Clutch assembly SUZUKI SWIFT 2005 2.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 7B-8 Air Conditioning System: Manual Type
Cool air does not come
out or insufficient cooling
(A/C system normal
operation)Insufficient or excessive charge of
refrigerant
Check the amount of refrigerant and system
for leaks.
Condenser clogged Check condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
A/C evaporator clogged or frosted Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Evaporator thermistor (Evaporator
temperature sensor) faulty Check evaporator thermistor (Evaporator
temperature sensor) referring to “Evaporator
Thermistor (Evaporator Temperature Sensor)
Inspection”.
Expansion valve faulty Check expansion valve referring to “Expansion
Valve Inspection”.
Desiccant clogged Replace receiver/dryer.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor faulty Check compressor.
Air in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Air leaking from HVAC unit or air duct Repair as necessary.
Heater and ventilation system faulty Check HVAC unit.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Excessive compressor oil in A/C system Drain excessive compressor oil from A/C
system circuit and compressor.
Cool air does not come
out only intermittently Wiring connection faulty
Repair as necessary.
Expansion valve faulty Check expansion valve referring to “Expansion
Valve Inspection”.
Excessive moisture in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Magnet clutch faulty Check magnet clutch referring to “Magnet
Clutch Inspection”.
Excessive amount of refrigerant Check the amount of refrigerant.
Cool air comes out only
when driving vehicle at
high speed Condenser clogged
Check condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
Insufficient charge of refrigerant Check the amount of refrigerant and system
for leaks.
Air in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air does not come
out only when driving
vehicle at high speed Excessive amount of refrigerant
Check the amount of refrigerant.
A/C evaporator frosted Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-9
Abnormal Noise Symptom Diagnosis of A/C SystemS7RS0B7214002
Abnormal Noise from Compressor
Abnormal Noise from Magnetic Clutch
Abnormal Noise from Tubing
Abnormal Noise from Condenser Assembly
Abnormal Noise from Crankshaft PulleyInsufficient airflow of
cooled air
A/C evaporator clogged or frosted
Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Air leaking from HVAC unit or air duct Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Wiring or grounding faulty Repair as necessary.
Condition Possible cause Correction / Reference Item
Condition
Possible cause Correction / Reference Item
During compressor
operation, a rumbling
noise is heard
proportional to engine
revolutions Inadequate clearance in scroll area
Replace compressor.
A loud noise is heard at a
certain rpm,
disproportionately to
engine revolution Loose or faulty compressor drive belt
Adjust drive belt tension or replace drive 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 operated in this
condition for a long time.
Condition Possible cause Correction / Reference Item
A rumbling noise is heard
when compressor is not
in operation Worn or damaged bearings
Replace magnet clutch assembly.
A chattering noise is
heard when compressor
is in operation Faulty magnet clutch clearance
(excessive clearance)
Adjust magnet clutch clearance.
Worn magnet clutch friction surface Replace magnet clutch assembly.
Compressor oil leaked from shaft seal,
contaminating the friction surface Replace compressor body assembly.
Condition
Possible cause Correction / Reference Item
A droning noise is heard
from inside of the 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 re frigerant pressure Attach a silencer to tubing, or modify its
position and length.
Condition
Possible cause Correction / Reference Item
Considerable vibration in
condenser assembly Resonance from condenser assembly
bracket and body Firmly insert a silenc
er between condenser
assembly bracket and body.
Condition Possible cause Correction / Reference Item
A large rattling noise is
heard at idle or sudden
acceleration Loosen crankshaft pulley bolt
Retighten bolt.

Downloaded from www.Manualslib.com manuals search engine 7B-28 Air Conditioning System: Manual Type
Compressor Drive Belt Removal and
Installation
S7RS0B7216017
Removal1) Loosen tension pulley nut (1).
2) Loosen belt tension by loosening tension pulley adjusting bolt (2).
3) Remove compressor drive belt (3).
Installation
Reverse removal procedure noting the following
instruction.
• Adjust belt tension referring to “Compressor Drive Belt Inspection and Adjustment”.
Compressor Assembly Removal and
Installation
S7RS0B7216018
Removal
1) Run engine at idle speed with A/C ON for 10 minutes.
2) Stop the engine.
3) Disconnect negative (–) cable from battery.
4) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
5) Remove compressor drive belt referring to “Compressor Drive Belt Re moval and Installation”.
6) Remove right side engine under cover.
7) Disconnect magnet clutch lead wire coupler (1).
8) Disconnect discharge hose (2) and suction hose (3) from compressor (4).
NOTE
Cap open fittings immediately to keep
moisture out of the system.

9) Remove compressor mounting bolts (1), and then remove compressor (2 ) from its bracket.
Installation
Reverse removal procedure noting the following
instructions.
• If compressor is replaced, pour new compressor oil referring to “Replenishi ng Compressor Oil” in
“Operation Procedure for Refrigerant Charge”.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust drive belt tension referring to “Compressor Drive Belt Inspecti on and Adjustment”.
I4RS0A720034-01
3
4 2
1
I7RS0A721009-01
1
1 2
I7RS0A721010-02

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-29
Compressor Assembly ComponentsS7RS0B7216020
Magnet Clutch InspectionS7RS0B7216022
• Check armature plate and magnet clutch pulley for wear and oil soak respectively.
• Check magnet clutch pulley bearing for noise, wear and grease leakage.
• Measure magnet clutch coil for resistance at 20 °C (68
° F). If the measured resistance does out of
specification, replace magnet clutch assembly.
Magnet clutch coil resistance
Standard: 3.5 – 4.0 Ω
Magnet Clutch Removal and InstallationS7RS0B7216024
Removal
1) Remove compressor from vehicle referring to “Compressor Assembly Re moval and Installation”.
2) Fix armature plate (1) with special tool and remove armature plate nut (2).
Special tool
(A): 09991–06310
3) Remove armature plate (1).
6
2
9
44
3 (b)
1 (a) 7
5
8
I4RS0A720037-01
1. Armature plate bolt
4. Circlip 7. Magnet clutch pulley: Do not reuse.
2. Compressor 5. Shim 8. Armature plate: 16 N⋅m (1.6 kgf-m, 11.5 lb-ft)
3. Relief valve 6. Magnet clutch coil and thermal switch 9. O-ring : 10 N⋅m (1.0 kgf-m, 7.5 lb-ft)
I4RS0A720038-01
2
1 (A)
I4RS0A720039-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-31
4) Install magnet clutch lead wire clamp.
5) Install magnet clutch pulley (1).
6) Install new circlip (2) directing chamfer side (3) upward.
Special tool
(B): 09900–06107
7) Tighten armature plate bolt to specified torque. Tightening torque
Armature plate bolt (a): 15 N·m (1.5 kgf-m, 11.0
lb-ft)
Special tool
(A): 09991–06310
8) Adjust clearance between magnet clutch plate (1) and magnet clutch pulley by putting shim(s) on
compressor shaft. To measure the clearance,
perform the following steps.
a) Put compressor in a vise (2).
b) Set dial gauge (3) on magnet clutch plate, and then adjust its pointer at 0.
c) Connect battery positive terminal (+) to magnet clutch coil lead wire.
d) Connect battery negative terminal (–) to compressor body assemb ly. (At this point,
magnet clutch plate and magnet clutch pulley are
kept in contact.) e) Disconnect battery negative terminal (–) to
compressor body assembly. (At this point,
magnet clutch plate and magnet clutch pulley are
not in contact.)
f) Read stroke of magnet clutch plate from dial gauge by performing step d) and e) repeatedly.
(Stroke of magnet clutch plate is clearance
between magnet clutch plate and magnet clutch
pulley.)
Standard clearance between magnet clutch plate
and magnet clutch plate
0.3 – 0.5 mm (0.012 – 0.020 in.)
Relief Valve InspectionS7RS0B7216028
By using special tool, chec k if there is refrigerant
leakage. If there is refrigerant leakage, replace the relief
valve.
Special tool
(A): 09990–86012
1
32 (B)
I4RS0A720044-01
(a)
(A)
I4RS0A720045-01
21
3
I4RS0A720046-01
(A)
I5RS0C721014-01

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 Air Conditioning System: Automatic Type 7B-41
Cool air does not come
out or insufficient cooling
(A/C system normal
operation)Insufficient or excessive charge of
refrigerant
Check the amount of refrigerant and system
for leaks.
Condenser clogged Check condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
A/C evaporator clogged or frosted Check A/C evaporator and evaporator
temperature sensor referring to “Evaporator
Inspection” and “Evaporator Thermistor
(Evaporator Temperature Sensor) Inspection”.
Evaporator temperature sensor faulty Check evaporator temperature sensor
referring to “Evaporator Thermistor
(Evaporator Temperature Sensor) Inspection”.
Expansion valve faulty Check expansion valve referring to “Expansion
Valve Inspection”.
Desiccant clogged Replace receiver/dryer.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Magnet clutch faulty Check magnet clutch. Referring to “Magnet
Clutch Inspection”.
Compressor faulty Check compressor.
Air in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Air leaking from HVAC unit or air duct Repair as necessary.
Heater and ventilation system faulty Check HVAC unit.
Temperature selector faulty Check temperature selector referring to
“Inspection of HVAC Control Module and Its
Circuit”.
HVAC control module faulty Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
Temperature control actuator faulty Check temperature control actuator referring to
“Temperature Control Actuator Inspection”.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Excessive compressor oil in A/C system Drain excessive compressor oil from A/C
system circuit and compressor.
Cool air does not come
out only intermittently Wiring connection faulty
Repair as necessary.
Expansion valve faulty Check expansion valve referring to “Expansion
Valve Inspection”.
Excessive moisture in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Magnet clutch faulty Check magnet clutch. Referring to “Magnet
Clutch Inspection”.
Excessive amount of refrigerant Check the amount of refrigerant.
Cool air comes out only at
high speed Condenser clogged
Check condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
Insufficient charge of refrigerant Check the amount of refrigerant and system
for leaks.
Air in A/C system Replace receiver/dryer, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-79
Compressor Drive Belt Removal and
Installation
S7RS0B7226032
Refer to “Compressor Drive Belt Removal and
Installation”.
Compressor Assembly Removal and
Installation
S7RS0B7226033
Refer to “Compressor Assembly Removal and
Installation”.
Compressor Assembly ComponentsS7RS0B7226034
Refer to “Compressor Assembly Components”.
Magnet Clutch Removal and InstallationS7RS0B7226035
Refer to “Magnet Clutch Removal and Installation”.
Magnet Clutch InspectionS7RS0B7226036
Refer to “Magnet Clutch Inspection”.
Relief Valve InspectionS7RS0B7226039
Refer to “Relief Valve Inspection”.
Special Tools and Equipment
Special ToolS7RS0B7228001
SUZUKI scan tool
—
This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12.) / )