Control system SUZUKI SWIFT 2008 2.G Service Workshop Manual

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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

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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

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HVAC Unit ComponentsS7RS0B7216005
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
15 *
15 *
15 *
14 *
614 *
12
11 *
21 *
20
2320
22
9 *
13
3 *
5
I5RS0C721007-01
1. Fresh air inlet duct 7. Airflow control door assembly 13. Heater core19. Evaporator thermistor
(evaporator temperature sensor)

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HVAC Unit Removal and InstallationS7RS0B7216006
Removal1) Disconnect negative (–) cable from battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Recover refrigerant from A/C system with recovery and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
4) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
5) Drain engine coolant, and then disconnect heater hoses (1) from HVAC unit (2).
6) Remove instrument panel from vehicle body referring to “Audio Unit Re moval and Installation in
Section 9C”.
7) Loosen suction hose and liquid pipe bolt (4).
8) Remove nuts (3).
9) Remove HVAC unit from vehicle body. Installation
Reverse removal procedure 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”.
• Install the padding (1) to the installation hole uniformly.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust control cables referr ing to “HVAC Control Unit
Removal and Installati on in Section 7A”.
• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
Evaporator InspectionS7RS0B7216007
Check the followings.
• Clog of A/C evaporator fins.If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage. If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage. If any defects are found, repair or replace A/C
evaporator.
2. Blower upper case 8. Temperature control door assembly 14. Temperature control lever 20. Packing
3. Air intake control actuator 9. Blower motor resistor 15. Airflow control lever21. Filter cover (if equipped)
4. HVAC Air filter (if equipped) 10. Blower lower case 16. Evaporator22. Drain hose
5. Heater unit upper case 11. Blower motor 17. O-ring23. Cable lock clamp
6. Foot duct 12. Heater unit lower case 18. Expansion valve: Do not reuse.
3
2
3
3
1
4
I4RS0B720009-01
1
I4RS0B720010-01

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A/C Switch InspectionS7RS0B7216014
• Check that there is continuity between terminal (1) and terminal (2) when A/C s witch is at ON position.
• Check that there is no continuity between terminal (1) and terminal (2) when A/C s witch is at OFF position.
If check result does not meet the above conditions,
replace HVAC control unit.
Compressor Relay InspectionS7RS0B7216015
1) Disconnect negative (–) cable from battery.
2) Remove compressor relay (1) from main fuse box.
3) Check that there is no continuity between terminal “c” and “d”. If there is continuity, replace relay.
4) Connect battery positive (+ ) terminal to terminal “b”
of relay and battery negative (–) terminal to terminal
“a” of relay, and then check continuity between
terminal “c” and “d”. If there is no continuity, replace
relay.
Compressor Drive Belt Inspection and
Adjustment
S7RS0B7216016
Inspection
• Check compressor drive belt (1) for wear, crack, deformation and cleanliness. If any defect is found,
replace the belt with new one referring to
“Compressor Drive Belt Re moval and Installation”.
• Check compressor drive belt tension by measuring how much it deflects when pushed intermediate point
between magnet clutch pulley (6) and crankshaft
pulley (3) with about 100 N (10 kg) force after rotating
crankshaft pulley 360 °. If belt tension is out of
specification, adjust belt tension referring to
“Adjustment”.
Compressor drive belt tension
“a”
: 7 – 8mm (0.28 – 0.31 in.)
NOTE
When replacing drive belt, adjust drive belt
tension to the following specification.

New compressor dr ive belt tension “a”
: 6 – 7mm (0.24 – 0.28 in.)
Adjustment 1) Loosen tension pulley nut (4).
2) Adjust belt tension by ti ghten or loosen tension
pulley adjusting bolt (5).
3) Tighten tension pulley nut.
4) Rotate the crankshaft pulley 360 °, and then recheck
belt tension.
1 2
I4RS0B720013-01
"d"
"b" "a"
"c"
1
I4RS0B720014-01
2. Tension pulley
I4RS0A720033-01

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Automatic Type
Precautions
A/C System CautionS7RS0B7220001
Refer to “A/C System Caution”.
Precautions in Diagnosing TroubleS7RS0B7220002
• Do not disconnect couplers from HVAC control module, battery cable from battery, HVAC control module ground
wire harness from body or main fuse before confirming diagnostic information (diagnostic trouble code) stored in
HVAC control module memory.
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC
control module. Also, it can be checked by using SU ZUKI scan tool. Before checking diagnostic information
(diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read
diagnostic information (diagnostic trouble code).
• When trouble is diagnosed using diagnostic information (diagnostic trouble code) on display of HVAC control
module, keep in your mind that each diagnostic inform ation (diagnostic trouble code) has priority, and only
diagnostic information (diagnostic troub le code) which has the highest priority is indicated. Therefore, after
troubleshooting the malfunction, make sure if there exists any other diagnostic information (diagnostic trouble
code).
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” before inspection.
Precautions on Servicing A/C SystemS7RS0B7220003
Refer to “Precautions on Servicing A/C System”.
General Description
Auto A/C System DescriptionS7RS0B7221001
The automatic type air conditioning system (auto A/C) is pr ovided with the function to automatically control the inside
air temperature, fan speed, air flow outl et direction and air intake position by HVAC control module in addition to
functions of the manual type air conditioning system (manua l A/C). Once the inside air temperature is set using the
temperature selector, HVAC control module automatically controls the inside air temperature at the constant level at all
times based on the inside air temperature, outside ai r temperature, amount of sunlight and engine coolant
temperature detected respectively by the inside air te mperature sensor, outside air temperature sensor, sunload
sensor and ECT sensor. At this time, “FULL AUTO A/ C” appears on the display of HVAC control module.
With the air intake selector pushed in the above state, it is possible to select any position of the air intake actuator.
Then, “FULL AUTO A/C” on the display changes to “AUTO A/C”.

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Electronic Control System Location
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

1
2
3 * 4 *
5
6 *
7 *
8 *
9 *
10 *
21
11
12 13
14
15161718
19
20
I5RS0C722001-01
1. ECT sensor
7. Blower motor13. AUTO switch19. MODE (air flow) selector
2. Outside air temperature sensor 8. Blower motor controller 14. Temperature selector 20. Blower speed selector
3. Sunload sensor 9. Temperature control actuator15. OFF switch21. HVAC control module
4. Air flow control actuator 10. Inside air temperature sensor 16. Air intake selector
5. Evaporator temperature sensor 11. Defroster switch 17. A/C switch
6. Air intake actuator 12. Display 18. Rear defogger switch

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Auto A/C Electronic Control Input / Output Table
HVAC Control Module Operation DescriptionS7RS0B7221002
Temperature Control
HVAC control module calculates the target temperature
control door position based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor and
controls the temperature control actuator so that the
current position of the temperature control door matches
its target position.
Fan Speed Control
HVAC control module calculates the target blower fan
speed based on signals from the temperature selector,
inside air temperature sensor, outside air temperature
sensor and sunload sensor, compares it with the current
blower fan speed inputted from the blower motor
controller to control the current blower fan speed to the
target level.
Air Flow Outlet Control
HVAC control module calculates the target temperature
control door position based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor.
Using thus obtained target temperature control door
position, it further calculates the target air flow control
door position and controls the ai r flow control actuator so
that the current air flow c ontrol door position becomes
the target position. Air Intake Position Control
HVAC control module determines the position of the air
intake control door based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor and
selects any of the following positions by controlling the
position of the air intake control door.
• FRESH position (FRE)
• RECIRCULATION position (REC)
• MIX position (MIX)
Refrigerant Type IdentificationS7RS0B7221003
Refer to “Refrigerant Type Identification”.
Sub-Cool A/C System DescriptionS7RS0B7221005
Refer to “Sub-Cool A/C System Description”.
A/C Operation DescriptionS7RS0B7221006
Refer to “A/C Operation Description”.
Sunload sensor
Outside air temperature sensor Evaporator temperature sensor
A/C refrigerant pressure sensor
Temperature selector
MODE (air flow) selector
Blower speed selector
Air intake selector
AUTO switch
A/C switch
Compressor
Blower motor controller
Temperature control actuator
Air flow control actuator
Air intake control actuator
BCM
ECM
Data link connector
HVAC control module
CPU
ECT sensor
Inside air temperature sensor
VSS
*
I5RS0C722002-02
*: CAN communication

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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

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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