Cool SUZUKI SWIFT 2006 2.G Service Workshop Manual

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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 Motor On-Vehicle
Inspection in Section 1F”.
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”.
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 controller faulty Check blower motor controller referring to
“Blower Motor Controller Inspection”.
Blower speed selector faulty Check blower speed 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”.
Wiring or grounding faulty Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Blower motor relay faulty Check blower motor relay referring to “Blower
Motor Relay Inspection in Section 7A”.
Condition Possible cause Correction / Reference Item

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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
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

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Abnormal Noise Symptom Diagnosis of A/C
System
S7RS0B7224002
Refer to “Abnormal Noise Symptom Diagnosis of A/C
System”.
DTC CheckS7RS0B7224003
Using SUZUKI Scan Tool1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool 3) Light over sunload sensor vertically with an
incandescent lamp of approximately 100 W apart
from about 100 mm (3.94 in.).
NOTE
If sunload sensor is not lighted over with an
incandescent lamp, DTC B1504 is detected
even though there is not any malfunction.

4) Turn ignition switch to ON position.
5) Read DTC displayed on SUZUKI scan tool.
NOTE
To know how to use SUZUKI scan tool, refer
to operator’s manual for SUZUKI scan tool.

6) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
data link connector (DLC).
Cool air does not come
out only at high speed
Excessive amount of refrigerant
Check the amount of refrigerant.
A/C evaporator frosted Check A/C evaporator and evaporator
temperature sensor referring to “Evaporator
Inspection” and “Evaporator Thermistor
(Evaporator Temperature Sensor) Inspection”.
Insufficient air flow of
cooled air 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”.
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
(A)
1
I5RS0A722005-01

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3) Light over sunload sensor vertically with an incandescent lamp approximately 100 W apart from
about 100 mm (3.94 in.).
NOTE
If sunload sensor is not lighted over with an
incandescent lamp, DTC B1504 is detected
as current DTC even though there is not any
malfunction.

4) Turn ignition switch to ON position.
5) Erase DTC according to instructions displayed on SUZUKI scan tool.
NOTE
To know how to use SUZUKI scan tool, refer
to operator’s manual for SUZUKI scan tool.

6) After completing the clearance, turn ignition switch to OFF position, and then di sconnect SUZUKI scan
tool from DLC.
Not Using SUZUKI Scan Tool 1) Turn ignition switch to ON position.
2) Set temperature selector to 25 °C (77 °F). 3) Push AUTO switch (1) and
MODE (air flow) selector
(2) at the same time to have history DTC displayed.
4) Push MODE (air flow) selector (2) and OFF switch (3) at the same time while history DTC is displayed.
5) Check that “CL” (4) appears on display. “CL” means that DTC has been cleared.
DTC TableS7RS0B7224005
CAUTION!
Be sure to perform “Air Conditioning Sy stem Check” before starting diagnosis.

1
2
3
2
4
I5RS0A722008-01
DTC No.
(displayed on
SUZUKI
scan tool) DTC
(indicated on
display of HVAC
control
module) Priority of
display
(current DTC) Priority
of
display
(history DTC) Diagnosis
“AUTO”
indicator lamp
) B1502 21 1 1 Inside air temperature sensor and/or its
circuit malfunction Open
Flashed
22 2 2 Short
) B1503 31 3 3 Evaporator temperature sensor and/or its
circuit malfunction Open
Flashed
32 4 4 Short
) B1504 41 21 — Sunload sensor and/or its circuit
malfunction Open —
42 5 5 Short Flashed
) B1511 61 6 6 Temperature control actuator (position
sensor) and/or its circuit malfunction Open
Flashed
62 7 7 Short
) B1512 71 8 8 Air flow control actuator (position sensor)
and/or its circuit malfunction Open
Flashed
72 9 9 Short
) B1513 63 10 10 Temperature control actuator and/or its circuit malfunction Flashed
) B1514 73 11 11 Air flow control actuator and/or its circuit malfunction Flashed
) B1541 E1 12 — HVAC control module back-up power supply malfunction —
) B1546 d5 22 — A/C refrigerant pressure malfunction —
) B1551 91 13 12
Serial communication circuit malfunction Open
Flashed
92 14 13 Short
) B1552 94 15 14 Serial communication signal malfunction Flashed
) B1553 A4 16 15 CAN communication signal malfunction Flashed
) B1557 b4 19 16 Vehicle speed sensor signal malfunction —
) B1561 54 17 17 Engine coolant temperature sensor signal malfunction Flashed

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NOTE
When no current DTC is detected, all contents displayed on display (1) of HVAC control module and
defroster indicator (2) flash at the same time.

Fail-Safe TableS7RS0B7224006
When any of the following malfunctions (DTCs) is detected, fail-safe mode is activated.
However, when HVAC control module detects normal ope ration of A/C system, fail-safe mode is cancelled.
)
B1562 14 18 18 Outside air temperatur e sensor signal malfunction Flashed
) B1563 d4 20 19 A/C refrigerant pressure sensor signal malfunction —
— See NOTE
below
(current DTC) ——Normal —
00 (history DTC)
DTC No.
(displayed on
SUZUKI
scan tool) DTC
(indicated on
display of HVAC
control
module) Priority of
display
(current DTC) Priority
of
display
(history DTC) Diagnosis
“AUTO”
indicator lamp
1
2
I5RS0A722009-01
DTC No.
Trouble Area Fail-Safe Operation
)
B1502 Inside air temperature sensor and/
or its circuit HVAC control module controls actu
ators assuming that inside air
temperature is 25 ° C (77 °F).
)
B1503 A/C evaporator temperature sensor
and its circuit • HVAC control module turn
s off A/C switch signal.
• HVAC control module controls actu ators assuming that evaporator
temperature is 0 ° C (32 °F).
)
B1504 Sunload sensor and/or its circuit HVAC control module controls actu
ators assuming that amount of
sunlight is 0 W/m
2.
) B1551 Serial communication circuit
HVAC control module controls actuators assuming that outside air
temperature is 20 ° C (68 °F), engine coolant temperature is 80 °C
(176 °F), and vehicle speed is 40 km/h (25 mph).
)
B1552 Serial communication circuit
)
B1553 CAN communication circuit
)
B1557 Vehicle speed sensor and/or its
circuit HVAC control module controls act
uators assuming that vehicle speed
is 40 km/h (25 mph).
)
B1561 Engine coolant temperature sensor
and/or its circuit HVAC control module controls act
uators assuming that engine coolant
temperature is 80 ° C (176 °F).
)
B1562 Outside air temperature sensor
and/or its circuit HVAC control module controls actu
ators assuming that outside air
temperature is 20 ° C (68 °F).

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Scan Tool DataS7RS0B7224007
As the data values given in the following are standard values estimated on the basis of values obtained from the
normally operation vehicles by using a scan tool, use them as reference values. Even when the vehicles are in good
condition, there may be cases where the checked values do not fall within each specifies data range. Therefore,
judgement as abnormal should not be ma de by checking with these data alone.
Scan Tool Data Condition Normal Condition / Reference
Va l u e
) TEMP CONT
SWITCH Each reference value is relative to the position of
temperature selector of HVAC control module. Max Cool, 18.5
°C (65 ° F), 19 °C (66
° C) – 31 °C (88 °F), 31.5 °C (89 °F),
Max Hot
) CABIN
TEMPERATURE Reference value is relative to in-car temperature. –6.5
°C – 57.25 ° C
(20.3 °F – 135.05 °F)
) OUTSIDE AIR TEMP Reference value is relative to outside air
temperature. –23.3
°C – 65.95 °C
(–9.94 °F – 150.71 °F)
) EVAPORATOR
TEMP Reference value is relative to temperature of
evaporator. –29.7
°C – 59.55 °C
(–21.46 °F – 139.19 °F)
) COOLANT TEMP At specified id le speed after warming up. 80 °C – 100 °C (176 ° F – 212 ° F)
) SUN LOAD Reference value depends on the situation. 0 W/m
2 – 4447.8 W/m2
)MODE CONT
SWITCH Each reference value is relative to the position of air
flow selector of HVAC control module.
AUTO, FACE, B/L, FOOT, D/F, DER
) FAN CONT SWITCH Each reference value is relative to the position of
blower speed selector of HVAC control module. AUTO, OFF, 1st, 2nd – 7th, 8th
) FAN DESIRED VOLT Reference value is relative to the position of blower
speed selector of HVAC control module. 0 – 16.0 V
) AIR MIX POS SEN Reference value is relative to the position of
temperature selector of HVAC control module. about 2.0 V (Max Hot)
about 4.0 V (Max Cool)
) MODE POS SENSOR Reference value is relative to the position of air flow
selector of HVAC control module. about 1.6 V (DEF)
about 4.0 V (VENT)
) A/C CONT SIG A/C system is ON. ON
A/C system is OFF. OFF
) BLOWER LOAD SIG Position of blower speed selector is 1st position or
more.
ON
Position of blower speed selector is OFF position. OFF
) AIR INTAKE MODE Fresh air (FRE) mode is activated. FRE
Recirculation air (REC) mode is activated. REC
AUTO mode is activated. AUTO
) REFRIGERANT
PRESSURE Engine running. A/C ON (A/C is operating)
at ambient temperature:
30
°C (86 °F) 1470 – 1770 kPa For more details,
refer to pressure of high pressure
gauge under “A/C System Performance Inspection”
A/C OFF (A/C is not
operating) at ambient
temperature: 30 °C (86
° F) and engine coolant
temperature: 90 ° – 100
° C 600 – 1000 kPa After longer than 10
min from A/C switch turned off
) A/C COMP CLUTCH Engine running. A/C switch and blower
motor switch turned ON
ON
A/C switch and/or blower
motor switch turned OFF OFF
) DFR INDICATOR Defroster indicator
lamp is lighted. ON
Defroster indicator la mp is not lighted. OFF
) VEHICLE SPEED At stop. OFF
0 km/h (0 mph)

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Scan Tool Data Definitions
TEMP CONT SWITCH (TEMPERATURE SELECTOR): Position of temperature control
selector of HVAC control module
CABIN TEMPERATURE: In-car temperature detected
by inside air temperature sensor installed in HVAC
control module
OUTSIDE AIR TEMP (OUTSIDE AIR TEMPERATURE): Outside air temperature
detected by outside air temperature sensor installed
in front bumper member
EVAPORATOR TEMP (EVAPORATOR TEMPERATURE): Temperature of air passed
through evaporator
COOLANT TEMP (ENGINE COOLANT TEMPERATURE): Engine coolant temperature
detected by engine coolant temperature sensor
SUN LOAD: Amount of sunlight detected by sunload
sensor installed on the driver side on the dashboard
MODE CONT SWITCH (MODE (AIR FLOW) SELECTOR): Position of air flow selector of HVAC
control module
FAN CONT SWITCH (BLOWER SPEED SELECTOR): Position of blower speed selector of HVAC control
module
FAN DESIRED VOLT: Voltage for blower motor AIR MIX POS SEN (TEMPERATURE CONTROL
ACTUATOR POSITI ON SENSOR): Input signal
from position sensor in temperature control actuator
MODE POS SENSOR (AIR FLOW CONTROL ACTUATOR POSITI ON SENSOR): Input signal
from position sensor in air flow control actuator
A/C CONT SIG (A/C SWITCH SIGNAL, ON or OFF): State of A/C switch
BLOWER LOAD SIG (BLO WER FAN LOAD SIGNAL,
ON or OFF): ON: Position of blower speed selector
is 1st position or more / OFF: Position of blower
speed selector is OFF position.
AIR INTAKE MODE (AUTO, FRE or REC): State of air
intake mode
REFRIGERANT PRESSURE (A/C REFRIGERANT ABSOLUTE PRESSURE): This parameter
indicates A/C refrigerant absolute pressure
calculated by ECM
A/C COMP CLUTCH (A/C COMPRESSOR MAGNET CLUTCH, ON or OFF): This parameter indicates
the state of the A/C switch
DFR INDICATOR (DEFROSTER INDICATOR LAMP, ON or OFF): State of defroster indicator lamp
VEHICLE SPEED: It is computed based on pulse
signals from vehicle speed sensor
Air Conditioning System CheckS7RS0B7224008
Step Action YesNo
1 Customer complaint analysis
1) Perform )”Customer complaint analysis”.
Was customer complaint analysis performed? Go to Step 2.
Perform customer
complaint analysis.
2 Visual inspection
1) Perform )“Visual inspection”.
Is there any faulty condition? Repair or replace
malfunction part.
Go to Step 3.
3 DTC check
1) Perform )“DTC check”.
Is there any DTC code? Go to Step 4.
Go to Step 5.
4 Troubleshooting malfunction
1) Perform ) “Troubleshooting malfunction”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 7.
Go to Step 5.
5 Perform A/C system symptom diagnosis
1) Inspect and repair referri ng to “A/C System Symptom
Diagnosis”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 7.
Go to Step 6.
6 Check for intermittent problem
1) Check for intermittent troubles referring to “Intermittent
and Poor Connection Inspection in Section 00”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 7.
Go to Step 7.
7 Final confirmation test
1) Perform ) “Final confirmation test”.
Is there any malfunction code? Go to Step 4.
End.

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DTC Troubleshooting
NOTE
• When DTC B1502, B1503 and B1514 are indicated together, it is possible that “ORN” wire circuit open.
• When DTC B1514 is indicated together, it is possible that “WHT” wire circuit open.

Step Action YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ON ignition switch and check DTC.
Is there DTC B1511? Go to applicable DTC
diag. flow.
Go to Step 2.
2 Visual check
1) Check if there is any obstruction in operating range of
actuator linkage and if actuator linkage operates
smoothly.
Is it in good condition? Go to Step 3.
Obstruction in operating
range of actuator
linkage, actuator linkage
faulty and/or internal
fault of HVAC unit.
3 Wire harness check
1) Disconnect connector from temperature control actuator
with ignition swit ch turned OFF.
2) Check for proper connection to temperature control actuator connector at “GRY /BLU” and “GRY/RED” wire
terminals.
3) If OK, measure voltage between “GRY/BLU” wire terminal of temperature control actuator connector and
vehicle body ground with ignition switch turned ON when
temperature selector is operation to COOL direction.
Is voltage 10 – 14 V? Go to Step 7.
Go to Step 4.
4 Wire harness check
1) Disconnect connector from HVAC control module with
ignition switch turned OFF.
2) Check for proper connection to HVAC control module connector at “G51-3” and “G51-4” terminals.
3) If OK, measure resistance between “GRY/BLU” wire terminal of temperature control actuator connector and
“G51-3” terminal of HVAC control module connector.
Is resistance below 5
Ω? Go to Step 5. “GRY/BLU” wire open or
high resistance circuit.
5 Wire harness check
1) Measure resistance between “GRY/BLU” wire terminal
of temperature control actuator connector and vehicle
body ground.
Is resistance infinity? Go to Step 6.
“GRY/BLU” wire shorted
to ground circuit.
6 Wire harness check
1) Measure voltage between “GRY/BLU” wire terminal of
temperature control actuator connector and vehicle body
ground with ignition switch turned ON.
Is voltage 0 V? Go to Step 7.
“GRY/BLU” wire shorted
to other circuit.

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DTC Troubleshooting
DTC B1553: CAN Communication Signal MalfunctionS7RS0B7224021
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC B1557: Vehicle Speed Sensor Signal MalfunctionS7RS0B7224022
DTC Detecting Condition and Trouble Area
DTC TroubleshootingStep Action Yes No
1 Serial communication signal data check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Check “Refrigerant Pressure”, “Vehicle Speed”, “Coolant Temp” and “Outside Air Temp” varies displayed on scan
tool.
Is displayed each va ries described varies in “Scan Tool
Data”? Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
Go to Step 2.
2 Serial communication signal check
1) Connect connectors to BCM and HVAC control module.
2) Using oscilloscope, check that serial communication
signal is outputted referring to “Reference waveform
No.8” of “Inspection of BCM and its Circuits in Section
10B”.
Is serial communication signal outputted at “G37-11”
terminal of BCM connector? HVAC control module
faulty.
BCM (included in
junction block
assembly) faulty.
DTC detecting condition
Trouble area
HVAC control module receives error code fr om BCM continuously.• CAN communication circuit
• BCM (included in junction block assembly)
•ECM
• HVAC control module
Step Action YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Check ECM and BCM for DTC.
Is there DTC(s)? Go to applicable DTC
diag. flow.
Substitute a known-
good HVAC control
module and recheck.
DTC detecting condition
Trouble area
HVAC control module receives error code from BCM continuously. • VSS circuit
• VSS
• HVAC control module
Step Action YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Check ECM for DTC.
Is there DTC P0500? Go to “DTC P0480: Fan
1 (Radiator Cooling
Fan) Control Circuit in
Section 1A”.
Substitute a known-
good HVAC control
module and recheck.

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DTC B1561: Engine Coolant Temperature Sensor Signal MalfunctionS7RS0B7224023
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC B1562: Outside Air Temperature Sensor Signal MalfunctionS7RS0B7224024
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC B1563: A/C Refrigerant Pressure Sensor Signal MalfunctionS7RS0B7224025
DTC Detecting Condition and Trouble Area
DTC TroubleshootingDTC detecting condition Trouble area
HVAC control module receives error code from BCM continuously. • ECT sensor circuit
• ECT sensor
• HVAC control module
StepAction YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Check ECM for DTC.
Are there DTC P0116, P0117 or P0118? Go to applicable DTC
diag. flow.
Substitute a known-
good HVAC control
module and recheck.
DTC detecting condition
Trouble area
HVAC control module receives er ror code from BCM continuously. • Outside air temperature sensor
circuit
• Outside air temperature sensor
• HVAC control module
Step Action YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Check BCM for DTC.
Are there DTC B1141, B1142 or B1143? Go to applicable DTC
diag. flow.
Substitute a known-
good HVAC control
module and recheck.
DTC detecting condition
Trouble area
HVAC control module receives er ror code from BCM continuously. • A/C refrigerant pressure sensor
circuit
• A/C refrigerant pressure sensor
• HVAC control module
Step Action YesNo
1 DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Check ECM for DTC.
Are there DTC P0532 or P0533? Go to applicable DTC
diag. flow.
Substitute a known-
good HVAC control
module and recheck.