Diagnost SUZUKI SWIFT 2004 2.G Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-3
Diagnostic Information and Procedures
Heater and Ventilation Symptom DiagnosisS7RS0B7104001
ConditionPossible cause Correction / Reference Item
Blower motor does not
operate with blower
speed selector ON Fuse blown
Check related fuses, and then check for short
circuit to ground.
Blower motor relay faulty Check blower motor relay referring to “Blower
Motor Relay Inspection”.
Blower motor resistor faulty Check blower motor resistor referring to
“Blower Motor Resistor Inspection”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection”.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection”.
Wiring or grounding faulty Repair as necessary.
Incorrect temperature
output Temperature control cable broken or
bent (manual A/C) Check temperature control cable.
Temperature control lever faulty (manual
A/C) Check temperature control lever.
Incorrect installation of temperature
control cable (manual A/C) Check position and adjust it as necessary.
Temperature control door assembly
broken Repair temperature control door assembly.
Air ducts clogged Repair air ducts.
Heater core leaked or clogged Replace heater core.
Heater hoses leaked or clogged Replace heater hoses.
Thermostat faulty Check thermostat referring to “Thermostat
Inspection in Section 1F”.
Temperature control actuator faulty
(automatic A/C) Check temperature control actuator referring to
“Temperature Control Actuator Inspection in
Section 7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air outlet port does not
change or does not agree
with air flow selector’s
position even if air flow
selector is changed Air flow control cable broken or bent
(manual A/C)
Check air flow control cable.
Air flow control lever faulty (manual A/C) Check air flow control lever.
Incorrect installation of air flow control
cable (manual A/C) Check position and adjust it as necessary.
Air flow control door assembly broken Repair air flow control door assembly.
Air ducts leaked or clogged Repair air ducts.
Air flow control actuator faulty
(automatic A/C) Check air flow control actuator referring to “Air
Flow Control Actuator
Inspection in Section
7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air intake door does not
change even if air intake
mode is changed Air intake door broken
Repair air intake door.
Air intake control actuator faulty Check air intake control actuator referring to
“Air Intake Control Actuator Inspection”.
Air intake selector faulty Check air intake selector referring to “Air Intake
Selector Inspection”.
Wiring or grounding faulty Repair as necessary.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-7
Diagnostic Information and Procedures
A/C System Symptom DiagnosisS7RS0B7214001
ConditionPossible cause Correction / Reference Item
No cool air comes out (A/
C system does not
operate) No refrigerant
Perform recovery, evacuation and charge
referring to “Operation Procedure for
Refrigerant Charge”.
Fuse blown Check related fuses, and then check for short
circuit to ground.
A/C switch faulty Check A/C switch referring to “A/C Switch
Inspection”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection in Section
7A”.
Evaporator thermistor (Evaporator
temperature sensor) faulty Check evaporator thermistor (evaporator
temperature sensor) referring to “Evaporator
Thermistor (Evaporator Temperature Sensor)
Inspection”.
A/C refrigerant pressure sensor faulty Check A/C refrigerant pressure sensor
referring to “A/C Refrigerant Pressure Sensor
and Its Circuit Inspection”.
Wiring or grounding faulty Repair as necessary.
ECM faulty Check ECM referring to “A/C System
Inspection at ECM”.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Compressor relay faulty Check compressor relay referring to
“Compressor Relay Inspection”.
BCM faulty Check BCM referring to “Inspection of BCM
and its Circuits in Section 10B”.
No cool air comes out
(radiator cooling fan
motor does not operate) Fuse blown
Check related fuses, and then check for short
circuit to ground.
Wiring or grounding faulty Repair as necessary.
Radiator cooling fan motor relay faulty Check radiator cooling fan motor relay
referring to “Radiator Cooling Fan Relay
Inspection in Section 1F”.
Radiator cooling fan motor faulty Check radiator cooling fan motor referring to
“Radiator Cooling Fan Removal and
Installation in Section 1F”.
ECM and/or its circuit faulty Check ECM and/or its circuit referring to “A/C
System Inspection at ECM”.
No cool air comes out
(blower motor does not
operate) Fuse blown
Check related fuses, and then check for short
circuit to ground.
Blower motor relay faulty Check blower motor relay referring to “Blower
Motor Relay Inspection in Section 7A”.
Blower motor resistor faulty Check blower motor resistor referring to
“Blower Motor Resistor Inspection in Section
7A”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection in Section
7A”.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.

Downloaded from www.Manualslib.com manuals search engine 7B-34 Air Conditioning System: Automatic Type
Automatic Type
Precautions
A/C System CautionS7RS0B7220001
Refer to “A/C System Caution”.
Precautions in Diagnosing TroubleS7RS0B7220002
• Do not disconnect couplers from HVAC control module, battery cable from battery, HVAC control module ground
wire harness from body or main fuse before confirming diagnostic information (diagnostic trouble code) stored in
HVAC control module memory.
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC
control module. Also, it can be checked by using SU ZUKI scan tool. Before checking diagnostic information
(diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read
diagnostic information (diagnostic trouble code).
• When trouble is diagnosed using diagnostic information (diagnostic trouble code) on display of HVAC control
module, keep in your mind that each diagnostic inform ation (diagnostic trouble code) has priority, and only
diagnostic information (diagnostic troub le code) which has the highest priority is indicated. Therefore, after
troubleshooting the malfunction, make sure if there exists any other diagnostic information (diagnostic trouble
code).
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” before inspection.
Precautions on Servicing A/C SystemS7RS0B7220003
Refer to “Precautions on Servicing A/C System”.
General Description
Auto A/C System DescriptionS7RS0B7221001
The automatic type air conditioning system (auto A/C) is pr ovided with the function to automatically control the inside
air temperature, fan speed, air flow outl et direction and air intake position by HVAC control module in addition to
functions of the manual type air conditioning system (manua l A/C). Once the inside air temperature is set using the
temperature selector, HVAC control module automatically controls the inside air temperature at the constant level at all
times based on the inside air temperature, outside ai r temperature, amount of sunlight and engine coolant
temperature detected respectively by the inside air te mperature sensor, outside air temperature sensor, sunload
sensor and ECT sensor. At this time, “FULL AUTO A/ C” appears on the display of HVAC control module.
With the air intake selector pushed in the above state, it is possible to select any position of the air intake actuator.
Then, “FULL AUTO A/C” on the display changes to “AUTO A/C”.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-37
On-Board Diagnostic System DescriptionS7RS0B7221007
NOTE
The diagnostic information as diagnostic
trouble code (DTC) can be known by using
SUZUKI scan tool. For further details, refer to
“DTC Check”.

HVAC control module detect s malfunctions, which may
occur in the following area.
• Outside air temperature sensor
• Inside air temperature sensor
• Evaporator temperature sensor
• Sunload sensor
• ECT sensor
• Temperature control actuator of HVAC unit
• Air flow control actuator of HVAC unit
• A/C refrigerant pressure sensor • HVAC control module
• VSS
• Serial Communication line
• CAN communication line
When HVAC control module detects malfunction, the
“AUTO” indicator lamp (1) flashes to warn and the
diagnostic trouble code (DTC) is stored in the memory of
the module. When diagnosing trouble, the DTC can be
checked according to “DTC Check”.
Schematic and Routing Diagram
Major Components of A/C SystemS7RS0B7222001
Refer to “Major Components of A/C System”.
1
I5RS0A722003-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-39
Diagnostic Information and Procedures
A/C System Symptom DiagnosisS7RS0B7224001
4. Rear defogger relay 15. Evaporator temperature sensor 26. Radiator cooling fan relay No.1 37. Rear defogger switch
5. Rear defogger 16. Sunload sensor 27. Radiator cooling fan relay No.2 38. To BCM
6. Blower motor relay 17. Junction block assembly 28. Radiator cooling fan relay No.3 39. To ECM
7. Blower motor 18. ECM 29. Information display 40. To main relay
8. Blower motor controller 19. ECT sensor 30. Lighting switch 41. To main fuse
9. DLC 20. Radiator cooling fan motor 31. A/C switch 42. Back-light
10. Air intake actuator 21. Compressor relay 32. MODE (air flow) selector 43. Defroster indicator 11. Air flow control actuator 22. Compressor 33. Air intake selector 44. Rear defogger indicator
Condition Possible cause Correction / Reference Item
No cool air comes out (A/
C system does not
operate) No refrigerant
Perform recovery, evacuation and charge
referring to “Operation Procedure for
Refrigerant Charge”.
Fuse blown Check related fuses, and then check for short
circuit to ground.
A/C switch faulty Check A/C switch referring to “Inspection of
HVAC Control Module and Its Circuit”.
Evaporator temperature sensor faulty Check evaporator temperature sensor
referring to “Evaporator Thermistor
(Evaporator Temperature Sensor) Inspection”.
A/C refrigerant pressure sensor faulty Check A/C refrigerant pressure sensor
referring to “A/C Refrigerant Pressure Sensor
and Its Circuit Inspection”.
Wiring or grounding faulty Repair as necessary.
ECT sensor faulty Check ECT sensor referring to “ECT Sensor
Inspection in Section 1C”.
ECM faulty Check ECM referring to “A/C System
Inspection at ECM”.
HVAC control module faulty Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
Magnet clutch faulty Check magnet clutch. Referring to “Magnet
Clutch Inspection”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Compressor relay faulty Check compressor relay referring to
“Compressor Relay Inspection”.
Temperature selector, blower speed
selector, and/or air flow selector faulty Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
BCM faulty Check BCM referring to “Inspection of BCM
and its Circuits in Section 10B”.

Downloaded from www.Manualslib.com manuals search engine 7B-48 Air Conditioning System: Automatic Type
Description for Each Step
Step 1. Customer complaint analysis
Talk to customer, and then record details of the problem.
Customer questionnaire (Example)
NOTE
The from is a standard sample. It should be modified according to conditions characteristic of each
market.

Step 2. Visual inspection
As a preliminary step, be sure to perform visual check of th e items that support proper function of the air conditioning
referring to “Visual Inspection”.
Step 3. DTC check
Check DTC referring to “DTC Check”.
Step 4. Troubleshooting malfunction
Based on the DTC, perform an applicable DTC diagnostic flow and locate the cause of the trouble, namely in a sensor,
wire harness, connector, actuat or, HVAC control module or other part and repair faulty parts.
Step 5. A/C system symptom diagnosis
Check any part or system suspected to be a possible cause referring to “A/C System Symptom Diagnosis”.
Step 6. Check for intermittent problem
Check any part where an intermittent trouble is easy to oc cur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Sect ion 00” and related circuit of trouble cord recorded.
I4RH01722014-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 8- i
8
Section 8
CONTENTS
Restraint
Precautions ................................................. 8-1
Precautions............................................................. 8-1
Precautions on Restraint ....................................... 8-1
Seat Belts .......... ............................... ........ 8A-1
Precautions........................................................... 8A-1
Precautions on Service a nd Diagnosis of Seat
Belt .................................................................... 8A-1
General Description ............................................. 8A-1 Seat Belt Construction ........................................ 8A-1
Diagnostic Information and Procedures ............ 8A-2 Repair and Inspection Required after Accident ............................................................ 8A-2
Repair Instructions .............................................. 8A-3 Front Seat Belt Components ............................... 8A-3
Front Seat Belt Removal and Installation ............ 8A-4
Front Seat Belt Inspection ................................... 8A-4
Rear Seat Belt Components ............................... 8A-6
Rear Seat Belt Removal and Installation ............ 8A-7
Rear Seat Belt Inspection ................................... 8A-7
Specifications ....................................................... 8A-7
Tightening Torque Specifications ........................ 8A-7
Air Bag System ............... ......................... 8B-1
Precautions........................................................... 8B-1
Precautions on Service and Diagnosis of Air Bag System....................................................... 8B-1
Precautions on Handling and Storage of Air Bag System Components . ................................ 8B-2
Precautions on Disposal of Air Bag and Seat
Belt Pretensioner .............................................. 8B-5
General Description ............................................. 8B-5 Air Bag System Construction .............................. 8B-5
Air Bag System Input / Output Table .................. 8B-6
Schematic and Routing Diagram ........................ 8B-7 Air Bag System Wiring Circuit Diagram .............. 8B-7
Component Locatio n ........................................... 8B-9
Air Bag System Components, Wiring and Connectors Location ......................................... 8B-9
Diagnostic Information and Procedures .......... 8B-10 Air Bag Diagnostic System Check .................... 8B-10
Air Bag Diagnostic System Check Flow ............ 8B-10
DTC Table ......................................................... 8B-11
DTC Check ....................................................... 8B-12 DTC Clearance ................................................. 8B-12
Scan Tool Data ................................................. 8B-13
“AIR BAG” Warning Right Comes ON Steady .. 8B-13
“AIR BAG” Warning Right Does Not Come
ON ................................................................... 8B-15
“AIR BAG” Warning Right Flashes .................... 8B-16
DTC B1013: SDM fault...................................... 8B-17
DTC B1014: “AIR BAG” Warning Right Circuit Failure ............................................................. 8B-17
DTC B1016: Power Source Voltage High ......... 8B-18
DTC B1017: Power Source Voltage Low .......... 8B-20
DTC B1021: Front Air Bag Module Deployed ... 8B-22
DTC B1024 / B1025: Side-Air Bag (Driver / Passenger) Deployed...................................... 8B-22
DTC B1026: Pretensioner Activated ................. 8B-23
DTC B1027: Reusable Number Exceeded ....... 8B-24
DTC B1031: Driver Air Bag Initiator Circuit
Resistance High .............................................. 8B-24
DTC B1032: Driver Air Bag Initiator Circuit
Resistance Low ............................................... 8B-29
DTC B1033: Driver Air Bag Initiator Circuit
Short to Ground............................................... 8B-34
DTC B1034: Driver Air Bag Initiator Circuit
Short to Power Circuit .... ................................. 8B-39
DTC B1041: Passenger Air Bag Initiator Circuit Resistance High ................................... 8B-44
DTC B1042: Passenger Air Bag Initiator Circuit Resistance Low.................................... 8B-47
DTC B1043: Passenger Air Bag Initiator Circuit Short to Ground ................................... 8B-50
DTC B1044: Passenger Air Bag Initiator Circuit Short to Power Circ uit .......................... 8B-53
DTC B1051 / B1055: Driver / Passenger Pretensioner Initiator Circuit Resistance
High ................................................................. 8B-56
DTC B1052 / B1056: Driver / Passenger Pretensioner Initiator Circu it Resistance Low .. 8B-58
DTC B1053 / B1057: Driver / Passenger Pretensioner Initiator Circuit Short to Ground .. 8B-60
DTC B1054 / B1058: Driver / Passenger Pretensioner Initiator Circuit Short to Power
Circuit .............................................................. 8B-62
DTC B1061 / B1065: Driver / Passenger Side- Air Bag Initiator Circuit Resistance High ......... 8B-64

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-2
Seat Belt with ELR
The seat belt with emergency locking retractor (ELR) is
designed so that it locks immediately (to prevent the
webbing from being pulled out of the retractor any
further) when any of the following items is detected as
exceeding each set value;
• Speed at which the webbing is pulled out of the retractor.
• Acceleration or deceleration of the vehicle speed.
• Inclination.
Seat Belt with A-ELR
The automatic and emergency locking retractor (A-ELR)
works as an Emergency Locking Retractor (ELR) till its
webbing is pulled all the way out and then on as an
Automatic Locking Retractor (ALR ) till it is retracted fully.
ALR: Automatically locks when the webbing is pulled out
from the retractor and allowed to retract even a little.
Then the webbing can not be pulled out any further,
unless it is wound all the way back into the retractor,
which releases the lock and allows the webbing to be
pulled out.
Seat Belt with ELR and Pretensioner
The seat belt with ELR and a pretensioner has a
pretensioner mechanism whic h operates in linkage with
the air bag in addition to the described ELR.
The pretensioner is incorporated in retractor assembly
and controlled by SDM as one of air bag system
components. It will be activated at the same time as the
driver and passenger air bag module when an impact at
the front of vehicle exceeds the specified value.
When servicing seat belt (retractor assembly) with
pretensioner, be sure to observe all WARNINGS and
CAUTIONS and “Precautions on Service and Diagnosis
of Air Bag System in Section 8B”. CAUTION!
Do not reuse the seat belt pretensioner
(retractor assembly) that has activated.
Replace it with a new seat belt assembly and
buckle together as a set. For checking
procedure of its activation, refer to “Repair
and Inspection Required after Accident in
Section 8B”.

Seat Belt Remainder
When driver’s seat belt is unfastened (under the
following conditions), seat belt reminder light and
warning buzzer inform that driver’s seat belt is
unfastened. Seat belt reminder light located in
combination meter and warning buzzer located inside
BCM operate as follows:
• Seat belt reminder light comes on when driver’s seat belt is unfastened while igni tion key switch is at ON
position.
• If vehicle speed exceeds 15 km/h with seat belt unfastened, warning buzzer operates for
approximately 95 seconds and seat belt reminder light
flashes synchronously with buzzer. When warning
buzzer stops operating, seat belt reminder light is
turned on.
• If driver’s seat belt state is changed from “fastened” to “unfastened” while vehicle speed is above 15 km/h,
warning buzzer operates for approximately 95
seconds and seat belt reminder light flashes
synchronously with buzzer. When warning buzzer
stops operating, seat belt reminder light is turned on.
Diagnostic Information and Procedures
Repair and Inspection Required after AccidentS7RS0B8104001
After an accident, whether the seat belt pretensioner has been activated or not, be sure to perform checks and repairs
described on “Repair and Inspection Required after Accident in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-1
Restraint
Air Bag System
Precautions
Precautions on Service and Diagnosis of Air
Bag System
S7RS0B8200001
WARNING!
• If the air bag system and another vehicle system both need repair, SUZUKI
recommends that the air bag system be
repaired first, to help avoid unintended air
bag system activation.
• Do not modify the steering wheel, dashboard, both front seat or any other on
or around air bag system components.
Modifications can adversely affect air bag
system performance and lead to injury.
• Be sure to follow the procedures described in this section. Failure to follow
procedures could result in possible air bag
system activation, personal injury or
unneeded air bag system repairs.

• WARNING / CAUTION labels are attached on each
part of air bag system components (SDM, air bag
(inflator) modules and seat belt pretensioners). Be
sure to follow the instructions.
• Many of service procedures require disconnection of
“A/BAG” fuse and air bag (inflator) module(s) (driver,
passenger, side of both si des and curtain of both
sides) from initiator circuit to avoid an accidental
deployment.
• Do not apply power to the air bag system unless all components are connected or a diagnostic flow
requests it, as this will set a DTC.
• The “Air Bag Diagnostic S ystem Check” must be the
starting point of any air bag diagnostics. The “Air Bag
Diagnostic System Check” will verify proper “AIR
BAG” warning right operatio n and will lead you to the
correct flow to diagnose any air bag malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacements. • Never use air bag component parts from another
vehicle.
• If the vehicle will be exposed to temperatures over 93
° C (200 °F) (for example, during a paint baking
process), remove the air bag system components
beforehand to avoid component damage or
unintended system activation.
• When handling the air bag (inflator) modules (driver, passenger, side of both si des and curtain of both
sides), seat belt pretensio ners (driver and passenger),
SDM, forward-sensor or side-sensor, be careful not to
drop it or apply an impact to it. If an excessive impact
was applied (e.g., SDM, forward-sensor and side-
sensor are dropped, air bag (inflator) module is
dropped from a height of 90 cm (3 ft) or more, seat
belt pretensioner (retractor assembly) is dropped from
a height of 30 cm (1 ft) or more), never attempt
disassembly or repair but replace it with a new one.
• When using electric welding, be sure to disconnect air bag (inflator) module connectors (driver, passenger,
side of both sides and curtain of both sides) and seat
belt pretensioner connectors (driver and passenger)
respectively.
• When applying paint around the air bag system related parts, use care so that the harness or
connector will not be expo sed to the paint mist.
• Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
WARNING!
When performing service on or around air
bag system components or air bag wiring,
follow the procedures listed in “Disabling Air
Bag System” to temporarily disable the air
bag system.
Failure to follow procedures could result in
possible air bag system activation, personal
injury or unneeded air bag system repairs.

Downloaded from www.Manualslib.com manuals search engine 8B-2 Air Bag System:
Precautions on Handling and Storage of Air Bag
System Components
S7RS0B8200002
SDM
WARNING!
Never power up air bag system when SDM is
not rigidly attached to the vehicle. Otherwise,
personal injury may result.

CAUTION!
After detecting one time of such collision as
to meet deployment conditions, SDM must
not be used. Refer to “Air Bag Diagnostic
System Check” when checking SDM.

• Never attempt disassembly of SDM.
• When storing SDM, select a place where neither high temperature nor high humidity is anticipated and oil,
water and dust are kept off.
• If SDM has been dropped, replace it with a new one.
• If SDM installation part of floor was damaged, repair that part completely before reinstallation.
• All SDM and mounting bracket fasteners must be carefully torqued and the arrow must be pointed
toward the front of the vehicle to ensure proper
operation of the air bag system. Live (Undeployed) Air Bag (Inflator) Modules
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) modules.
The rapid gas generation produced during deployment
of the air bag could cause the air bag (inflator) module,
or an object in front of the air bag (inflator) module, to be
thrown through the air in the unlikely event of an
accidental deployment.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver,
passenger and side of both sides and curtain
of both sides). It is
very dangerous as the
electric current from the tester may deploy
the air bag.

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