2005 SUZUKI JIMNY pressure

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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.

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Abnormal Noise Diagnosis
There are various types of noise, ranging from those produced in the engine compartment to those from the
passenger compartment, also from rumbling noises to whistling noises.
Abnormal noise from compressor
Abnormal noise from magnetic clutch
Abnormal noise from tubing
Abnormal noise from condenser
Condition Possible Cause Correction
During compressor
operation, a rumbling
noise is heard propor-
tional to engine revo-
lutions.Inadequate clearance in piston area (piston or
swash-plate).Repair or replace compressor as
necessary
A loud noise is heard
at a certain rpm, dis-
proportionately to
engine revolution.Loose or faulty compressor drive belt. Adjust drive belt tension, or replace
belt.
Loose compressor mounting bolts. Retighten mounting bolts.
A loud rattle is heard
at low engine rpm.Loose compressor clutch plate bolt. Retighten clutch plate bolt.
Replace compressor if it was oper-
ated in this condition for a long
time.
Condition Possible Cause Correction
A rumbling noise is
heard when compres-
sor is not operating.Worn or damaged bearings. Replace magnet clutch assembly.
A chattering noise is
heard when compres-
sor is engaged.Faulty clutch clearance (excessive). Adjust clutch clearance.
Worn clutch friction surface. Replace magnet clutch assembly.
Compressor oil leaked from lip type seal. Replace lip type seal.
Contaminating the friction surface. Replace compressor body assem-
bly.
Condition Possible Cause Correction
A droning noise is
heard inside vehicle,
but not particularly
noticeable in engine
compartment.Faulty tubing clamps. Reposition clamps or increase the
number of clamps.
Resonance caused by pulsation from variations
in refrigerant pressure.Attach a silencer to tubing, or mod-
ify its position and length.
Condition Possible Cause Correction
Considerable vibra-
tion in condenser.Resonance from condenser bracket and body. Firmly insert a silencer between
condenser bracket and body.

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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.

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Performance Diagnosis
1) Confirm that vehicle and environmental conditions are as fol-
lows.
Vehicle is not exposed to direct sun.
Ambient temperature is within 15 – 35 °C (59 – 95 °F).
2) Make sure that high pressure valve (1) and low pressure
valve (2) of manifold gauge set (3) are firmly closed.
3) Connect high pressure charging hose (4) to high pressure
service valve (5), and connect low pressure charging hose
(6) to low pressure service valve (7).
4) Bleed the air in charging hoses (4), (6) by loosening their
respective nuts on manifold gauge set (3), utilizing the refrig-
erant pressure. When a hissing sound is heard, immediately
tighten nut.
5) Warm up engine to normal operating temperature (engine
coolant temperature at 80 – 90 °C (176 – 194 °F)) and keep
it at specified idle speed. (Radiator cooling fan should not be
working when checking pressure and temperature.)
6) Turn A/C switch ON, and set blower switch at “HI” (3rd posi-
tion), temperature knob at “COOL” air outlet control knob at
“FACE” and fresh / circulation control knob at “CIRCULA-
TION”. (Confirm that A/C compressor and radiator / con-
denser cooling fan are working.)
Keep all windows, doors and engine food open.
Performance diagnosis condition
7) With dry bulb thermometer (1) inserted into center duct air
outlet and another one set near evaporator air inlet, read
temperature indicated on each thermometer. CAUTION:
Do not interchange high and low pressure charging
hoses by mistake.
Ambient temperature 15 – 35 °C (59 – 95 °F)
Engine rpm Keep to 1,500 rpm.
Blower fan motor switch “H” (3rd position)
Temperature control “Cool”
Air outlet control “Face”
Vehicle doors All open
Air inlet door position Recirculation

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8) Check if each pressure on low side and on high side is within
shaded range of the graph.
If each gauge reading is out of specified pressure, correct
defective part referring to “Performance Diagnosis Table” in
this section.
Low side and high side pressure example :
9) Check inlet port temperature-to-outlet port temperature rela-
tionship using graph.
For example, if evaporator inlet port temperature is 25 °C
(77 °F) and center duct air outlet temperature is 8 °C
(46.4 °F), their crossing point is within acceptable range as
shown in the graph.
If crossing point is out of acceptable range, diagnose trouble
referring to “Performance Diagnosis Table” in this section. NOTE:
Pressure registered on gauge varies with ambient tem-
perature. Therefore, use graph when determining if pres-
sures are normal or not.
Gauges should read as follows when ambient tempera-
ture is 30 °C (86 °F).
Pressure on high pres-
sure 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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Performance diagnosis table
HIGH PRESSURE GAUGE
LOW PRESSURE GAUGE
NOTE:
If ambient temperature is approximately 30 °C (86 °F), it is possible to diagnose A/C system in detail
referring to “Detail Diagnosis Table (Ambient Temperature At 30 °C (86 °F))” under “Performance
Diagnosis” in this section.
Condition Possible Cause Correction
Pressure in higher
than acceptable range
(“A” area)Refrigerant overcharged Recharge
Expansion valve frozen or clogged Check expansion valve
Clogged refrigerant passage of high side Clean or replace
Condenser cooling fan malfunction (Insufficient
cooling of condenser)Check condenser cooling fan
Dirty or bent condenser fins (Insufficient cooling
of condenser)Clean or repair
Compressor malfunction (Insufficient oil etc.) Check compressor
Engine overheat Check engine cooling system refer-
ring to Section 6B.
Pressure is lower than
acceptable range
(“B” area)Insufficient refrigerant (Insufficient charge or
leakage)Check for leakage, repair if neces-
sary and recharge
Expansion valve malfunction (valve opens too
wide)Check expansion valve
Compressor malfunction (Insufficient compres-
sion)Check compressor
Condition Possible Cause Correction
Pressure is higher
than acceptable range
(“C” area)Expansion valve malfunction (valve opens too
wide)Check expansion valve
Compressor malfunction (Insufficient compres-
sion)Check compressor
Pressure is lower than
acceptable range
(“D” area)Insufficient refrigerant (Insufficient charge or
leakage)Check for leakage, repair if neces-
sary and recharge
Expansion valve malfunction (valve opens too
narrow)Check expansion valve
Clogged refrigerant passage (crashed pipe) Repair or replace

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CROSSING POINT OF CENTER VENTILATION LOUVER TEMPERATURE AND RECIRCULATION AIR
INLET TEMPERATURE
Detail diagnosis table (Ambient temperature at 30°C (86°F))
Condition Possible Cause Correction
Crossing point is
higher than accept-
able range
(“E” area)Insufficient or excessive charge of refrigerant Check refrigerant pressure
Dirty or bent A/C evaporator fins Clean or repair
Air leakage from cooling (heater) unit or air duct Repair or replace
Malfunctioning, switch over function of door in
cooling (heater) unitRepair or replace
Compressor malfunction Check compressor
Crossing point is
lower than acceptable
range
(“F” area)Insufficient air volume from center duct (Heater
blower malfunction)Check blower motor and fan
Compressor malfunction Check compressor
Condition
Possible Cause Correction MANIFOLD
GAUGEMPa
(kg/cm
2)
(psi)Detail
Lo Hi
0.23 – 0.35
(2.3 – 3.5)
(33 – 50)1.4 – 1.75
(14 – 17.5)
(200 – 249)Normal condition
––
Negative
pressure0.5 – 0.6
(5 – 6)
(71.2 – 85.3)The low pressure side
reads a negative pres-
sure, and the high pres-
sure side reads an
extremely low pressure.
Presence of frost
around tubing to and
from receiver / dryer
and expansion valve.Dust particles or water
droplets are either stuck
or frozen inside expan-
sion valve, preventing the
refrigerant from flowing.Clean expansion valve.
Replace it if it cannot be
cleaned.
Replace receiver / dryer.
Evacuate the A/C sys-
tem and recharge with
fresh refrigerant.
Normal :
0.23 – 0.35
(2.3 – 3.5)
(33 – 50)
↑
↑ ↑ ↑ ↓
↓↓ ↓
Abnormal :
Negative
pressureNormal :
1.4 – 1.75
(14 – 17.5)
(200 – 249)
↑
↑ ↑ ↑ ↓
↓↓ ↓
Abnormal :
0.69 – 0.98
(7 – 10)
(100 – 142)During A/C operation,
the low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.Expansion valve is frozen
due to moisture in the
system, and temporarily
shuts off the refrigeration
cycle.Replace expansion valve.
Replace receiver / dryer.
Evacuate A/C system
and recharge with fresh
refrigerant.

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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