light SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 6C-18 Power Assisted Steering System:
“EPS” Warning Light Remains ON Steady after Engine StartsS6RW0D6304011
Wiring Diagram
Refer to ““EPS” Warning Light Does Not Come ON with Ignition Switch Turned ON before Engine Starts”.
Circuit Description
Operation (ON/OFF) of “EPS” warning light is controlled by P/S control module through combination meter.
If the P/S system is in good condition, P/S control module turns “EPS” warning light ON at the ignition switch ON, and
then turns it OFF at the engine start. If an abnormality in the system is detected, “EPS” warning light is turned ON
continuously by P/S control module. If P/S control module is disconnected, “EPS” warning light is not turned ON.
Troubleshooting
Step Action Yes No
1 Check DTC referring to “DTC Check”.
Is there any DTC(s) (NO CODES on SUZUKI scan tool)?Go to applicable DTC
diag. flow.Go to Step 2.
2“EPS” warning light circuit check
1) With ignition switch turned OFF, disconnect P/S control
module connector.
2) Check for proper connection to the P/S control module at
“E11-5” terminal.
3) If OK, then turn ignition switch to ON position.
Does “EPS” warning light turn ON?Go to Step 3. Replace P/S control
module.
3Combination meter ground circuit check
1) Remove combination meter and disconnect combination
meter connector with ignition switch turned OFF.
2) Check combination meter connector for proper
connection.
3) If connections are OK, check that “EPS warning light
circuit” is as follows.
• Insulation resistance of “EPS warning light circuit”
wire is infinity between its terminal and each terminal
at combination meter connector.
• Insulation resistance of “EPS warning light circuit”
wire is infinity between its terminal and vehicle body
ground.
Is circuit in good condition?Replace combination
meter.Repair defective circuit.

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DTC Detecting Condition and Trouble Area
DTC TroubleshootingDTC detecting condition Trouble area
DTC C1121:
Vehicle speed signal is 0 km/h even though engine speed
is more than 4000 rpm for more than 60 seconds
continuously (before elapse of 5 min from engine start)
or
Vehicle speed signal is 0 km/h even though engine speed
is more than 2500 rpm for more than 60 seconds
continuously (after elapse of 5 min for engine start).
(1 driving cycle detection logic but “EPS” warning light
does not light up)
DTC C1123:
Vehicle speed signal is 0 km/h with continuously more
than 3 driving cycles even though engine speed is more
than 4000 rpm for more than 30 seconds continuously
(before elapse of 5 min from engine start)
or
Vehicle speed signal is 0 km/h with continuously more
than 3 driving cycles even though engine speed is more
than 2500 rpm for more than 30 seconds continuously
(after elapse of 5 min for engine start).
(3 driving cycle detection logic)
DTC C1124:
Vehicle speed signal is less than 5 km/h for more than 5
seconds continuously with more than specified
deceleration speed (–20 m/s
2) from over 20 km/h.
(1 driving cycle detection logic but “EPS” warning light
does not light up)• Vehicle speed signal circuit
•BCM
•ECM
• TCM (A/T model)
• ABS control module (M/T model)
• P/S control module
• CAN communication line circuit
Step Action Yes No
1Was “EPS System Check” performed?Go to Step 2. Go to “EPS System
Check”.
2DTC check
1) DTC check for ECM referring to “DTC Check in Section
1A”.
Is there any DTC detected?Go to applicable DTC
diag. flow.Go to Step 3.
3Vehicle spec check
Is vehicle equipped with A/T?Go to Step 4 Go to Step 5
4DTC check
1) Check TCM for DTC referring to “DTC Check in Section
5A”.
Is there any DTC detected?Go to applicable DTC
diag. flow.Go to Step 6.
5DTC check
1) Check ABS control module and BCM for DTC referring
to “DTC Check in Section 4E” and “DTC Check in
Section 10B”.
Is there any DTC detected?Go to applicable DTC
diag. flow.Go to Step 6.

Downloaded from www.Manualslib.com manuals search engine 6C-28 Power Assisted Steering System:
DTC Troubleshooting
DTC C1155: P/S Control Module Internal FailureS6RW0D6304018
Wiring Diagram
Refer to “DTC C1153: P/S Control Module Power Supply Circuit”.
DTC Detecting Condition and Trouble Area
DTC TroubleshootingStep Action Yes No
1Was “EPS System Check” performed?Go to Step 2. Go to “EPS System
Check”.
2Battery voltage check
1) Check circuit fuse for P/S control module.
2) If OK, measure voltage between positive (+) battery
terminal and vehicle body ground with engine running.
Is voltage 10 V or more?Go to Step 3. Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.
3P/S control module power supply circuit check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition?Substitute a known-
good P/S control
module and recheck.Repair defective circuit.
DTC detecting condition Trouble area
Internal memory (EEPROM) is data error.
(In this case, “EPS” warning light does not light up)
or
Internal circuit is faulty.
or
Power supply voltage of P/S control module exceeded
17.5 V
(1 driving cycle detection logic)• Generator
• P/S control module
Step Action Yes No
1Was “EPS System Check” performed?Go to Step 2. Go to “EPS System
Check”.
2P/S control module power supply and ground circuit
check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition?Go to Step 3. Repair or replace
defective circuit.
3Battery voltage check
1) Check voltage between positive (+) battery terminal and
vehicle body ground with engine speed at 3000 rpm.
Is voltage 15.5 V or less?Replace P/S control
module.Check charging system
referring to “Generator
Test (Overcharged
Battery Check) in
Section 1J”.

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Terminal Wire color Circuit Normal voltage Condition
E11-1 LT GRN/BLKIgnition switch signal for P/S
control module10 – 14 V Ignition switch ON
E11-2 — — — —
E11-3 — — — —
E11-4 PPL Vehicle speed signal*0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.7”
under “Inspection
of BCM and Its
Circuits in
Section 10B”)• Ignition switch ON
• Front left tire turned quickly with right
tire locked
E11-5 GRY “EPS” warning light0 V Ignition switch ON
0 – 14 V Engine running
E11-6 — — — —
E11-7 — — — —
E11-8 GRN9 V power supply for torque
sensorAbout 9 V• Ignition switch ON
• Voltage between “E11-8” and “E11-9”
terminals
E11-9 BLK Ground for torque sensors — —
E11-10 WHT Torque sensor signal (Sub)About 2.5 – 4.0 V• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 1.0 – 2.5 V• Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E11-11 BLUSerial communication circuit for
data link connector——
E11-12 BRN Engine speed signal*0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.24
and No.25” under
“Inspection of
ECM and Its
Circuits in
Section 1A”)Engine idling
E11-13 — — — —
E11-14 RED/BLU P/S active signal (idle up signal)About 12 V Ignition switch ON
0 – 1 VEngine idling and turned steering wheel
to the right or left until it stops
E11-15 — — — —
E11-16 — — — —
E11-17 — — — —
E11-18 YEL Torque sensor signal (Main)About 1.0 – 2.5 V• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 2.5 – 4.0 V• Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E11-19 GRY Ground for shield wire — —

Downloaded from www.Manualslib.com manuals search engine 7A-2 Heater and Ventilation:
Schematic and Routing Diagram
Heater and Ventilation Wiring Circuit DiagramS6RW0D7102001
Non–A/C
Manual A/C
Refer to “A/C System Wiring Diagram in Section 7B”.
Auto A/C
Refer to “A/C System Wiring Diagram in Section 7B”.
Component Location
Electronic Control System Components LocationS6RW0D7103001
Refer to “Electronic Control System Components Location in Section 7B” (non-A/C and manual A/C) or “Electronic
Control System Components Location in Section 7B” (auto A/C).
5V
BLK
RED/BLK3
5 72
G154-3
G154-4
G154-7
G154-8
G154-10
G154-13
G155-2
G155-3
G155-7
G155-6
G155-1
G154-9
G154-14
BLK/WHT
YEL
BLU/WHT
RED
RED/BLKRED
GRN
GRN/YEL
RED/YEL
RED/BLU
BLK/ORN
46
8
BLU
YELGRN
WHT
13
1514
[A]21
BLK/RED
12V
BLK/YELBLK/WHTM
BLK
1IG1
IG2
12
BLK/RED
M 10
11
11
BLU/WHT 19
16
17
18 9 20
I6RW0C710003-01
[A]: Illumination control model 6. Blower motor resistor 12. Main fuse box 18. Illumination light
1. Ignition switch 7. Junction block assembly 13. Blower speed selector 19. Rear defogger relay
2. Blower motor 8. BCM 14. Air intake selector 20. Rear defogger
3. HVAC control unit 9. ECM 15. Rear defogger switch 21. Tail light
4. Lighting switch 10. Air intake control actuator 16. “REC” indicator light
5. Blower motor relay 11. To BCM 17. Rear defogger indicator

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-5
A/C System Wiring DiagramS6RW0D7212002
[A]
7
WHT
GRN5YELBLK
3
G154-3
G154-4
G154-7
G154-8
G154-10
G154-13
G154-5
G154-6
G155-5
G155-2
G155-3
G155-7
G155-6
G155-1
G154-9
G154-14
BLK/WHT
YEL
BLU/WHT
RED
BRN
GRN/WHT
RED/BLK
RED
GRN
GRN/YEL
RED/YEL
RED/BLU
20
21
23 22
BLK/RED
6 2
MBLK/WHTBLK/YEL
M
11
4RED/YEL 1
E01-49
12
E01-16
GRY 13
12V
BLU/WHTE01-3510
E01-48
18
19RED/BLK
BLK/RED
BLK/RED
BRN/WHTE01-60
E01-1
E01-29BLK/WHT
M
BLU/YELBLK/YEL
5V5V 5V
WHT/BLK
9
ORN
14E01-36
C01-12C01-14GRY/REDRED/BLU
E01-41
RED/BLK
RED
WHT
8
BLK
BLK/ORN
BLU IG1
IG2
5V
17
28
29
31
2726 2524
16
16
30
34
33E01-4 E01-19WHTRED
C01-50C01-49WHTRED
32
LT GRN
C01-57
C01-2415
GRY/BLU5V
I6RW0C721002-01
[A]: Illumination control model 9. A/C refrigerant pressure
sensor18. Condenser cooling fan relay 27. Illumination light
1. Ignition switch 10. ECM 19. Condenser cooling fan motor 28. Rear defogger relay
2. Blower motor 11. Air intake control actuator 20. Blower speed selector 29. Rear defogger
3. HVAC control unit 12. Compressor relay 21. A/C switch 30. Main relay
4. Lighting switch 13. Compressor 22. Air intake selector 31. Tail light
5. Blower motor relay 14. Evaporator temperature
sensor23. Rear defogger switch 32. TCM
6. Blower motor resistor 15. ECT sensor 24. “A/C” indicator light 33. To other control module and DLC
7. Junction block assembly 16. To BCM 25. “REC” indicator light 34. ABS control module
8. BCM 17. Main fuse box 26. Rear defogger indicator

Downloaded from www.Manualslib.com manuals search engine 7B-12 Air Conditioning System: Manual Type
A/C System Inspection at ECMS6RW0D7214003
When checking voltage at ECM terminals related to A/C system, refer to “Inspection of ECM and Its Circuits in Section
1A”.0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3)0.7 – 1.0
(7 – 10)
(100 – 142)Both low and high
pressure sides indicate
low readings.
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
manifold gauges are
attached, check for any
leaks, repair them, and
evacuate the system.
0.4 – 0.6
(4 – 6)
(56.9 – 85.3)Pressure on low pressure
side is high.
Pressure on high pressure
side is low.
Both pressure becoming
equal right after A/C is
turned OFF.Internal leak in
compressor.Inspect compressor
and repair or replace
as necessary.
0.40 – 0.45
(4.0 – 4.5)
(57 – 64)2.0 – 2.5
(20 – 25)
(285 – 355)High pressure reading on
both low and high
pressure sides.Overcharged A/C
system.Adjust refrigerant to
specified amount.
Faulty condenser
cooling operation.Clean condenser.
Faulty condenser
cooling fan operation.Inspect and repair
condenser cooling fan.
High pressure reading on
both low and high
pressure sides.
Low pressure side tubing
is not cold when touched.Presence of air in A/C
system
(Improperly
evacuated).Replace desiccant and
cap with filter.
Inspect quantity of
compressor oil and
presence of
contaminants in oil.
Evacuate system and
recharge with fresh
refrigerant.
0.45 – 0.55
(4.5 – 5.5)
(64 – 78)High pressure reading on
both low and high
pressure sides.
Large amount of frost or
dew on the low pressure
side tubing.Faulty expansion
valve.
Refrigerant flow is not
regulated properly.Replace expansion
valve. Condition
Possible cause Correction Manifold gauge MPa (kgf/cm
2) (psi)
Detail
Lo Hi

Downloaded from www.Manualslib.com manuals search engine 7B-16 Air Conditioning System: Manual Type
Abnormal Noise from Tubing
Abnormal Noise from Condenser Assembly
Abnormal Noise from Crankshaft Pulley
Abnormal Noise from Tension Pulley
Abnormal Noise from A/C Evaporator
Abnormal Noise from Blower MotorCondition Possible cause Correction / Reference Item
A droning noise is heard
from inside of the vehicle,
but not particularly
noticeable in engine
compartmentFaulty tubing clampsReposition clamps or increase the number of
clamps.
Resonance caused by pulsation from
variations in refrigerant pressureAttach a silencer to tubing, or modify its
position and length.
Condition Possible cause Correction / Reference Item
Considerable vibration in
condenser assemblyResonance from condenser assembly
bracket and bodyFirmly insert a silencer between condenser
assembly bracket and body.
Condition Possible cause Correction / Reference Item
A large rattling noise is
heard at idle or sudden
accelerationLoosen crankshaft pulley boltRetighten bolt.
Condition Possible cause Correction / Reference Item
Clattering noise is heard
from pulleyWorn or damaged bearingReplace tension pulley.
Pulley cranks upon
contactCracked or loose bracketReplace or retighten bracket.
Condition Possible cause Correction / Reference Item
Whistling sound is heard
from A/C evaporatorDepending on the combination of the
interior / exterior temperatures, engine
rpm and refrigerant pressure, the
refrigerant flowing out of the expansion
valve may, under certain conditions,
make a whistling soundAt times, slightly decreasing refrigerant volume
may stop this noise.
Inspect expansion valve and replace if faulty.
Condition Possible cause Correction / Reference Item
Blower motor emits a
chirping sound in
proportion to its speed of
rotationWorn or damaged motor brushes or
commutatorReplace blower motor.
Fluttering noise or large
droning noise is heard
from blower motorLeaves or other debris introduced from
fresh air inlet to blower motorRemove debris and make sure that the screen
at fresh air inlet is intact.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-17
Repair Instructions
Operation Procedure for Refrigerant ChargeS6RW0D7216001
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 (21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) is exposed to your eyes, it may
cause a serious injury. To protect your eyes from such accident, it is necessary to always wear
goggles. Should it occur that HFC-134a (R-134a) is exposed to your eyes, consult a doctor
immediately.
– Do not use your hand to rub the affected eye(s). Instead, use 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 liquid refrigerant HFC-134a (R-134a) is exposed to your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.
• Do not handle refrigerant near any place where welding or steam cleaning is performed.
• Refrigerant should be kept in a cold and dark place. It should never be stored in any place where
temperature is high, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).
• Avoid breathing fume produced when HFC-134a (R-134a) is burned. Such fume may be hazardous to
your health.

Start evacuation.Start evacuation.
Stop evacuation.Stop evacuation.
15 minutes (above -100 kPa)15 minutes (above -100 kPa)
Wait 10 minutesWait 10 minutes
Check A/C system forCheck A/C system for
pressure tighteness.pressure tighteness.
Recharge A/C system withRecharge A/C system withrefrigerant.refrigerant.
Check A/C system for refrigerantCheck A/C system for refrigerantleaks and amount of refrigerantleaks and amount of refrigerantcharged.charged.
Performance testPerformance test
Inspect and repair connections.Inspect and repair connections.
If gauge showsIf gauge showsabnormal conditionsabnormal conditions
Recharge 430 20 g ofRecharge 430 20 g ofrefrigerant.refrigerant.
I5RW0A721011-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-21
7) When refrigerant container (1) is emptied, use the
following procedure to replace it with a new
refrigerant container.
a) Close low pressure valve.
b) Replace empty container with a refrigerant
container which has been charged with
refrigerant. When using refrigerant container tap
valve (2), use the following procedure for
replacement.
i) Retract needle (3) and remove refrigerant
container tap valve by loosening its plate nut
(4).
ii) Install the refrigerant container tap valve to a
new refrigerant container.
c) Purge any air existing in center charging hose.
When using refrigerant container tap valve, use
the following 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 as well as low pressure side valve.
iv) Turn handle of tap valve clockwise so that its
needle is screwed into the new container to
make a hole for refrigerant flow.8) After the system has been charged with specified
amount of refrigerant or when low pressure gauge
(1) and high pressure gauge (2) have indicated the
following specified value, close low pressure side
valve (3) on manifold gauge set (4).
Specified amount of refrigerant
430 ± 20 g (15.2 ± 0.7 oz))
Low side and high side pressure example
Removal of Manifold Gauge Set
WARNING!
High pressure side is under high pressure.
Therefore, be careful not to get injured
especially on your eyes and skin.

For the A/C system charged with the specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set.
(The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service
valves. This operation must be performed quickly.
5) Put caps on service valves.
I2RH01720018-01
I2RH01720019-01
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
Pressure
on high pressure gauge1130 – 1560 kPa
(11.4 – 15.6 kgf/cm
2)
(162.3 – 221.8 psi)
Pressure
on low pressure gauge270 – 390 kPa
(2.7 – 3.9 kgf/cm
2)
(38.8 – 56.0 psi)
4
2
1
3
I7RW01721013-02