2005 SUZUKI JIMNY light

Downloaded from www.Manualslib.com manuals search engine 1B-8 AIR CONDITIONING (OPTIONAL)
Abnormal noise from crankshaft pulley
Abnormal noise from tension pulley
Abnormal noise from A/C evaporator
Abnormal noise from blower fan motor
Condition Possible Cause Correction
A large rattling noise
is heard at idle or sud-
den acceleration.Loosen crankshaft pulley bolt. Retighten bolt.
Condition Possible Cause Correction
Clattering noise is
heard from pulley.Worn or damaged bearing. Replace tension pulley.
Pulley cranks upon
contact.Cracked or loose bracket. Replace or retighten bracket.
Condition Possible Cause Correction
Whistling sound is
heard from A/C evapo-
rator.Depending on the combination of the interior /
exterior temperatures, engine rpm and refriger-
ant pressure, the refrigerant flowing out of the
expansion valve may, under certain conditions,
make a whistling sound.At times, slightly decreasing refrig-
erant volume may stop this noise.
Inspect expansion valve and
replace if faulty.
Condition Possible Cause Correction
Blower fan motor
emits a chirping
sound in proportion to
its speed of rotation.Worn or damaged motor brushes or commuta-
tor.Repair or replace blower fan motor.
Fluttering noise or
large droning noise is
heard from blower fan
motor.Leaves or other debris introduced from fresh air
inlet to blower fan motor.Remove debris and make sure that
the screen at fresh air inlet is intact.

Downloaded from www.Manualslib.com manuals search engine 1B-14 AIR CONDITIONING (OPTIONAL)
0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3)
0.69 – 0.98
(7 – 10)
(100 – 142)Both low and high pres-
sure sides indicate low
readings.
Continuous air bub-
bles are visible through
sight glass.
Output air is slightly
cold.Insufficient refrigerant in
system.
(Refrigerant leaking)Using leak detector,
check for leaks and repair
as necessary.
Recharge refrigerant to a
specified amount.
If the pressure reading is
almost 0 when the mani-
fold gauges are attached,
check for any leaks,
repair them, and evacu-
ate the system.
0.4 – 0.6
(4 – 6)
(56.9 – 85.3)Pressure on low pres-
sure side is high.
Pressure on high pres-
sure side is low.
Both pressure becom-
ing equal right after A/C
is turned OFF.Internal leak in compres-
sor.Inspect compressor and
repair or replace as nec-
essary.
0.35 – 0.45
(3.5 – 4.5)
(50 – 64)
1.96 – 2.45
(20 – 25)
(285 – 355)Pressure on both low
and high pressure
sides is high.
Air bubbles are not visi-
ble even when engine
rpm is lowered.Overcharged A/C sys-
tem.Adjust refrigerant to
specified amount.
Faulty condenser cooling
operation.Clean condenser.
Faulty condenser cooling
fan operation.Inspect and repair con-
denser cooling fan.
Pressure on both low
and high pressure
sides is high.
Low pressure side tub-
ing is not cold when
touched.
Air bubbles are visible
through sight glass.Presence of air in A/C
system.
(Improperly evacuated)Replace receiver / dryer.
Inspect quantity of com-
pressor oil and presence
of contaminants in oil.
Evacuate system and
recharge with fresh
refrigerant.
0.45 – 0.55
(4.5 – 5.5)
(64 – 78)Pressure on both low
and high pressure
sides is high.
Large amount of frost
or dew on the low pres-
sure side tubing.Faulty expansion valve.
Refrigerant flow is not
regulated properly.Replace expansion valve. Condition
Possible Cause Correction MANIFOLD
GAUGEMPa
(kg/cm
2)
(psi)Detail
Lo Hi

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 AIR CONDITIONING (OPTIONAL) 1B-21
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

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 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 AIR CONDITIONING (OPTIONAL) 1B-39
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.