M
Hi

Downloaded from www.Manualslib.com manuals search engine 1B-6 AIR CONDITIONING (OPTIONAL)
Cool air won’t come
out or insufficient
cooling (A/C system
normal operative)Insufficient or excessive charge of
refrigerantCheck charge of refrigerant and system for
leaks.
Condenser clogged Check condenser.
A/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator
thermistor.
A/C evaporator thermistor faulty Check A/C evaporator thermistor.
Expansion valve faulty Check expansion valve.
Receiver / dryer clogged Check receiver / dryer.
Compressor drive belt loosen or broken Adjust or replace drive belt.
Magnetic clutch faulty Check magnetic clutch.
Compressor faulty Check compressor.
Air in A/C system Replace receiver / dryer, and perform
evacuation and charging.
Air leaking from cooling unit or air duct Repair as necessary.
Heater and ventilation system faulty Check air inlet box (cooling unit), heater
control lever assembly and heater unit
referring to Section 1A.
Blower fan motor faulty Check blower fan motor referring to Sec-
tion 1A.
Excessive compressor oil existing in
A/C systemPull out compressor oil in A/C system cir-
cuit, and replace compressor.
Cool air won’t come
out only intermittentlyWiring connection faulty Repair as necessary.
Expansion valve faulty Check expansion valve.
Excessive moisture in A/C system Replace receiver / dryer, and perform
evacuation and charging.
Magnetic clutch faulty Check magnetic clutch.
Excessive charge of refrigerant Check charge of refrigerant.
Thermal switch faulty Check thermal switch.
Cool air comes out
only at high speedCondenser clogged Check A/C condenser.
Insufficient charge of refrigerant Check charge of refrigerant.
Air in A/C system Replace receiver / dryer, and perform
evacuation and charging.
Compressor drive belt loosen or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air won’t come
out only at high speedExcessive charge of refrigerant Check charge refrigerant.
A/C evaporator frosted Check A/C evaporator and A/C evaporator
thermistor.
Insufficient velocity of
cooled airA/C evaporator clogged or frosted Check A/C evaporator and A/C evaporator
thermistor.
Air leaking from cooling unit or air duct Repair as necessary.
Blower fan motor faulty Check blower fan motor referring to Sec-
tion 1A.
Wiring or grounding faulty Repair as necessary. Condition Possible Cause Correction

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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-36 AIR CONDITIONING (OPTIONAL)
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 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.

Downloaded from www.Manualslib.com manuals search engine 3C-8 STEERING WHEEL AND COLUMN
3) Tighten steering shaft nut to specified torque.
Tightening torque
Steering shaft nut (a) : 33 N·m (3.3 kg-m, 23.5 lb-ft)
4) Install steering wheel pad (for vehicle without air bag system)
or driver air bag (inflator) module (for vehicle with air bag
system) as follows.
For vehicle without air bag system
–For TYPE A
a) Connect horn connector.
b) Install steering wheel pad.
–For TYPE B
a) To install the pad, hook (1) the upper part of the pad to the
pawl of the steering wheel and push in the lower part of the
pad until it fits to the set spring securely.
For vehicle with air bag system
a) Install driver air bag (inflator) module to steering wheel.
Refer to “Driver Air Bag (Inflator) Module” in this section.
Centering contact coil (for vehicle with air bag sys-
tem)
1) Check that vehicle’s wheels (front tires) are set at straight-
ahead position.
2) Check that ignition switch is at “LOCK” position.
3) Turn contact coil counterclockwise slowly with a light force till
contact coil will not turn any further. NOTE:
After installing the steering wheel, turn the steering
wheel about 1 full rotation so that the cancel cam pin fits
into the pin hole in the steering wheel and then check the
turn signal lever for proper function.
NOTE:
Contact coil can turn about 5 turns at maximum, that is, if
it is at the center position, can turn about two and a half
turns both clockwise and counterclockwise.