Auto SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 7B-66 Air Conditioning System: Automatic Type
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.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-67
Inspection of HVAC Control Module and Its CircuitS7RS0B7224026
HVAC control module and its circuits can be checked at HVAC control module wiring couplers by measuring voltage.
CAUTION!
HVAC control module can not be checked by itself. It is strictly prohibited to connect voltmeter to
HVAC control module with couplers disconnected from it.

Voltage Check
1) Remove HVAC control module referring to “HVAC Control Module Removal and Installation”.
2) Check voltage at each terminal.
NOTE
As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when ignition
switch is ON.

7812910
65 431516 14 13 12 11
G52
789101920121112
65 431718 16 15 14 13
G51
1
2
I5RS0A722017-02
1. HVAC control module2. HVAC control module connector (viewed from harness side)
Terminal Wire Color CircuitNormal
Vo l ta g e Condition
G51-1 BRN/WHT Air flow control actuator
(DEF) 10 – 14 V
Ignition switch turned ON, ai
r flow control actuator is
working in operation fr om VENT to DEF position
0 – 1 V Ignition switch turned ON, except the above condition
G51-2 BRN/YEL Air flow control actuator
(FACE) 10 – 14 V
Ignition switch turned ON, ai
r flow control actuator is
working in operation fr om DEF to VENT position
0 – 1 V Ignition switch turned ON, except the above condition
G51-3 GRY/BLU Temperature control
actuator (COOL) 10 – 14 VIgnition switch turned ON, temperature control
actuator is working in ope
ration from HOT to COOL
position
0 – 1 V Ignition switch turned ON, except the above condition
G51-4 GRY/RED Temperature control
actuator (HOT) 10 – 14 VIgnition switch turned ON, temperature control
actuator is working in operation from COOL to HOT
position
0 – 1 V Ignition switch turned ON, except the above condition
G51-5 PPL/WHT Serial communication line
of data link connector 10 – 14 V Ignition switch turned ON
G51-6 — — — —
G51-7 YEL Serial communication line
of BCM Refer to “Inspection of BCM a
nd its Circuits in Section 10B”

Downloaded from www.Manualslib.com manuals search engine 7B-68 Air Conditioning System: Automatic Type
G51-8 BLU/REDBlower motor control
voltage feedback 10 – 14 V Ignition switch turned ON, blower speed selector OFF
About 8.5 V Ignition switch turned ON, blower speed selector 1st
position
About 6.5 V Ignition switch turned ON, blower speed selector 2nd
position
About 5.5 V Ignition switch turned ON, blower speed selector 3rd
position
About 4.0 V Ignition switch turned ON, blower speed selector 4th
position
About 3.0 V Ignition switch turned ON, blower speed selector 5th
position
About 2.0 V Ignition switch turned ON, blower speed selector 6th
position
About 1.0 V Ignition switch turned ON, blower speed selector 7th
position
Below 1.0 V Ignition switch turned ON, blower speed selector HIGH
position
G51-9 GRY Blower motor controller 0 – 1 V
Ignition switch turned ON, blower speed selector OFF
position
2 – 3 V Ignition switch turned ON, blower speed selector
between 1st and HIGH position
G51-10 BLK/RED Rear defogger indicator 0 – 1 V Ignition switch turned ON, rear defogger switch OFF
10 – 14 V Ignition switch turned ON, rear defogger switch ON
G51-11 RED/YEL Illumination switch 0 – 1 V Ignition switch turned ON, lighting switch OFF position
10 – 14 V Ignition switch turned ON, lighting switch ON position
G51-12 BLK/YEL Illumination ground 0 – 1 V Full-time
G51-13 — — — —
G51-14 — — — —
G51-15 RED Air intake actuator
(RECIRCULATION AIR) 0 – 1 VIgnition switch turned ON, air intake selector is
recirculation air mode or air intake actuator is working
in operation to recirculation air position or fresh air
position.
10 – 14 V Ignition switch turned ON, ai
r intake selector is fresh
air mode (air intake actuator fresh air position).
G51-16 GRN/RED Air intake actuator
(MIX AIR) 10 – 14 V
Ignition switch turned ON, air intake actuator is
recirculation air or fresh air position.
0 – 1 V Ignition switch turned ON, air intake actuator is mix air
position or air intake actuator is working in operation to
recirculation air position or fresh air position.
G51-17 GRN Air intake actuator
(FRESH AIR) 0 – 1 V
Ignition switch turned ON, ai
r intake selector is fresh
air mode or air intake actuator is working in operation
to recirculation air position or fresh air position.
10 – 14 V Ignition switch turned ON, air intake selector is
recirculation air mode (air intake actuator recirculation
air position).
G51-18 GRN/WHT A/C switch signal Refer to “Inspe ction of BCM and its Circuits in Section 10B”
G51-19 BLU/WHT Electric load signal for
blower motor 10 – 14 V
Ignition switch turned ON, blower speed selector OFF
or between 1st and 5th position
0 – 2 V Ignition switch turned ON, blower speed selector
between 6th and HIGH position
G51-20 BRN Rear defogger switch 0 – 1 V
Ignition switch turned ON, rear defogger switch ON
(rear defogger switch is kept in push) position
4 – 6 V Ignition switch turned ON, rear defogger switch OFF
position
Terminal Wire Color Circuit
Normal
Vo l ta g e Condition

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-69
Terminal Wire Color CircuitNormal
Vo l ta g e Condition
G52-1 WHT Output of 5 V power
source for air flow control
actuator position sensor
and temperature control
actuator position sensor 4 – 6 V Ignition switch turned ON
G52-2 PNK Output of 5 V power
source for sunload sensor 4 – 6 V Ignition switch turned ON
G52-3 ORN Ground for sensors Below 0.3 V Ignition switch turned ON
G52-4 WHT/BLK Evaporator temperature
sensor signal 3.45 – 3.65 V
Ignition switch turned ON, evaporator temperature 0
°
C (32 °F)
2.55 – 2.85 V Ignition switch turned ON, evaporator temperature
15
°C (59 ° F)
1.7 – 2.1 V Ignition switch turned ON, evaporator temperature
30
°C (86 ° F)
G52-5 YEL/BLK Sunload sensor signal
G52-6 PNK/BLK Inside air temperature
sensor signal About 2.0 V
Ignition switch turned ON, room temperature 25
°C
(77 °F)
About 2.8 V Ignition switch turned ON, room temperature 0
°C
(32 °F)
G52-7 — — — —
G52-8 RED/BLK Electric power source 10 – 14 V Ignition switch turned ON
G52-9 — — — —
G52-10 — — — —
G52-11 BLK/ORN Ground for HVAC control
module Below 0.3 V Ignition
switch turned ON
G52-12 — — — —
G52-13 YEL Temperature control
actuator position sensor
signal About 4.0 V
Ignition switch turned ON, temperature selector MAX
COOL position
About 2.0 V Ignition switch turned ON, temperature selector MAX
HOT position
G52-14 WHT/BLU Air flow control actuator
position sensor signal About 4.0 V
Ignition switch turned ON
, air flow selector VENT
position
About 1.6 V Ignition switch ON, air flow selector DEF position
G52-15 — — — —
G52-16 WHT/RED Electric power source for
back-up 10 – 14 V Full-time

Downloaded from www.Manualslib.com manuals search engine 7B-70 Air Conditioning System: Automatic Type
A/C System Performance InspectionS7RS0B7224027
Refer to “A/C System Performance Inspection”.
A/C System Inspection at ECMS7RS0B7224028
Voltage Check
ECM and its circuits can be checked by measuring voltage with special tool connected.
CAUTION!
• ECM connectors are waterproofed. Each terminal of the ECM connectors is sealed up with the
grommet. Therefore, do not measure circuit voltage and resistance by inserting the tester’s probe
into the sealed terminal at the harness side. Or, ECM and its circuits may be damaged by water.
• ECM cannot be checked by itself. It is strictly prohibited to connect voltmeter or ohmmeter to ECM with couplers disconnected from ECM.

1) Remove ECM (1) from its bracket by referring to “Electric Throttle Body System Calibration in Section 1C”.
2) Connect special tool (2) between ECM and ECM connectors securely.
3) Check voltage at each terminal.
NOTE
As each terminal voltage is affected by the battery voltage, confirm that the battery voltage is 11 V or
more when ignition sw itch is ON position.

Terminal arrangement of ECM coupler (Viewed from harness side)
1
2
I5RS0A722018-01
E23 C37
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
34
1819
567
1011
17
20
47 46
495051
2122
52 16
25 9
24
14
29
55
57 54 53
59
60 58 2
262728
15
30
56 4832 31
34353637
40
42 39 38
44
45 43 41 331
1213
238
I4RS0A720010-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-71
ECM Voltage Values Table for Relation of A/C Control
Repair Instructions
Operation Procedure for Refrigerant ChargeS7RS0B7226001
Refer to “Operation Procedure for Refrigerant Charge”.Terminal Wire Color Circuit Normal Value Condition
C37-14 GRY/RED Output of 5 V power
source 4.5 – 5.5 V Ignition switch turned ON
C37-15 BLK Ground for ECM Below 0.3 V Ignition switch turned ON
C37-24 LT GRN Engine coolant temp.
(ETC) sensor signal 3.3 – 3.8 V Ignition switch turned ON, ECT at 0
°C (32 ° F)
1.38 – 1.72 V Ignition switch turned ON, ECT at 50 °C (122 °F)
C37-30 BLK Ground for ECM Below 0.3 V Ignition switch turned ON
C37-55 ORN Ground for sensors Below 0.3 V Ignition switch turned ON
C37-58 BLK/ORN Ground for ECM Below 0.3 V Ignition switch turned ON E23-1 BLK/RED Main power supply 10 – 14 V Ignition switch turned ON
E23-3 RED CAN (high)
communication line
(active high signal)
for BCM and
combination meterRefer to “DTC P2101: Throttle Actu
ator Control Motor Circuit Range /
Performance in Section 1A”
E23-16 BLK/RED Main power supply 10 – 14 V Ignition switch turned ON
E23-18 WHT CAN (low)
communication line
(active low signal) for
BCM and
combination meterRefer to “DTC P2101: Throttle Actu
ator Control Motor Circuit Range /
Performance in Section 1A”
E23-19 BLU/WHT Electric load signal
for blower motor 10 – 14 V
Ignition switch turned ON, blower speed selector
OFF or between 1st and 5th position
0 – 1 V Ignition switch turned ON, blower speed selector
between 6th and HIGH position
E23-46 LT GRN Radiator fan relay
No.1 output 10 – 14 V
Ignition switch turned ON, engine coolant temp.:
below 95
°C (203 ° F), or A/C refrigerant pressure:
below 600 kPa (87 psi).
0 – 2 V Ignition switch turned ON, engine coolant temp.:
97.5
°C (207.5 °F) or higher, or A/C refrigerant
pressure: 1100 kPa (159.5 psi) or higher.
E23-47 GRY A/C compressor relay
output 10 – 14 V Engine running, A/C request signal high input
0 – 1 V Engine running, A/C request signal low input
E23-48 GRN Radiator fan relay
No.2 and No.3 output 10 – 14 V
Ignition switch turned ON, engine coolant temp.:
below 100
°C (212 °F), or A/C refrigerant
pressure: below 1200 kPa (174 psi).
0 – 2 V Ignition switch turned ON, engine coolant temp.:
102.5
°C (216.5 ° F) or higher, or A/C refrigerant
pressure: 1500 kPa (217.5 psi) or higher.
E23-55 RED A/C refrigerant
pressure sensor
signal 1.46 – 1.71 V
Engine running, A/C refrigerant pressure at 0.8
MPa (8.0 kg/cm
2) (A/C refrigerant pressure
measured by manifold gauge)
2.55 – 2.80 V Engine running, A/C refrigerant pressure at 1.6
MPa (16.0 kg/cm
2) (A/C refrigerant pressure
measured by manifold gauge)
E23-60 BRN/WHT Main power supply
relay output 10 – 14 V Ignition switch turned OFF
0 – 2 V Ignition switch turned ON

Downloaded from www.Manualslib.com manuals search engine 7B-72 Air Conditioning System: Automatic Type
HVAC Unit ComponentsS7RS0B7226002
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

10 * 2 *
6
7
1 *
4 *
2 *
5
7
8
8
17
16
18
19
6
12
11 *
21 *
20
20
22
9 *
13
3 *
5
15 *
14 *
15 *
23 *
24 *
25 *
26 *
I5RS0C722003-01
1. Fresh air inlet duct
8. Temperature control door assembly 15. Air flow control links 22. Drain hose

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-73
HVAC Unit Removal and InstallationS7RS0B7226003
Refer to “HVAC Unit Removal and Installation”.
Temperature Control Actuator Removal and
Installation
S7RS0B7226004
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hol e cover from instrument
panel.
3) Remove foot duct from HVAC unit.
4) Disconnect temperature control actuator connector (1).
5) Detach temperature control actuator rods (2) from linkage (3).
6) Remove temperature control actuator (4) from HVAC unit.
Installation
Reverse removal procedure.
Temperature Control Actuator InspectionS7RS0B7226005
1) Remove temperature control actuator from HVAC unit referring to “Temperature Control Actuator
Removal and Installation”.
2) Connect connector to temperature control actuator.
3) Set temperature selector of HVAC control module to MAX HOT position with ignition switch ON, and
make sure if the position of actuator lever is MAX
HOT position (A).
4) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
5) Measure resistance between terminal “3” and “5”.
Temperature control actuator resistance between
terminal “3” and “5” (MAX HOT position)
Approximately 2.5 k Ω at 25 °C (77 °F) 6) Connect connector to tem
perature control actuator.
7) Set temperature selector of HVAC control module to MAX COOL position with ignition switch ON, and
make sure if the position of actuator lever is MAX
COOL position (B).
8) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
9) Measure resistance between terminal “3” and “5”
Temperature control actuator resistance between
terminal “3” and “5” (MAX COOL position)
Approximately 4.8 k Ω at 25 °C (77 °F)
If check result is not satisfactory, replace the actuator
with new one.
2. Blower upper case 9. Blower motor controller 16. Evaporator 23. Temperature control actuator
3. Air intake control actuator 10. Blower lower case 17. O-ring24. Air flow control actuator
4. Air filter (if equipped) 11. Blower motor 18. Expansion valve25. Inside air temperature sensor
5. Heater unit upper case 12. Heater unit lower case 19. Evaporator temperature sensor 26. Aspirator hose
6. Foot duct 13. Heater core 20. Packing : Do not reuse.
7. Air flow control door assembly 14. Temperature control links 21. Filter cover
1
2
2
3
4
I5RS0A722020-02
I5RS0A722021-03
I5RS0A722022-03

Downloaded from www.Manualslib.com manuals search engine 7B-74 Air Conditioning System: Automatic Type
Air Flow Control Actuator Removal and
Installation
S7RS0B7226006
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hol e cover from instrument
panel.
3) Remove foot duct from HVAC unit.
4) Disconnect air flow contro l actuator connector (2).
5) Remove air flow control actuator (1) from HVAC unit, and then detach air flow actuator rod from linkage.
Installation
Reverse removal procedure.
Air Flow Control Actuator InspectionS7RS0B7226007
1) Remove air flow control actuator from HVAC unit referring to “Air Flow C ontrol Actuator Removal and
Installation”.
2) Connect actuator connector to the actuator.
3) Set air flow selector of HVAC control module to DEF position with ignition switch ON, and make sure if the
position of actuator lever is DEF position (8).
4) Turn ignition switch OFF, and then disconnect connector from air flow control actuator.
5) Measure resistance between terminal “3” and “5”
Air flow control actuator resistance between
terminal “3” and “5” (DEF position)
Approximately 4.8 k Ω at 25 °C (77 °F)
I5RS0A722023-03
[A]: LH steering vehicle [B]: RH steering vehicle
8
[A]
[B]
8
7654 321
I5RS0C722004-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-75
6) Connect connector to air flow control actuator.
7) Set air flow selector of HVAC control module to VENT position with ignition switch ON, and make
sure if the position of act uator lever is VENT position
(8).
8) Turn ignition switch OFF, and then disconnect connector from air flow control actuator.
9) Measure resistance between terminal “3” and “5”.
Air flow control actuator resistance between
terminal “3” and “5” (VENT position)
Approximately 2.0 k Ω at 25 °C (77 °F)
If check result is not satisfactory, replace the actuator
with new one.
Air Intake Control Actuator Removal and
Installation
S7RS0B7226008
Refer to “Air Intake Control Actuator Removal and
Installation in Section 7A”.
Air Intake Control Actuator InspectionS7RS0B7226009
Check air intake contro l actuator as follows:
1) Using service wire, connect battery positive terminal
to terminal “7” and battery negative terminal to
terminal “1”. And, check if air intake selector link
operates smoothly and it stops at “REC” position (A).
2) Using service wire, connect battery positive terminal
to terminal “7” and battery negative terminal to
terminal “5”. And, check if air intake selector link
operates smoothly and it stops at “MIX” position (B).
3) For auto A/C model, using service wire, connect battery positive terminal to terminal “7” and battery
negative terminal to “3” terminal. And, check air
intake selector link operates smoothly and it stops at
“FRE” position (C).
If malfunction is found, replace air intake control
actuator.
[A]: LH steering vehicl e [B]: RH steering vehicle
[A]
[B]
8
8765 4 3 21
I5RS0C722005-02
A
C
B“a”
“a”“a”
-
+
A
C
B “1” “3” “5” “7”
“1”
“3”
“5”
“7”
120
°
120° 120
°
I7RS0A722002-01