Receiver SUZUKI SWIFT 2007 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

Downloaded from www.Manualslib.com manuals search engine 7-ii Table of Contents
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 7B-4 Air Conditioning System: Manual Type
Sub-Cool A/C System DescriptionS7RS0B7211003
In the sub-cool A/C system (condenser integrated with receiver/dryer), the inside of the condenser is divided into the
condensation part and the sub-cooler part, and the receiver/dryer is located between those. In the receiver/dryer, the
refrigerant is separated into the vapor refrigerant and the liqui d refrigerant. Only the liquid refrigerant is delivered to the
sub-cooler part of the condenser. The refrigerant is supercooled by the sub-cooler part of the condenser.
A/C Operation DescriptionS7RS0B7211004
ECM controls the radiator fan relay and the compressor relay by following signals.
• ON/OFF signal of A/C switch
• A/C refrigerant pressure sensor
• Evaporator thermistor (evaporator temperature sensor)
• ECT sensor
NOTE
The signal of A/C swit ch is fed from BCM to ECM usin g CAN communication system. For CAN
communication system, refer to “CAN Communication System Description in Section 1A”.

I7RS0A721001-01
[A]: Liquid 2. Magnet clutch 6. Expansion valve10. Desiccant
[B]: Vapor 3. Condenser 7. A/C evaporator11. Filter
[C]: Superheated vapor 4. Receiver/dryer (Modulator) 8. Condensation part12. Vapor refrigerant
1. Compressor 5. Refrigerant pressure sensor 9. Sub-cooler part 13. Liquid refrigerant

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-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 7B-14 Air Conditioning System: Manual Type
ConditionPossible cause Correction
Manifold gauge MPa (kg/cm2) (psi)
Detail
Lo Hi
0.27 – 0.43
(2.7 – 4.3)
(38 – 61) 1.59 – 1.94
(15.9 – 19.4)
(226 – 276)
Normal condition — —
Negative pressure 0.5 – 0.6
(5 – 6)
(71.2 – 85.3) The low pressure side
reads a negative
pressure, and the high
pressure side reads an
extremely low pressure.
Presence of frost around
tubing to and from
receiver/dryer and
expansion valve. Dust particles or water
droplets are either
stuck or frozen inside
expansion valve,
preventing the
refrigerant from
flowing.Clean expansion
valve.
Replace it if it cannot
be cleaned.
Replace receiver/
dryer.
Evacuate the A/C
system and recharge
with fresh refrigerant.
Normal:
0.27 – 0.43
(2.7 – 4.3)
(38 – 61)
↑ ↓
Abnormal:
Negative pressure Normal:
1.59 – 1.94
(15.9 – 19.4)
(226 – 276)
↑
↓
Abnormal:
0.7 – 1.0
(7 – 10)
(100 – 142) During A/C operation, the
low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.
Expansion valve is
frozen due to
moisture in the
system, and
temporarily shuts off
the refrigeration cycle.
Replace expansion
valve.
Replace receiver/
dryer.
Evacuate A/C system
and recharge with
fresh refrigerant.
0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3) 0.7 – 1.0
(7 – 10)
(100 – 142) Both low and high
pressure sides indicate
low readings.
Output air is slightly cold.
Insufficient refrigerant
in system
(Refrigerant leaking).Using leak detector,
check for leaks and
repair as necessary.
Recharge refrigerant
to a specified amount.
If the pressure reading
is almost 0 when the
manifold gauges are
attached, check for
any leaks, repair
them, and evacuate
the system.
0.4 – 0.6
(4 – 6)
(56.9 – 85.3) Pressure on low pressure
side is high.
Pressure on high
pressure side is low.
Both pressure becoming
equal right after A/C is
turned OFF.
Internal leak in
compressor.
Inspect compressor
and repair or replace
as necessary.

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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

Downloaded from www.Manualslib.com manuals search engine 7B-18 Air Conditioning System: Manual Type
When replacing other parts
Replenish the following amount of oil to compressor.
Amount of compressor oil to be replenished
Evaporator: 25 cm3 (25 ml, 0.85 US. oz, 0.88 Imp. oz)
Condenser: 15 cm3 (15 ml, 0.51 US. oz, 0.53 Imp. oz)
Receiver/dryer: 10 cm3 (10 ml, 0.34 US. oz, 0.35 lmp.
oz)
Hoses: 10 cm
3 (10 ml, 0.34 US. oz, 0.35 Imp. oz) each
Pipes: 10 cm3 (10 ml, 0.34 US. oz, 0.35 Imp. oz) each
Evacuation
CAUTION!
Do not evacuate before recovering
refrigerant in A/C system.

NOTE
Once air conditioning system circuit is
opened (exposed) to atmospheric air, system
must be evacuated by using a vacuum pump.
The A/C system should be attached with a
manifold gauge set, and should be evacuated
for approximately 15 minutes.

1) Connect high charging hose (1) and low charging hose (2) of manifold gauge set (3) respectively as
follows:
High charging hose → High pressure charging valve
(4) on condenser outlet pipe
Low charging hose → Low pressure charging valve
(5) on suction pipe
2) Attach center charging hose (6) of manifold gauge set to vacuum pump (7).
3) Operate vacuum pump, and then open discharge
side valve (Hi) (8) of manifold gauge set.
If there is no blockage in the system, there will be an
indication on high pressure gauge (9).
In this case, open the other side valve (Lo) (10) of
the set and repair the system.
4) Approximately 10 minutes later, low pressure gauge (11) should show a vacuum lower than –100 kPa (–
1.0 kg/cm
2, –760 mmHg, –14.7 psi) providing no
leakage exists.
NOTE
• If the system does not show a vacuum below –100 kPa (–1.0 kg/cm
2, –760 mmHg,
–14.7 psi), close both valves, stop vacuum
pump and watch movement of low
pressure gauge.
• Increase in the gauge reading suggests existence of leakage. In this case, repair
the system before continuing its
evacuation.
• If the gauge shows a stable reading (suggesting no leakage), continue
evacuation.

5) Evacuation should be carried out for a total of at least 15 minutes.
6) Continue evacuation until low pressure gauge indicates a vacuum less than –100 kPa (–1.0 kg/cm
2,
–760 mmHg, –14.7 psi), and then close both valves.
7) Stop vacuum pump. Disconnect center charging hose from pump inlet. No w, the system is ready for
charging refrigerant.
Checking A/C System for Pressure Leaks
After completing the evacuation, close manifold gauge
high pressure valve and low pressure valve and wait 10
minutes. Verify that low pressure gauge reading has not
changed.
CAUTION!
If the gauge reading moves closer to “0”,
there is a leak somewhere. Inspect the tubing
connections and make necessary
corrections. And then, evacuate system once
again and make sure that there are no leaks.

7 5
2
4
1
10
11
3
9 8
6
I4RS0A720014-01

Downloaded from www.Manualslib.com manuals search engine 7B-22 Air Conditioning System: Manual Type
5) Remove condenser assembly (1) as shown.
Installation
Reverse the removal procedure to install condenser
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”.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Receiver/Dryer Removal and InstallationS7RS0B7216031
Removal
1) Remove front bumper referring to “Front Bumper and Rear Bumper Components in Section 9K”.
2) Remove receiver/dryer bolt (1), and then remove receiver/dryer (2) from condenser.
3) Remove joints (3) and O-rings (4). Installation
Reverse the removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “When replacing
other parts” in “Operation Procedure for Refrigerant
Charge”.
• Use new receiver/dryer and O-ring.
• Do not remove plug from receiver/dryer until just before installin g it condenser.
• Apply compressor oil to O-ring.
: Compressor oil 99000–99015–00A
(MATSUSHITADENKI GU10)
• Tighten receiver/dryer bolts to the specified torque. Tightening torque
Receiver/dryer bolt: 10 N· m (1.0 kgf-m, 7.5 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
1
I4RS0A720018-01
1
4
4
3
2
I7RS0A721008-01

Downloaded from www.Manualslib.com manuals search engine 7B-32 Air Conditioning System: Manual Type
Relief Valve Removal and InstallationS7RS0B7216030
Removal1) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Remove relief valve (1) from compressor (2). Installation
Reverse removal procedure nothing the following
instructions.
• Use new O-ring.
• Apply compressor oil to O-ring.
• Tighten relive valve to the specified torque.
Tightening torque
Relief valve (a): 8 N·m (0.8 kgf-m, 6.0 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Specifications
Tightening Torque SpecificationsS7RS0B7217001
NOTE
The specified tightening torque is also described in the following.
“Compressor Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
12I4RS0A720048-01
(a)I4RS0A720049-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Receiver/dryer bolt 10 1.0 7.5 )
Expansion valve mount bolt 3.5 0.35 2.5 )
A/C refrigerant pressure sensor 11 1.1 8.0 )
Armature plate bolt 15 1.5 11.0 )
Relief valve 8 0.8 6.0 )