2005 SUZUKI JIMNY leak

Downloaded from www.Manualslib.com manuals search engine 1A-8 HEATER AND VENTILATION
CAUTION:
When the heater unit is disassembled and reassembled,
locking force of the heater case lock may reduce. In such
a case, tighten the heater case with a tapping screw of
M4
×L16 (1) as shown in the figure, or air may leak from its
joint section.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-1
6F1
6F2
1B
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 1B
AIR CONDITIONING (OPTIONAL)
CONTENTS
General Description ....................................... 1B-3
Major Components and Location ................. 1B-3
Refrigerant Circulation ................................. 1B-4
Refrigerant Type .......................................... 1B-4
Diagnosis ........................................................ 1B-5
General Diagnosis Table .............................. 1B-5
Abnormal Noise Diagnosis ........................... 1B-7
Abnormal noise from compressor ............ 1B-7
Abnormal noise from magnetic clutch ...... 1B-7
Abnormal noise from tubing ..................... 1B-7
Abnormal noise from condenser .............. 1B-7
Abnormal noise from crankshaft pulley .... 1B-8
Abnormal noise from tension pulley ......... 1B-8
Abnormal noise from A/C evaporator ....... 1B-8
Abnormal noise from blower fan motor .... 1B-8
Quick Checking of Refrigerant Charge......... 1B-9Performance Diagnosis.............................. 1B-10
Performance diagnosis table.................. 1B-12
Detail diagnosis table (Ambient
temperature at 30°C (86°F)) .................. 1B-13
Compressor Drive Belt ............................... 1B-15
Electronical Diagnosis ................................ 1B-16
Wiring Diagram .......................................... 1B-16
A/C System Inspection of ECM and ITS
Circuits ....................................................... 1B-17
Refrigerant Recovery, Evacuating and
Charging ....................................................... 1B-21
Operation Procedure for Refrigerant
Charging .................................................... 1B-21
Recovery .................................................... 1B-22
Replenishing Compressor Oil .................... 1B-22 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to “Refrigerant Type” in this section.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
NOTE:
For basic servicing method of the air conditioning system that is not described in this section, refer to
AIR CONDITIONING BASIC MANUAL (Part number: 99520-02130).

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 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

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-7
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.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-9
Quick Checking of Refrigerant Charge
The following procedure can be used for quickly checking whether
the A/C system has a proper charge of refrigerant or not.
Run engine at fast idle, and operate A/C at its maximum cooling
capacity for a few minutes. Then, look at the sight glass (1) on
receiver / dryer (2) and compare what is observed with the symp-
toms listed in below.
CHECKING REFRIGERANT CHARGE
3. Bubbles
Symptom Charge of refrigerant condition Correction
Bubbles observed in sight glass Insufficient charge of refrigerant in
systemCheck system for leaks with a
leak tester.
No bubbles observed in sight glass No or insufficient charge of refrig-
erant in systemRefer to the items 3 and 4.
No temperature difference between
compressor inlet and outletEmpty or nearly empty system Evacuate and charge system and
then check it for leaks with a leak
tester.
Noticeable temperature difference
between compressor inlet and outletProper or too much charge of
refrigerant in systemRefer to the items 5 and 6.
When A/C is turned OFF, refrigerant in
sight glass clears immediately and
remains clearToo much charge of refrigerant in
systemDischarge excess refrigerant in
order to obtain a specified charge.
When A/C is turned OFF, refrigerant in
sight glass once produces bubbles and
then clearsProper charge of refrigerant in
systemNo correction needed because
charge of refrigerant is normal.

Downloaded from www.Manualslib.com manuals search engine 1B-12 AIR CONDITIONING (OPTIONAL)
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

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-13
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.