Hose SUZUKI SWIFT 2008 2.G Service Workshop Manual

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Scan Tool Data Definitions
Battery Voltage
This parameter indicates battery positive voltage.
TQS Power Supply (Torque Sensor Power Supply, V)
This parameter indicates the power supply voltage which
the P/S control module supplies to the torque sensor.
TQS Main Torque (Torque Sensor Main Torque, N ⋅m)
The torque sensor is installed to detect the steering force
and the steering directio n. It consists of two
potentiometers and the main torque sensor is one of
these.
TQS Sub Torque (Torque Sensor Sub Torque, N ⋅m)
The torque sensor is installed to detect the steering force
and the steering directio n. It consists of two
potentiometers and the sub-torque sensor is one of
these. Its output characteristics are compared with those
of the main torque sensor.
Assist Torque (N ⋅m)
This parameter is an internal parameter of the P/S
control module. It is obtained by computing the torque
sensor input signal. Motor Control (Motor Control Current, A)
Based on the input signal, the P/S control module
determines the assist amount
and controls the current to
the motor suitable for that a ssist amount. This parameter
indicates that control value.
Motor Monitor (Motor Monitor Current, A)
This parameter indicates the actually measured value of
the current flowing to the motor. The motor circuit
condition is diagnosed by co mparing this parameter with
“Motor Control” parameter described previously.
Vehicle Speed (km/h, MPH)
Vehicle speed signal is fed from BCM. P/S control
module determines the amount of power assist based on
this vehicle speed signal and the torque sensor signal.
Engine Speed (rpm)
Engine speed signal is fed from the ECM so that it can
be used for trouble diagnos is of the electric power
steering system.
Motor Volt (V)
This parameter indicates the voltage between motor
terminals.
Ignition switch (ON, OFF)
This parameter indicates the condition of the power
supply through the ignition switch.
Visual InspectionS7RS0B6304007
Visually check the following pats and system.
P/S System Symptom DiagnosisS7RS0B6304008
This section describes trouble diagnosis of the P/S system parts whose trouble is not indicated by the on-board
diagnostic system (self-diagnostic functi on). When no malfunction is indicated by the on-board diagnostic system
(self-diagnosis function) and those stee ring basic parts as described in “Steering Symptom Diagnosis in Section 6A”
are all in good condition, check the following power steer ing system parts which may be a possible cause for each
symptom of the steering. Inspection Item Referring section
Battery Level, leakage, color “Batte ry Description in Section 1J”
Connectors of electric wire
harness Disconnection friction “Intermittent and Poor
Connection Inspection in Section 00”
Fuses Burning “Cautions in Body Electric al System Servicing in Section 9A”
Parts Installation, damage
Other parts that can be checked visually
Condition Possible cause Correction / Reference Item
Steering wheel feels
heavy (Perform “Steering
Force Check” before
diagnosis.) Steering wheel installed improperly
(twisted)
Install steering wheel correctly.
Poor performance of torque sensor Check torque sensor referring to “Torque
Sensor and Its Circuit Inspection”.
Poor performance of P/S motor Check motor referring to “P/S Motor and Its
Circuit Inspection”.
Steering gear case assembly faulty Replace.
Poor performance of vehicle speed
signal from ECM Check vehicle speed signal circuit referring to
“DTC C1121 / C1123 / C1124: VSS Circuit
Failure”.

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Installation1) Mount steering gear case (1) to front suspension frame (2) and tighten gear case mounting No.1 bolts
(3), No.2 bolts (4) and No .3 bolts (5) to specified
torque.
Tightening torque
Steering gear case mounting No.1 bolt (a): 55
N·m (5.5 kgf-m, 40.0 lb-ft)
Steering gear case mounting No.2 bolt (b): 55
N·m (5.5 kgf-m, 40.0 lb-ft)
Steering gear case mounting No.3 bolt (c): 40
N·m (4.0 kgf-m, 29.0 lb-ft)
2) Install earth cable (6) as shown in figure. Tightening torque
Earth cable bolt (d): 4.5 N·m (0.45 kgf-m, 3.5 lb-
ft)
3) Install grommet (1) whose projection (2) orients vehicle forward.
4) Install front suspension frame with steering gear case assembly referring to “Front Suspension
Frame, Stabilizer Bar and/or Bushings Removal and
Installation in Section 2B”.Steering Rack Boot InspectionS7RS0B6306007
Hoist vehicle.
Inspect each boot for tear. A torn boot allows entry of
dust and water which can cause wear to steering rack
and pinion to produce noise as well as rust to result in
malfunction of steering system.
Even if boot tear is small, replace with new one.
Also, check each boot for dent. If there is a dent, keep
boot in most compressed st ate for some seconds to
correct dent.
Boots should be visually inspected for any damage, dent
and tear during every periodical inspection at specified
intervals and whenever vehicle is hoisted for any other
purpose.
Tie-Rod / Rack Boot Removal and InstallationS7RS0B6306008
Removal
1) Remove steering gear case assembly referring to
“Steering Gear Case Assembly Removal and
Installation”.
2) For ease of adjustment after installation, make marking (1) of tie-rod end lock nut position of tie-rod
thread.
3) Loosen tie-rod end lock nut and remove tie-rod end.
4) Remove boot band (2) and clip (1).
5) Remove boot from tie-rod.
F: Vehicle forward
1 2
3, (a) 4, (b)
6, (d)
5, (c)
I6RS0C630019-02
12
F
I6RS0C630020-01
I2RH01630012-01
I4RS0A630044-01
IYSQ01630034-01

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Diagnostic Information and Procedures
Heater and Ventilation Symptom DiagnosisS7RS0B7104001
ConditionPossible cause Correction / Reference Item
Blower motor does not
operate with blower
speed selector ON 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”.
Blower motor resistor faulty Check blower motor resistor referring to
“Blower Motor Resistor Inspection”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection”.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection”.
Wiring or grounding faulty Repair as necessary.
Incorrect temperature
output Temperature control cable broken or
bent (manual A/C) Check temperature control cable.
Temperature control lever faulty (manual
A/C) Check temperature control lever.
Incorrect installation of temperature
control cable (manual A/C) Check position and adjust it as necessary.
Temperature control door assembly
broken Repair temperature control door assembly.
Air ducts clogged Repair air ducts.
Heater core leaked or clogged Replace heater core.
Heater hoses leaked or clogged Replace heater hoses.
Thermostat faulty Check thermostat referring to “Thermostat
Inspection in Section 1F”.
Temperature control actuator faulty
(automatic A/C) Check temperature control actuator referring to
“Temperature Control Actuator Inspection in
Section 7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air outlet port does not
change or does not agree
with air flow selector’s
position even if air flow
selector is changed Air flow control cable broken or bent
(manual A/C)
Check air flow control cable.
Air flow control lever faulty (manual A/C) Check air flow control lever.
Incorrect installation of air flow control
cable (manual A/C) Check position and adjust it as necessary.
Air flow control door assembly broken Repair air flow control door assembly.
Air ducts leaked or clogged Repair air ducts.
Air flow control actuator faulty
(automatic A/C) Check air flow control actuator referring to “Air
Flow Control Actuator
Inspection in Section
7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air intake door does not
change even if air intake
mode is changed Air intake door broken
Repair air intake door.
Air intake control actuator faulty Check air intake control actuator referring to
“Air Intake Control Actuator Inspection”.
Air intake selector faulty Check air intake selector referring to “Air Intake
Selector Inspection”.
Wiring or grounding faulty Repair as necessary.

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Repair Instructions
HVAC Unit ComponentsS7RS0B7106001
For manual type A/C, refer to “HVAC Unit Components
in Section 7B”.
For automatic type A/C, refer to “HVAC Unit
Components in Section 7B”.
HVAC Unit Removal and InstallationS7RS0B7106002
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove cowl top panel from vehicle body referring to “Cowl Top Components in Section 9K”.
4) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
5) Remove instrument panel from vehicle body referring to “Instrument Panel Removal and
Installation in Section 9C”.
6) Remove nuts (3).
7) Remove HVAC unit from vehicle body.
Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness in inappropriate position.
• Adjust control cables of HVAC control unit referring to “HVAC Control Unit Remo val and Installation”.
• Fill engine coolant to radiator.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor Removal and InstallationS7RS0B7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Disconnect connector (1) from blower motor (2).
4) Remove blower motor from HVAC unit by removing screws (3).
Installation
Reverse removal procedure noting the following
instruction.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Blower Motor InspectionS7RS0B7106004
• Check for continuity between two terminals as shown. If there is no continuity, replace blower motor.
3
2
3
1
3I4RS0B710004-01
3
1
2
3
3
I4RS0B710005-01
I4RS0A710006-01

Downloaded from www.Manualslib.com manuals search engine 7B-2 Air Conditioning System: Manual Type
Refrigerant Line
• Never use heat for bending pipes. When bending a pipe , try to make its bending angle as smooth as possible.
• Keep internal parts of air conditioning free from moistu re and dirt. When disconnecting any line from system, install
a blind plug or cap to the fitting immediately.
• When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to O-ring.
• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
• Check local governmental regulations regarding working with refrigerator systems and its tooling.
• Route drain hose so that drained water does not make any contact to vehicle components.
• If pipes or hoses are replaced, replenish specified amount of compressor oil to compre ssor suction side referring to
“Replenishing Compressor Oil” in “Operation Procedure for Refrigerant Charge”.
Refrigerant Recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a (R-1 34a) into atmosphere would cause adverse effect to
environments.
NOTE
When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.

Refrigerant Charge
After performing compressor oil replenishment and evacuat ion, charge a proper amount of refrigerant to A/C system
referring to “Charge” in “Operation Procedure for Refrigerant Charge”.
3
1
2
4
5
I4RS0B720001-02
1. Suction hose : Apply compressor oil (refrigerant oil) to O-ring. 4. Expansion valve
: Apply compressor oil (refrigerant oil) to O-ring.
2. Discharge hose : Apply compressor oil (refrigerant oil) to O-ring. 5. A/C refrigerant pressure sensor
: Apply compressor oil (refrigerant oil) to O-ring.
3. Liquid pipe : Apply compressor oil (refrigerant oil) to O-ring.

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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

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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

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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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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
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1
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11
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I4RS0A720014-01

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Charge
CAUTION!
• Because the sight glass is not used for this A/C system, do not perform an additional
charge to the A/C system. To charge the
proper amount of refrigerant, recover and
evacuate the A/C system first. And then,
charge the proper amount of refrigerant
into the A/C system.
• Always charge refrigerant through low pressure side of A/C system after the initial
charge is performed from the high
pressure side with the engine stopped.
• Never charge refrigerant through high pressure side of A/C system with engine
running.
• Do not charge refrigerant while compressor is hot.
• When installing tap valve to refrigerant container to make a hole there through,
carefully follow dire ctions given by
manufacturer.
• A pressure gauge should always be used before and during refrigerant charge.
• The refrigerant container should be emptied of refrigerant when discarding it.
• The refrigerant container should not be heated up to 40 °C (104 °F) or over.
• Refrigerant container should not be reversed in direction during refrigerant
charge. Reversing in direction causes
liquid refrigerant to enter compressor,
causing troubles, such as compression of
liquid refrigerant and the like.

NOTE
The air conditioning system contains HFC-
134a (R-134a).
Described here is a method to charge the air
conditioning system with refrigerant from the
refrigerant service container.
When charging refrigerant recovered by
using the refrigerant and recycling
equipment (when recycling refrigerant),
follow the procedure described in the
equipment manufacturer’s instruction
manual.

Charge proper amount of refrigerant accurately in
accordance with the following procedure.
Specified amount of refrigerant
370 ± 20 g (13.0 ± 0.7 oz)
The initial charge of the A/C system is performed
through the high pressure side with the engine stopped.
And next, this method must be followed by charging from
the low pressure side with the engine running.
1) Check if hoses are routed properly after evacuating the system.
2) Connect low charging hose (1) and high charging hose (2) of the manifold gauge set (3) in position.
Then, open refrigerant container valve (4) to purge
the charging line.
3) Open the high pressure side valve (5) and charge refrigerant to system.
4) After a while, open the low pressure side valve (6) and close the high pressure side valve.
WARNING!
Make sure that high pressure side valve is
closed securely.

5) Start engine and keep engine speed at 1500 r/min, and then operate A/C system.
6) Charge A/C system with refrigerant in vapor state. At this time, refrigerant container should be held
upright.
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2 6 3
5 4
I4RS0A720015-01