2005 SUZUKI JIMNY ect

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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.

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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

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Compressor Drive Belt
INSPECTION
Check belt for wear and cracks, and replace as required.
Check belt tension by measuring how much it deflects when
pushed at intermediate point between compressor pulley (1)
and crankshaft pulley (2) with about 100 N (10 kg, 22 lb)
force.
If belt tension is out of above specification, adjust belt ten-
sion according to the following procedures.
Deflection of compressor drive belt
“a” : 6 – 9 mm (0.24 – 0.35 in.)
ADJUSTMENT
For Vehicle With P/S
1) Loosen tension pulley bolts (3) and set hexagon wrench (4)
to hexagon hole.
2) Turn tension pulley (5) counterclockwise by hexagon wrench
in order to obtain above specified tension.
3) Tighten tension pulley bolts (3) to specified torque.
Tightening torque
Tension pulley bolts
(a) : 25N·m (2.5 kg-m, 18.0 lb-ft)
For Vehicle Without P/S
1) Loosen tension pulley tightening nut (6).
2) Adjust belt tension by tighten or loosen tension pulley adjust-
ing bolt (7) in order to obtain above specified tension.
3) Tighten tension pulley tightening nut (6).
[A] : Vehicle with P/S
[B] : Vehicle without P/S

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