air conditioning diagram SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Table of Contents 7- i
7
Section 7
CONTENTS
HVAC
Precautions ................................................. 7-1
Precautions............................................................. 7-1
Precautions on HVAC ........................................... 7-1
Heater and Ventilation.... ......................... 7A-1
General Description ............................................. 7A-1
Heater and Ventilation Construction ................... 7A-1
Schematic and Routing Diagram ........................ 7A-2 Heater and Ventilation Wiring Circuit Diagram .... 7A-2
Diagnostic Information and Procedures ............ 7A-3 Heater and Ventilation Symptom Diagnosis........ 7A-3
Repair Instructions .............................................. 7A-4 HVAC Unit Components ..................................... 7A-4
HVAC Unit Removal and Installation .................. 7A-4
Blower Motor Removal and Installation............... 7A-4
Blower Motor Inspection ..................................... 7A-4
Blower Motor Resistor Removal and Installation ......................................................... 7A-5
Blower Motor Resistor Inspection ....................... 7A-5
Blower Motor Relay Inspection ........................... 7A-6
HVAC Control Unit Components ......................... 7A-6
HVAC Control Unit Remova l and Installation ...... 7A-7
Blower Speed Selector In spection ...................... 7A-9
Air Intake Selector Inspec tion ............................. 7A-9
Air Intake Control Actuator Removal and Installation ......................................................... 7A-9
Air Intake Control Actuator Inspection .............. 7A-10
Center Ventilation Louver Removal and Installation ....................................................... 7A-10
Side Ventilation Louver Removal and Installation ....................................................... 7A-11
HVAC Air Filter Removal and Installation (If Equipped)........................................................ 7A-12
HVAC Air Filter Inspection (If Equipped) ........... 7A-12
Air Conditioning System... ...................... 7B-1
Manual Type ............................................................ 7B-1
Precautions........................................................... 7B-1A/C System Caution ............................................ 7B-1
Precautions on Servicing A/C System ................ 7B-1
General Description ............................................. 7B-3 Refrigerant Type Identifica tion ............................ 7B-3
Sub-Cool A/C System Description ...................... 7B-4
A/C Operation Description .................................. 7B-4 Schematic and Routing Diagram ........................7B-5
Major Components of A/C System ...................... 7B-5
A/C System Wiring Diagram ............................... 7B-6
Diagnostic Information and Procedures ............7B-7 A/C System Symptom Diagnosis ........................ 7B-7
Abnormal Noise Sympto m Diagnosis of A/C
System .............................................................. 7B-9
A/C System Performance Inspection ................ 7B-10
A/C System Inspection at ECM ......................... 7B-15
Repair Instructions ........... .................................7B-16
Operation Procedure for Re frigerant Charge .... 7B-16
Condenser Assembly On-Vehicle Inspection .... 7B-21
Condenser Assembly Removal and Installation ....................................................... 7B-21
Receiver/Dryer Removal and Installation .......... 7B-22
HVAC Unit Components ................................... 7B-23
HVAC Unit Removal and In stallation ................ 7B-24
Evaporator Inspection ....................................... 7B-24
Evaporator Thermistor (Evaporator Temperature Sensor) Removal and
Installation ....................................................... 7B-25
Evaporator Thermistor (Evaporator Temperature Sensor) Inspec tion..................... 7B-25
Expansion Valve Removal and Installation ....... 7B-26
Expansion Valve Inspection .............................. 7B-26
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-26
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-26
A/C Switch Inspection ....................................... 7B-27
Compressor Relay Inspection ........................... 7B-27
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-27
Compressor Drive Belt Removal and Installation ....................................................... 7B-28
Compressor Assembly Removal and Installation ....................................................... 7B-28
Compressor Assembly Components................. 7B-29
Magnet Clutch Inspection.................................. 7B-29
Magnet Clutch Removal and Installation........... 7B-29
Relief Valve Inspection...................................... 7B-31
Relief Valve Removal and Installation............... 7B-32
Specifications .................... .................................7B-32
Tightening Torque Specifications ...................... 7B-32
Special Tools and Equipmen t ...........................7B-33

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Recommended Service Material ....................... 7B-33
Special Tool ...................................................... 7B-33
Automatic Type .................... .................................7B-34
Precautions.........................................................7B-34 A/C System Caution .......................................... 7B-34
Precautions in Diagnosing Trouble ................... 7B-34
Precautions on Servicing A/C System .............. 7B-34
General Description .......... .................................7B-34
Auto A/C System Descript ion ............................ 7B-34
HVAC Control Module Operation Description ... 7B-36
Refrigerant Type Identifica tion .......................... 7B-36
Sub-Cool A/C System Description .................... 7B-36
A/C Operation Description ................................ 7B-36
On-Board Diagnostic System Description ......... 7B-37
Schematic and Routing Diagram ......................7B-37 Major Components of A/C System .................... 7B-37
A/C System Wiring Diagra m ............................. 7B-38
Diagnostic Information and Procedures ..........7B-39 A/C System Symptom Diagnosis ...................... 7B-39
Abnormal Noise Sympto m Diagnosis of A/C
System ............................................................ 7B-42
DTC Check........................................................ 7B-42
DTC Clearance ................................................. 7B-43
DTC Table ......................................................... 7B-44
Fail-Safe Table ................. ................................. 7B-45
Scan Tool Data ................................................. 7B-46
Air Conditioning System Check......................... 7B-47
Visual Inspection ............................................... 7B-49
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction .......................... 7B-49
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction .............. 7B-50
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction ......... ................................. 7B-52
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-53
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-55
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction .......................... 7B-57
DTC B1514: Air Flow Co ntrol Actuator and/or
Its Circuit Malfunction ...................................... 7B-60
DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction .............................. 7B-62
DTC B1546: A/C Refrigerant Pressure Malfunction ...................................................... 7B-63
DTC B1551: Serial Communication Circuit Malfunction ...................................................... 7B-63
DTC B1552: Serial Communication Signal Malfunction ...................................................... 7B-64
DTC B1553: CAN Communication Signal Malfunction ...................................................... 7B-65
DTC B1557: Vehicle Speed Sensor Signal Malfunction ...................................................... 7B-65
DTC B1561: Engine Coolant Temperature Sensor Signal Malfunctio n .............................. 7B-66 DTC B1562: Outside Air Temperature Sensor
Signal Malfunction ........................................... 7B-66
DTC B1563: A/C Refr igerant Pressure
Sensor Signal Malfunction .............................. 7B-66
Inspection of HVAC Control Module and Its Circuit .............................................................. 7B-67
A/C System Performance Inspection ................ 7B-70
A/C System Inspection at ECM ......................... 7B-70
Repair Instructions ............ ................................7B-71
Operation Procedure for Refrigerant Charge .... 7B-71
HVAC Unit Components ................................... 7B-72
HVAC Unit Removal and In stallation ................ 7B-73
Temperature Control Actuator Removal and Installation ....................................................... 7B-73
Temperature Control Actuat or Inspection ......... 7B-73
Air Flow Control Actuator Removal and Installation ....................................................... 7B-74
Air Flow Control Actuator Inspection ................. 7B-74
Air Intake Control Actuator Removal and Installation ....................................................... 7B-75
Air Intake Control Actuator Inspection............... 7B-75
Actuator Linkage Inspection .............................. 7B-76
Blower Motor Controller Removal and Installation ....................................................... 7B-76
Blower Motor Controller Inspection ................... 7B-76
HVAC Control Module Removal and Installation ....................................................... 7B-77
Sunload Sensor Removal and Installation ........ 7B-77
Sunload Sensor Inspection ............................... 7B-77
Outside Air Temperature Sensor Removal and Installation ................................................ 7B-77
Outside Air Temperature Sensor Inspection ..... 7B-77
Inside Air Temperature Sensor Removal and Installation ....................................................... 7B-78
Inside Air Temperature Sens or Inspection ........ 7B-78
Condenser Assembly On-Vehicle Inspection .... 7B-78
Condenser Assembly Removal and Installation ....................................................... 7B-78
Receiver/Dryer Removal and Installation .......... 7B-78
Evaporator Inspection ....................................... 7B-78
Evaporator Temperature Sensor Removal and Installation ................................................ 7B-78
Evaporator Temperature Se nsor Inspection ..... 7B-78
Expansion Valve Removal an d Installation ....... 7B-78
Expansion Valve Inspection .............................. 7B-78
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-78
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-78
Compressor Relay Inspection .
.......................... 7B-78
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-78
Compressor Drive Belt Removal and Installation ....................................................... 7B-79
Compressor Assembly Removal and Installation ....................................................... 7B-79
Compressor Assembly Components................. 7B-79
Magnet Clutch Removal and Installation........... 7B-79
Magnet Clutch Inspection.................................. 7B-79
Relief Valve Inspection...................................... 7B-79

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-5
Schematic and Routing Diagram
Major Components of A/C SystemS7RS0B7212001
Airflow diagram
Major components of A/C system
I4RS0A720003-01
7
2
34
1 8
6
5
I4RS0B720002-01
1. HVAC unit 5. Discharge hose9. Side ventilation air 13. Side defroster air
2. Compressor 6. Suction hose10. Center ventilation air 14. Fresh air
3. Condenser assembly 7. Liquid pipe11. Foot air 15. Recirculation air
4. Receiver/dryer (Modulator) 8. Expansion valve12. Front defroster air 16. Evaporator

Downloaded from www.Manualslib.com manuals search engine 7B-6 Air Conditioning System: Manual Type
A/C System Wiring DiagramS7RS0B7212002
BLK/REDBLK/RED
BLK/YELBLK/YEL
BLK/YEL
BRN/WHT
12V5V
5V 5V
5V11
E23-1
E23-60
BLK/REDBLK/REDE23-16
E23-57WHT/BLK
9
13
E23-55C37-14GRY/REDRED
BLK
ORN
E23-47 GRY
WHTBLU/YEL
RED/BLK
14 3
1
15
5
7
BLK
2
M
12VBLU/WHTE23-19
C37-24
C37-55ORN
5V
LT GRN16
G18-3
G18-4
G18-7
G18-8
G18-10
G18-13
G18-5
G18-6
G19-5
G19-2
G19-3
G19-7
G19-6
G19-1
G18-9
G18-14
BLK/WHT
YEL
BLU/WHT
RED
BRN/WHT
GRN/WHT
RED/BLK
RED
GRN
BRN
BLK/RED
RED/YEL
BLK
BLK/YEL
BLK/ORN
4
6
12
10
M
E23-54
REDWHTE23-3E23-18
17 18
LT GRNE23-46
L+
L–
H–
H
+
BLU/RED
BLK
BLU/WHTBLK
BLU/BLK
20
GRN
GRY
E23-48
19
21
22
BLU/REDC37-58
C37-15 C37-30
BLK/ORN
BLKBLKE23-31 BLK
BLU
YEL
GRN
WHT
23
24
26 25
28
27
8
29
I7RS0B721001-01
1. Ignition switch
9. A/C refrigerant pressure sensor 17. I ndividual circuit fuse box (No.1) 25. Air intake selector
2. Blower motor 10. ECM 18. Main fuse box 26. Rear defogger switch
3. HVAC control unit 11. Main relay 19. Radiator cooling fan relay No.1 27. Rear defogger
4. Lighting switch 12. Air intake control actuator 20. Radiator cooling fan relay No.2 28. Rear defogger relay
5. Blower motor relay 13. Compressor relay 21. Radiator cooling fan relay No.3 29. ABS / ESP ® control module
6. Blower motor resistor 14. Compressor 22. Radiator cooling fan motor
7. Junction block assembly 15. Evaporator thermistor (evaporator temperature sensor)23. Blower speed selector
8. BCM 16. ECT sensor 24. A/C switch

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 7B-38 Air Conditioning System: Automatic Type
A/C System Wiring DiagramS7RS0B7222002
6
13
15
1610
11
12 9
12V
5V
5V5V
12V
12V
5V 5V
5V +BB
PNK/BLK
WHT/BLK
GRYBLK
WHT/BLU
WHT YEL
ORN
BRN/WHT
BRN/YEL
GRY/BLU
GRY/RED
PNK
YEL/BLK
BLK/ORN
PPL/WHT
12V BLK/YEL
WHT
ORN
ORN
ORN
5V
BLK/RED
BRN
RED/BLK
5V
5VGRY/REDRED
ORN
BLU/WHT
14
YEL/REDYEL/BLK
GRN/WHT
12V
YEL
L+
H+
L
H
WHTGRYBLK/RED
REDWHTREDWHT
M
M
WHT/RED
5
BLU
YEL
WHT
WHT/BLU
RED/BLKWHT
RED/YEL
BLU/YEL
LT GRN
GRN
BLU/RED
G52-6
G52-4
G52-2
G52-5
G51-1
G51-2
G52-14
G51-3
G51-4
G52-1
G52-13
G52-3
G51-19
G51-7
G51-18
G51-10
G51-20
G51-5
G52-11
G51-9
G51-8
G51-12
G51-11
G52-16
5V
12V
5V
12V
LT GRNORN
5V
23
1
2
3 4
8
17
18 19
20
21
22
24
25
26
27
28
29
30
36 35 34 33 32 31 37
38 3938
41 40
42
43
44
MRED/BLK
GRN/RED
G52-8G51-15
G51-17G51-16
REDGRN
BLK/YEL
BLK/WHT
M7
I7RS0A722001-01
1. Main fuse box 12. Temperature control actuator 23. HVAC control module 34. Defroster switch
2. Ignition switch 13. Inside air temperature sensor 24. BCM 35. AUTO switch
3. Individual circuit fuse box No.1 box 14. Outside air temper ature sensor 25. A/C refrigerant pressure sensor 36. OFF switch

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Step 7. Final confirmation test
Confirm if the problem symptom is troubleshoot and the A/C system is free from any abnormal conditions. If there
existed DTC, clear the DTC. Then , check if the DTC is still detected and if there is any other DTC.
Visual InspectionS7RS0B7224009
Check visually the following parts and systems.
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit MalfunctionS7RS0B7224010
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
NOTE
When DTC B1503, B1513 and B1514 are indicated together, it is possible that “ORN” wire circuit open.

Inspection item Correction
• Refrigerant ---- leakage and amount
• A/C pipe or hose ---- disconnection, looseness and deterioration
• A/C compressor drive belt ---- looseness and damage Refer to “Compressor Drive Belt Inspection and
Adjustment”.
• Battery ---- fluid level and corrosion of terminal
• Connectors of electric wire harn ess ---- disconnection and friction
• Fuses ---- burning
• Parts ---- installation and damage
• Other parts that can be checked visually
5V
PNK/BLK
ORN G52-6
G52-3
2
1
3
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I5RS0A722010-01
1. HVAC control module
2. Inside air temperature sensor 3. To other sensors
DTC Detecting Condition Trouble Area
Inside air temperature sensor signal voltage is higher than or lower than
specified value for specified time continuously. • Inside air temperature sensor circuit
• Inside air temperature sensor
• HVAC control module
Step
Action YesNo
1 Inside air temperature sensor signal circuit check
1) Disconnect inside air temperature sensor connector.
2) Check for proper connection to inside air temperature
sensor at “PNK/BLK” and “ORN” wire terminals.
3) If OK, measure voltage between “PNK/BLK” wire terminal of inside air temp erature sensor connector and
vehicle body ground with ignition switch turned ON.
Is voltage 4 – 6 V? Go to Step 5.
Go to Step 2.

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DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit MalfunctionS7RS0B7224011
Wiring Diagram2
Inside air temperature sensor signal circuit check
1) Disconnect connector from HVAC control module with
ignition switch turned OFF.
2) Check for proper connection to HVAC control module connector at “G52-6” and “G52-3” terminals.
3) If OK, measure resistance between “PNK/BLK” wire terminal of inside air temp erature sensor connector and
“G52-6” terminal of HVAC control module connector.
Is resistance below 5
Ω? Go to Step 3. “PNK/BLK” wire open or
high resistance circuit.
3 Inside air temperature sensor signal circuit check
1) Measure resistance between “PNK/BLK” wire terminal of
inside air temperature sensor connector and vehicle
body ground.
Is resistance infinity? Go to Step 4.
“PNK/BLK” wire shorted
to ground circuit.
4 Inside air temperature sensor signal circuit check
1) Measure voltage between “PNK/BLK” wire terminal of
inside air temperature sensor connector and vehicle
body ground with ignition switch turned ON.
Is voltage 0 V? Go to Step 5.
“PNK/BLK” wire shorted
to other circuit.
5 Inside air temperature sensor ground circuit check
1) Connect HVAC control module connector with ignition
switch turned OFF.
2) Measure resistance between “ORN” wire terminal of inside air temperature sensor connector and vehicle
body ground.
Is resistance below 5
Ω? Go to Step 7. Go to Step 6.
6 Inside air temperature sensor ground circuit check
1) Measure resistance between “G52-3” terminal of HVAC
control module connector and vehicle body ground.
Is resistance below 5
Ω? “ORN” wire open or high
resistance circuit.
HVAC control module
faulty.
7 Inside air temperature sensor check
1) Check inside air temperature sensor referring to “Inside
Air Temperature Sensor Inspection”.
Is it in good condition? HVAC control module
faulty.
Inside air temperature
sensor faulty.
Step Action Yes No
5V
WHT/BLK
ORN G52-4
G52-3
2
1
3
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I5RS0A722011-01
1. HVAC control module
2. Evaporator temperature sensor 3. To other sensors

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DTC B1504: Sunload Sensor and/or Its Circuit MalfunctionS7RS0B7224012
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting7
Evaporator temperature sensor check
1) Check evaporator temperature sensor referring to
“Evaporator Thermistor (Evaporator Temperature
Sensor) Inspection”.
Is it in good condition? HVAC control module
faulty.
Evaporator temperature
sensor faulty.
Step Action Yes No
5V
PNK G52-2
G52-5
YEL/BLK
2
1
7812910
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G51
I5RS0A722012-01
1. HVAC control module
2. Sunload sensor
DTC Detecting Condition Trouble Area
Sunload sensor signal voltage is higher than or lower than specified value for
specified time continuously. • Sunload sensor circuit
• Sunload sensor
• HVAC control module
Step
Action YesNo
1 Sunload sensor power supply circuit check
1) Disconnect sunload sensor connector.
2) Check for proper connection to sunload sensor at “PNK”
and “YEL/BLK” wire terminals.
3) If OK, measure voltage between “PNK” wire terminal of sunload sensor connector and vehicle body ground with
ignition switch turned ON.
Is voltage 4 – 6 V? Go to Step 5.
Go to Step 2.
2 Sunload sensor power supply circuit check
1) Disconnect connector from HVAC control module with
ignition switch turned OFF.
2) Check for proper connection to HVAC control module connector at “G52-2” and “G52-5” terminals.
3) If OK, measure resistance between “PNK” wire terminal of sunload sensor connector and “G52-2” terminal of
HVAC control module connector.
Is resistance below 5
Ω? Go to Step 3. “PNK” wire open or high
resistance circuit.
3 Sunload sensor power supply circuit check
1) Measure resistance between “PNK” wire terminal of
sunload sensor connector and vehicle body ground.
Is resistance infinity? Go to Step 4. “PNK” wire shorted to
ground circuit.

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DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit MalfunctionS7RS0B7224013
Wiring Diagram
DTC Detecting Condition and Trouble Area4
Sunload sensor power supply circuit check
1) Measure voltage between “PNK” wire terminal of
sunload sensor connector and vehicle body ground with
ignition switch turned ON.
Is voltage 0 V? Go to Step 5. “PNK” wire shorted to
other circuit.
5 Sunload sensor signal circuit check
1) Disconnect HVAC control modul e connector with ignition
switch turned OFF.
2) Measure resistance between “YEL/BLK” wire terminal of sunload sensor connector and vehicle body ground.
Is resistance infinity? Go to Step 6. “YEL/BLK” wire shorted
to ground circuit.
6 Sunload sensor signal circuit check
1) Measure resistance between “G52-5” terminal of HVAC
control module connector and “YEL/BLK” wire terminal
of sunload sensor connector.
Is resistance below 5
Ω? Go to Step 7. “YEL/BLK” wire open or
high resistance circuit.
7 Sunload sensor signal circuit check
1) Measure voltage between “YEL/BLK” wire terminal of
sunload sensor connector and vehicle body ground with
ignition switch turned ON.
Is voltage 0 V? Go to Step 8.
“YEL/BLK” wire shorted
to other circuit.
8 Sunload sensor check
1) Check sunload sensor referring to “Sunload Sensor
Inspection”.
Is it in good condition? HVAC control module
faulty.
Sunload sensor faulty.
Step
Action YesNo
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G51
M 12V
5V 5V
YEL
WHT
GRY/BLU
GRY/RED
2
1
ORN
G51-3
G51-4
G52-1
G52-13
G52-3
3
4
I5RS0A722013-01
1. HVAC control module 2. Temperature control actuator 3. To air flow control actuator4. To other sensors
DTC Detecting Condition Trouble Area
Temperature control actuator position sensor signal voltage is higher than or
lower than specified value for specified time continuously. • Temperature control actuator circuit
• Temperature control actuator
• HVAC control module