motor SUZUKI SWIFT 2006 2.G Service Workshop Manual

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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”.

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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

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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.

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Abnormal Noise from Tension Pulley
Abnormal Noise from A/C Evaporator
Abnormal Noise from Blower Motor
A/C System Performance InspectionS7RS0B7214003
1) Confirm that vehicle and environmental conditions are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 35 °C (77 – 95
° F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal.
• Blower motor is normal.
• There is no air leakage from air ducts.
• Condenser fins are clean.
• Air filter in HVAC unit is not clogged with dirt and
dust.
• Battery voltage is about 12 V.
• Radiator cooling fan operates normally.
2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly
closed.
3) Connect high pressure charging hose (3) to high pressure service valve (5) on vehicle and low
pressure charging hose (4) to low pressure service
valve (6).
4) Bleed the air in charging hoses (3) and (4) by loosening their nuts respectively utilizing the
refrigerant pressure. When a hissing sound is heard,
immediately tighten nut.
CAUTION!
Do not connect high and low pressure
charging hoses in reverse.

Condition Possible cause Correction / Reference Item
Clattering noise is heard
from pulley Worn or damaged bearing
Replace tension pulley.
Pulley cranks upon
contact Cracked or loose bracket
Replace or retighten bracket.
ConditionPossible cause Correction / Reference Item
Whistling sound is heard
from A/C evaporator Depending 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 sound At times, slightly decrea
sing 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
rotation Worn or damaged motor brushes or
commutator
Replace blower motor.
Fluttering noise or large
droning noise is heard
from blower motor Leaves or other debris introduced from
fresh air inlet to blower motor
Remove debris and make sure that the screen
at fresh air inlet is intact.
53
2
1
4 6
I4RS0A720006-01

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11) Check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature
near air inlet of HVAC unit is 30 °C (86 °F) and the one at air outlet of center ventilation louver is 17 °C (62.6 °F),
their crossing point is within acceptable range as shown in the graph. In this case, cooling performance is
satisfactory and proper.
12) If crossing point is out of acceptable range, diagnose trouble referring to the following table.
Thermometer at center duct
NOTE
If ambient temperature is approximately 30 °C (86 °F), it is possible to diagnose A/C system in detail
referring to the following table.

[A]: Temp at air outlet of center ventilation louver [C]: Humidity
[B]: Temp near air inlet of HVAC unit [D]: Acceptable range
ConditionPossible cause Correction
Crossing point is higher
than acceptable 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) unit Repair or replace.
Compressor malfunct ion 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 malfunct ion Check compressor.
8 9
10 11 12 13 14
15 16 17 18 19
20
21
22
23
24
25 26
27
28
46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4
66.2 68.0
69.8
71.6
73.4
75.2
77.0
78.8 80.6
82.4
25 30 35
77 86 95
F C
C
F
“E”
“F”30 70 %
[A]
[B][C]
[D]
I7RS0A721007-01

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A/C System Inspection at ECMS7RS0B7214004
Voltage Check
When checking voltage at ECM connector terminals related to A/C system, refer to “DTC P2101: Throttle Actuator
Control Motor Circuit Range / Performance in Section 1A”.
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 radiator cooling
fan operation. Inspect and repair
radiator 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 receiver/
dryer.
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 (kg/cm
2) (psi)
Detail
Lo Hi

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HVAC Unit Removal and InstallationS7RS0B7216006
Removal1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
4) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
5) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
6) Remove instrument panel from vehicle body referring to “Audio Unit Re moval and Installation in
Section 9C”.
7) Loosen suction hose and liquid pipe bolt (4).
8) Remove nuts (3).
9) Remove HVAC unit from vehicle body. Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole uniformly.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust control cables referr ing to “HVAC Control Unit
Removal and Installati on in Section 7A”.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Evaporator InspectionS7RS0B7216007
Check the followings.
• Clog of A/C evaporator fins.If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage. If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage. If any defects are found, repair or replace A/C
evaporator.
2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing
3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever21. Filter cover (if equipped)
4. HVAC Air filter (if equipped) 10. Blower lower case 16. Evaporator22. Drain hose
5. Heater unit upper case 11. Blower motor 17. O-ring23. Cable lock clamp
6. Foot duct 12. Heater unit lower case 18. Expansion valve: Do not reuse.
3
2
3
3
1
4
I4RS0B720009-01
1
I4RS0B720010-01

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Electronic Control System Location
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

1
2
3 * 4 *
5
6 *
7 *
8 *
9 *
10 *
21
11
12 13
14
15161718
19
20
I5RS0C722001-01
1. ECT sensor
7. Blower motor13. AUTO switch19. MODE (air flow) selector
2. Outside air temperature sensor 8. Blower motor controller 14. Temperature selector 20. Blower speed selector
3. Sunload sensor 9. Temperature control actuator15. OFF switch21. HVAC control module
4. Air flow control actuator 10. Inside air temperature sensor 16. Air intake selector
5. Evaporator temperature sensor 11. Defroster switch 17. A/C switch
6. Air intake actuator 12. Display 18. Rear defogger switch

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Auto A/C Electronic Control Input / Output Table
HVAC Control Module Operation DescriptionS7RS0B7221002
Temperature Control
HVAC control module calculates the target temperature
control door position based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor and
controls the temperature control actuator so that the
current position of the temperature control door matches
its target position.
Fan Speed Control
HVAC control module calculates the target blower fan
speed based on signals from the temperature selector,
inside air temperature sensor, outside air temperature
sensor and sunload sensor, compares it with the current
blower fan speed inputted from the blower motor
controller to control the current blower fan speed to the
target level.
Air Flow Outlet Control
HVAC control module calculates the target temperature
control door position based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor.
Using thus obtained target temperature control door
position, it further calculates the target air flow control
door position and controls the ai r flow control actuator so
that the current air flow c ontrol door position becomes
the target position. Air Intake Position Control
HVAC control module determines the position of the air
intake control door based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor and
selects any of the following positions by controlling the
position of the air intake control door.
• FRESH position (FRE)
• RECIRCULATION position (REC)
• MIX position (MIX)
Refrigerant Type IdentificationS7RS0B7221003
Refer to “Refrigerant Type Identification”.
Sub-Cool A/C System DescriptionS7RS0B7221005
Refer to “Sub-Cool A/C System Description”.
A/C Operation DescriptionS7RS0B7221006
Refer to “A/C Operation Description”.
Sunload sensor
Outside air temperature sensor Evaporator temperature sensor
A/C refrigerant pressure sensor
Temperature selector
MODE (air flow) selector
Blower speed selector
Air intake selector
AUTO switch
A/C switch
Compressor
Blower motor controller
Temperature control actuator
Air flow control actuator
Air intake control actuator
BCM
ECM
Data link connector
HVAC control module
CPU
ECT sensor
Inside air temperature sensor
VSS
*
I5RS0C722002-02
*: CAN communication

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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”.