Air flow sensor SUZUKI SX4 2006 1.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 7B-50 Air Conditioning System: Automatic Type
Not Using SUZUKI Scan Tool
NOTE
In case of malfunction of temperature
selector, blower speed selector and air flow
selector, DTC can not be checked by the
following procedure. Use SUZUKI scan tool
for DTC check.

1) Light over sunload sensor vertically with an
incandescent light of approximately 100 W apart
from about 100 mm (3.94 in.).
NOTE
If sunload sensor is not lighted over with an
incandescent light, DTC of sunload sensor is
detected as current DTC even though there is
not any malfunction.

2) Set the following selectors to specified positions
below respectively with ignition switch off position.
• Temperature selector (1) is maximum cool
position
• Blower speed selector (2) is OFF position
• Air flow selector (3) is AUTO position
3) While pressing A/C switch (4) and air intake selector
(5) simultaneously, turn ignition switch to ON
position.
4) Wait for about 5 seconds (start of diagnosis).
5) Read flashing pattern of “FRE” (6) and “REC” (7)
indicator lights which represents DTC and write it
down.
NOTE
• When 2 or more current DTCs are
detected, only DTC having the highest
priority is indicated. Therefore, after
troubleshooting the malfunction, DTC
check has to be performed again to see if
any other DTC(s) is detected.
• Pressing “A/C” switch alternates display
of current DTC and history DTC. “A/C”
indicator light (8) remains off when display
is in current DTC mode and it lights up
when display is in history DTC mode.
• When a history DTC is indicated while 2 or
more history DTCs are detected, it is
possible to have other history DTC(s)
stored in HVAC control module displayed
by pressing the air intake selector.

Example: When inside air temperature sensor
circuit malfunction (Open) is set
Example: When VSS signal failure (Data error) is
set
6) After completing above check, turn ignition switch to
“OFF” position.
[A]: “REC” indicator light L: OFF
[B]: “FRE” indicator light a. About 0.5 seconds
H: ON b. About 2 seconds
[A]: “REC” indicator light a. About 0.5 seconds
[B]: “FRE” indicator light b. About 3 seconds
H: ON c. About 1.5 seconds
L: OFF
123
458
6
7I5RW0A722005-01
[A]
[B]H
L
H
L [B]
[A]
ab
aI5RW0A722006-02
[A]
[B]H
L
H
L [B]
[A]
ab
aaaa
c
I5RW0A722025-01

Downloaded from www.Manualslib.com manuals search engine 7B-52 Air Conditioning System: Automatic Type
DTC TableS6RW0D7224006
CAUTION!
Be sure to perform “Air Conditioning System Check” before starting diagnosis.

NOTE
• History DTC is such DTC which HVAC control module saves in its memory when it detects current
DTC for 60 seconds or more continuously.
• DTC B1504, B1541, B1546, B1570 and B1571 are displayed as a current DTC only when a current
malfunction is detected.
• When HVAC control module detects DTC B1513 and B1514, both current and history DTCs are
displayed at the same time.

DTC No.
(displayed
on SUZUKI
scan tool)Detection itemDTC (indicated on
HVAC control
module)
Condition when trouble detected (DTC is
determined when following condition detected)“A/C”
indicator
light Indicated
by “REC”
indicator
lightIndicated
by “FRE”
indicator
light
) B1502Inside Air
Temperature
Sensor Circuit
Malfunction21Signal voltage of inside air temperature sensor is
higher than specification.Flashed
22Signal voltage of inside air temperature sensor is
lower than specification.Flashed
) B1503Evaporator
Temperature
Sensor Circuit
Malfunction31Signal voltage of evaporator temperature sensor is
higher than specification. Flashed
32Signal voltage of evaporator temperature sensor is
lower than specification.Flashed
) B1504Sun load Sensor
Circuit
Malfunction41• Signal voltage of sun load sensor is higher than
specification.
• Without sunlight.—
42Signal voltage of sun load sensor is lower than
specification.Flashed
) B1511Temperature
Control Actuator
(Position Sensor)
and/or Its Circuit
Malfunction61Signal voltage of position sensor included in
temperature control actuator is higher than
specification.Flashed
62Signal voltage of position sensor included in
temperature control actuator is lower than
specification.Flashed
) B1512Air Flow Control
Actuator
(Position Sensor)
and/or Its Circuit
Malfunction71Signal voltage of position sensor included in airflow
control actuator is higher than specification. Flashed
72Signal voltage of position sensor included in airflow
control actuator is lower than specification.Flashed
) B1513Temperature
Control Actuator
(Motor) and/or Its
Circuit
Malfunction63
Motor of temperature control actuator is not
operated more than specified time.Flashed
) B1514Air Flow Control
Actuator (Motor)
and/or Its Circuit
Malfunction73Motor of air flow control actuator is not operated
more than specified time.Flashed
) B1520Temperature
Selector
Malfunction15 1Signal voltage of temperature selector in HVAC
control module is higher than specification.Flashed
15 2Signal voltage of temperature selector in HVAC
control module is lower than specification.Flashed

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-53
) B1521Blower Speed
Selector
Malfunction16 1Signal voltage of blower speed selector in HVAC
control module is higher than specification.Flashed
16 2Signal voltage of blower speed selector in HVAC
control module is lower than specification.Flashed
) B1522Air Flow Selector
Malfunction17 1Signal voltage of airflow selector in HVAC control
module is higher than specification.Flashed
17 2Signal voltage of airflow selector in HVAC control
module is lower than specification.Flashed
) B1541Back-up Power
Supply Circuit
Malfunction14 1• Back-up power supply voltage of HVAC control
module is higher than or lower than
specification.
• When connect battery with vehicle and then,
turn ignition switch to ON position for first time.—
) B1546A/C Refrigerant
Pressure
Malfunction13 5• Signal voltage of outside air temperature sensor
is more than specified value. However, A/C
refrigerant pressure is less than specified value.
• Insufficient refrigerant in A/C system.—
) B1551Serial
Communication
Circuit
Malfunction91Circuit voltage of serial communication circuit is
higher than specification.Flashed
92Circuit voltage of serial communication circuit is
lower than specification.Flashed
) B1552HVAC Control
Module Check
Sum Error94HVAC control module received unspecified data
from BCM more than 8 times.Flashed
) B1553CAN
Communication
Circuit
Malfunction10 4HVAC control module received signal indicating
reception error from ECM.Flashed
) B1557VSS Signal
Failure11 4HVAC control module receives invalid data of VSS
signal from BCM.—
) B1561ECT signal
Failure54HVAC control module receives invalid data of ECT
signal from BCM.Flashed
) B1562Outside
Temperature
Sensor Signal
Failure14HVAC control module receives invalid data of
outside air temperature sensor signal from BCM.Flashed
) B1563A/C Refrigerant
Pressure Sensor
Signal Failure13 4HVAC control module receives invalid data of A/C
refrigerant pressure sensor signal from BCM.—
) B1570Engine Type
Signal Failure20 4HVAC control module receives invalid data of
engine type signal from BCM.—
) B1571Combination
Meter Spec
Signal Failure21 4HVAC control module receives invalid data of
combination meter spec signal from BCM.—
NO CODE Normal See NOTE below — —DTC No.
(displayed
on SUZUKI
scan tool)Detection itemDTC (indicated on
HVAC control
module)
Condition when trouble detected (DTC is
determined when following condition detected)“A/C”
indicator
light Indicated
by “REC”
indicator
lightIndicated
by “FRE”
indicator
light

Downloaded from www.Manualslib.com manuals search engine 7B-54 Air Conditioning System: Automatic Type
DTC of A/C System detected by ECM
NOTE
When no DTC is detected, “FRE” [A] and “REC” [B] indicator lights on HVAC control module flash at
the same time in specific pattern.

Fail-Safe TableS6RW0D7224007
When any of the following malfunctions (DTCs) is detected, fail-safe mode is activated.
However, when HVAC control module detects normal operation of A/C system, fail-safe mode is canceled. DTC No. Detection itemDetecting condition
(DTC will set when detecting)MIL
P0481 Fan 2 Control Circuit
Refer to “Fail-Safe Table in Section 1A”. P0532A/C Refrigerant Pressure
Sensor Circuit Low
P0533A/C Refrigerant Pressure
Sensor Circuit High
H: ON a. About 3 seconds
L: OFF b. About 1 seconds
DTC No. Trouble AreaFail-Safe Operation
When ignition switch is turned ON
after malfunction is already detectedWhen malfunction is detected during
ignition switch is ON
) B1502Inside air temperature
sensor circuitHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that inside air temperature is
25 °C (77 °F).
) B1503A/C evaporator
temperature sensor
circuitHVAC control module assuming that
evaporator temperature is 0 °C (32 °F).• HVAC control module turns off A/C
switch signal.
• HVAC control module controls
actuators assuming that evaporator
temperature is 0 °C (32 °F).
) B1504 Sunload sensor circuitHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that amount of sunlight is 0 W/
m
2.
) B1520Temperature selector
malfunctionHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that setting of temperature
selector is 25 °C (77 °F) position.
) B1521Blower speed selector
malfunctionHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that setting of blower speed
selector is low (1st) position.
) B1522Air flow selector
malfunctionHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that setting of air flow selector
is DEF position.
[A]
[A]H
L
H
L [B]
[B]
baaba
baaba
I5RW0A722008-01

Downloaded from www.Manualslib.com manuals search engine 7B-56 Air Conditioning System: Automatic Type
Scan Tool Data Definitions
TEMP CONT SWITCH: (Temperature control selector
position, Max Cool, °C / °F, Max Hot): This
parameter indicates the selected position of
temperature control selector.
CABIN TEMPERATURE: (In-car temperature, °C, °F):
This parameter indicates the in-car temperature
detected by inside air temperature sensor.OUTSIDE AIR TEMP (Outside air temperature, °C,
°F): This parameter indicates the outside air
temperature detected by outside air temperature
sensor.
EVAPORATOR TEMP (Evaporator temperature, °C,
°F): This parameter indicates the temperature of air
passed through evaporator.
COOLANT TEMP (Engine Coolant Temperature °C,
°F): This parameter indicates the engine coolant
temperature detected by engine coolant temperature
sensor. ) COOLANT TEMP
Ignition switch turned ONEngine coolant temperature is
displayed
) SUN LOAD Reference value depends on the situation 0 W/m
2 – 1988 W/m2
)MODE CONT
SWITCHIgnition switch turned ON and air flow selector at
AUTO positionAUTO (Selected position of air flow
selector is displayed)
) FAN CONT SWITCHIgnition switch turned ON and blower speed selector
at AUTO positionAUTO (Selected position of blower
speed selector is displayed)
) FAN DESIRED VOLTIgnition switch turned ON and blower speed selector
at HighApprox. 12.0 V
Ignition switch turned ON and blower speed selector
at LowApprox. 4.0 V
) AIR MIX POS SENIgnition switch turned ON and temperature selector
at maximum cool positionApprox. 0.5 V
Ignition switch turned ON and temperature selector
at maximum hot positionApprox. 4.5 V
)MODE POS SENSORIgnition switch turned ON and air flow selector at
DEF positionApprox. 4.5 V
Ignition switch turned ON and air flow selector at
VENT positionApprox. 0.5 V
) A/C CONT SIGA/C switch turned ON, blower speed selector at other
than OFF position with engine runningON
A/C switch turned OFF with engine running OFF
) BLOWER LOAD SIGIgnition switch turned ON, blower speed selector at
other than OFF positionON
Ignition switch turned ON, blower speed selector at
OFF positionOFF
) AIR INTAKE MODEIgnition switch turned ON and air intake selector at
fresh air (FRE) positionFRE
Ignition switch turned ON and air intake selector at
recirculation air (REC) positionREC
Ignition switch turned ON, air flow selector and
blower speed selector at AUTO positionAUTO
) REFRIGERANT
PRESSUREA/C ON (A/C is operating) with engine running at
ambient temperature 30 °C (86 °F)1130 – 1560 kPa (For details, refer to
pressure of high pressure gauge
under “A/C System Performance
Inspection”)
A/C OFF (A/C is not operating) with engine running
at ambient temperature 30 °C (86 °F) and engine
coolant temperature 90 °C (194 °F) – 100 °C (212
°F)600 – 1000 kPa after longer than 10
minute for A/C switch turned off
) A/C COMP CLUTCHA/C switch turned ON, blower speed selector at other
than OFF position with engine runningON
A/C switch turned OFF with engine running OFF
) VEHICLE SPEED At stop with ignition switch turned ON 0 km/h (0 mph)
) ENGINE TYPE Ignition switch turned ON Engine type is displayed.
) METER SPEC Ignition switch turned ONCombination meter spec is displayed. Scan Tool Data ConditionNormal Condition / Reference
Va l u e

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-57
SUN LOAD (W/m2): This parameter indicates the
amount of sunlight detected by sunload sensor.
MODE CONT SWITCH (Air flow selector position,
AUTO, FACE, B/L, FOOT, D/F, DEF): This
parameter indicates the selected position of air flow
selector.
FAN CONT SWITCH (Blower speed selector, AUTO,
OFF, 1st – 8th): This parameter indicates the
selected position of blower speed selector.
FAN DESIRE VOLT (Fan desired voltage, V): This
parameter indicates the consumption voltage of
blower motor.
AIR MIX POS SENSOR (Temperature control
actuator position sensor, V): This parameter
indicates the input signal from position sensor in
temperature control actuator.
MODE POS SENSOR (Air flow control actuator
position sensor, V): This parameter indicates the
input signal from position sensor in air flow control
actuator.
A/C CONT SIG (A/C control signal, ON, OFF): This
parameter indicates the state of A/C switch.BLOWER LOAD SIG (Blower fan load signal, ON,
OFF): ON: Position of blower speed selector is 1st
position or more.
OFF: Position of blower speed selector is OFF
position.
AIR INTAKE MODE (Air intake selector position,
AUTO, FRE, REC): This parameter indicates the
selected position of air intake selector.
REFRIGERANT PRESSURE (A/C refrigerant absolute
pressure, kPa): This parameter indicates the A/C
refrigerant absolute pressure calculated by ECM
A/C COMP CLUCH (A/C compressor magnet clutch,
ON, OFF): This parameter indicates the state of the
A/C compressor magnet clutch.
VEHICLE SPEED (km/h, mph): This parameter
indicates the vehicle speed calculated by ECM.
ENGINE TYPE (Engine type signal, J20, M16 or
M15): This parameter indicates the engine type
signal transmitted by ECM.
METER SPEC (Combination meter spec signal, EU,
UK, US, Canada, DOM): This parameter indicates
the combination meter spec signal transmitted by
combination meter.
Visual InspectionS6RW0D7224009
Check visually the following parts and systems.
DTC B1502: Inside Air Temperature Sensor Circuit MalfunctionS6RW0D7224010
Wiring DiagramInspection item Correction
• Refrigerant leakage and amount
• A/C pipe or hose disconnection,
looseness and
deterioration
• A/C compressor drive belt looseness and damageRefer to “Compressor Drive Belt Inspection
and Adjustment”.
• Battery fluid level and corrosion
of terminal
• Connectors of electric wire harness disconnection and
friction
• Fuses burning
• Parts installation and damage
• Other parts that can be checked visually
5V
G20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30
ORNORNPNK/BLKG20-10
21
3 [S]
[G]
G20-24
I7RW01722004-01
[S]: Inside air temperature sensor signal circuit 1. HVAC control module 3. To other sensors
[G]: Inside air temperature sensor ground circuit 2. Inside air temperature sensor

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-61
DTC Troubleshooting
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit MalfunctionS6RW0D7224013
Wiring DiagramStep Action Yes No
1Was “Air Conditioning System Check” performed?Go to Step 2. Go to “Air Conditioning
System Check”.
2Wire harness check
1) Turn ignition switch to OFF position.
2) Disconnect connectors from sunload sensor and HVAC
control module.
3) Check for proper connection to each signal circuit
terminal and ground circuit terminal of sunload sensor
and HVAC control module connectors.
4) If OK, check that sunload sensor circuit is as follows.
• Wiring harness resistance of each sunload sensor
signal circuit and ground circuit is less than 3 Ω
• Insulation resistance of each sunload sensor signal
circuit and ground circuit between sunload sensor
connector and vehicle body ground is Infinity
• Circuit voltage of each sunload sensor signal circuit
and ground circuit is 0 – 1 V with ignition switch turned
ON
Are they in good condition?Go to Step 3. Sunload sensor power
supply circuit and/or
signal circuit are open,
short or high resistance.
3Sunload sensor power supply voltage check
1) Connect connector to HVAC control module with ignition
switch turned OFF.
2) Turn ignition switch to ON position.
3) Measure voltage between signal terminal and ground
terminal of sunload sensor connector.
Is voltage 4.5 – 5.5 V?Go to Step 4. Substitute a known-
good HVAC control
module and recheck.
4Sunload sensor check
1) Check sunload sensor for performance referring to
“Sunload Sensor Inspection”.
Is it in good condition?Substitute a known-
good HVAC control
module and recheck.Replace sunload
sensor.
G20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30
GRY/BLUGRY/RED
5V5V
12V
ORN
WHT
YEL
G20-12
G20-27
G20-24
G20-1G20-2
2
[P]
[S]3
4
[G]
1
I6RW0C722004-01
[P]: Position sensor power supply circuit [G]: Position sensor ground circuit 2. Temperature control actuator 4. To other sensors
[S]: Position sensor signal circuit 1. HVAC control module 3. To air flow control actuator

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-63
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit MalfunctionS6RW0D7224014
Wiring Diagram
DTC Detecting Condition and Trouble Area4Temperature control actuator check
1) Check position sensor of temperature control actuator
for performance referring to “Temperature Control
Actuator and Its Circuit Inspection”.
Is it in good condition?Substitute a known-
good HVAC control
module and recheck.Replace temperature
control actuator.
5Position sensor of temperature control actuator power
supply voltage check
1) Turn ignition switch to OFF position.
2) Disconnect connector from air flow control actuator.
3) Turn ignition switch to ON position.
4) Measure voltage between.
• Position sensor power supply terminal and position
sensor ground terminal of temperature control
actuator connector
• Position sensor signal terminal and position sensor
ground terminal of temperature control actuator
connector
Is voltage 4.5 – 5.5 V?Check air flow control
actuator and its circuit.Substitute a known-
good HVAC control
module and recheck. Step Action Yes No
G20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30
BRN/YELBRN/WHT
5V5V
12V
ORN
WHTG20-12
G20-28
G20-24
G20-15G20-16
WHT/BLU 2
3
4
[P]
[G][S]1
I6RW0C722005-01
[P]: Position sensor power supply circuit [G]: Position sensor ground circuit 2. Air flow control actuator 4. To other sensors
[S]: Position sensor signal circuit 1. HVAC control module 3. To temperature control actuator
DTC Detecting Condition Trouble Area
Air flow control actuator position sensor signal voltage is higher than or lower
than specified value for specified time continuously.• Air flow control actuator circuit
• Air flow control actuator
• HVAC control module

Downloaded from www.Manualslib.com manuals search engine 7B-64 Air Conditioning System: Automatic Type
DTC Troubleshooting
NOTE
• When DTC B1502, B1503, B1504 and B1511 are indicated together, it is possible that sensor ground
circuit is open.
• When DTC B1511 is indicated together, it is possible that position sensor power supply circuit is
open.

Step Action Yes No
1Was “Air Conditioning System Check” performed?Go to Step 2. Go to “Air Conditioning
System Check”.
2Wire harness check
1) Turn ignition switch to OFF position.
2) Disconnect connectors from air flow control actuator and
HVAC control module.
3) Check for proper connection to position sensor power
supply, signal and ground circuit terminals of air flow
control actuator and HVAC control module connectors.
4) If OK, check that position sensor of air flow control
actuator circuit is as follows.
• Wiring harness resistance of each position sensor
power supply, signal and ground circuit is less than 3
Ω
• Insulation resistance of each position sensor power
supply, signal and ground circuit is infinity between air
flow control actuator connector and vehicle body
ground
• Circuit voltage of each position sensor power supply,
signal and ground circuit is 0 - 1 V with ignition switch
turned ON
Are they in good condition?Go to Step 3. Position sensor power
supply, signal circuit
and/or ground circuit are
open, short or high
resistance.
3Position sensor of air flow control actuator power
supply voltage check
1) Connect connector to HVAC control module with ignition
switch turned OFF.
2) Turn ignition switch to ON position.
3) Measure voltage between.
• Position sensor power supply terminal and position
sensor ground terminal of air flow control actuator
connector
• Position sensor signal terminal and position sensor
ground terminal of air flow control actuator connector
Is voltage 4.5 – 5.5 V?Go to Step 4. Go to Step 5.
4Air flow control actuator check
1) Check position sensor of air flow control actuator for
performance referring to “Air Flow Control Actuator and
Its Circuit Inspection”.
Is it in good condition?Substitute a known-
good HVAC control
module and recheck.Replace air flow control
actuator.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-65
DTC B1513: Temperature Control Actuator (Motor) and/or Its Circuit MalfunctionS6RW0D7224015
Wiring Diagram
DTC Detecting Condition and Trouble Area5Position sensor of temperature control actuator power
supply voltage check
1) Turn ignition switch to OFF position.
2) Disconnect connector from temperature control actuator.
3) Turn ignition switch to ON position.
4) Measure voltage between.
• Position sensor power supply terminal and position
sensor ground terminal of air flow control actuator
connector
• Position sensor signal terminal and position sensor
ground terminal of air flow control actuator connector
Is voltage 4.5 – 5.5 V?Check temperature
control actuator and its
circuit.Substitute a known-
good HVAC control
module and recheck. Step Action Yes No
G20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30
GRY/BLUGRY/RED
5V5V
12V
ORN
WHT
YEL
G20-12
G20-27
G20-24
G20-1G20-2
2
[D]
3
41
I6RW0C722006-02
[D]: Temperature control actuator motor drive circuit 2. Temperature control actuator 4. To other sensors
1. HVAC control module 3. To air flow control actuator
DTC Detecting Condition Trouble Area
Motor of temperature control actuator does not move longer than specified
time.• Temperature control actuator circuit
• Temperature control linkage
• Temperature control actuator
• HVAC unit
• HVAC control module