battery voltage SUZUKI SWIFT 2008 2.G Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine 6C-36 Power Assisted Steering System:
Voltage Check1) Remove console box.
2) Check for voltage at each terminal with co nnectors connected to the P/S control module.
NOTE
As each terminal voltage is affected by the battery voltage, confirm if the battery voltage is 11 V or
more when ignition switch is ON.
*: The voltage of this circuit may not be checked by voltmeter. If so, use oscilloscope.

Terminal Wire colorCircuit Normal voltage Remarks
E49-1 GRN Main power supply for
internal memory and P/S
motor 10 – 14 V
—
E49-2 BLK Ground for P/S control
module Below 0.3 V
—
E51-1 BLK Motor output 1 *0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.1: ”, “Reference
waveform No.2:
”and “Reference
waveform No.3: ”) • Engine idling and steering wheel at
straight position
• Voltage between “E51-1” and vehicle body ground
E51-2 RED Motor output 2 *0 – 1 V
↑↓
10 – 14 V
(“Reference
waveform No.1: ”, “Reference
waveform No.2: ” and “Reference
waveform No.3: ”) • Engine idling and steering wheel at
straight position
• Voltage between “E51-2” and vehicle body ground
E52-1 LT GRN/BLK Ignition switch signal for P/S
control module 10 – 14 V Ignition switch ON
E52-2 — —— —
E52-3 — —— —
E52-4 PPL Vehicle speed signal *0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.9”
under “Inspection of
ECM and Its Circuits in Section 1A”.) • Ignition switch ON
•Front left tire tu
rned quickly with right
tire locked
E52-5 GRY “EPS” warning light 0 V “EPS” warning light OFF
E52-6 BLU Torque sensor signal (Sub) About 0 – 2.5 V
• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 2.5 – 6 V • Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E52-7 — —— —
E52-8 GRN Main power supply for torque
sensor About 12 V• Ignition switch ON
• Check voltage between “E52-8” and
“E52-9” terminals
E52-9 BRN Ground for torque sensors Below 0.3 V —
E52-10 — —— —

Downloaded from www.Manualslib.com manuals search engine 6C-46 Power Assisted Steering System:
P/S Control Module Removal and InstallationS7RS0B6306011
Removal1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connectors (1) from P/S control module (2).
4) Disconnect connector from yaw rate / G sensor
(ESP ® model).
5) Remove P/S control module (2) with bracket (3) from floor panel.
6) Separate P/S control module and bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten each screw to the specified torque. Tightening torque
P/S control module bracket screw (ABS model)
(a): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
P/S control module bracket screw (ESP ® model)
(a): 7 N·m (0.7 kgf-m, 5.0 lb-ft)
P/S control module mounting screw (b): 5 N·m (
0.5 kgf-m, 3.7 lb-ft)
Torque Sensor and Its Circuit InspectionS7RS0B6306012
1) Remove console box.
2) With ignition switch turned OFF, connect scan tool to DLC or connect voltage tester between “E52-18” –
“E52-9” (main sensor) or “E52-6” – “E52-9” (sub
sensor) with connected connector (1) to P/S control
module. 3) Set torque wrench to stee
ring wheel referring to
“Steering Force Check” for checking steering force.
4) Turn ON ignition switch without engine running and select scan tool “Data list” mode due to check of
“TQS Main Torque”, “TQS Sub Torque” and “Assist
Torque” display on scan tool when steering wheel
turned left and right (if used).
5) Check that characteristic of torque sensor (main and sub) output voltage or scan tool data and steering
force is as following graph when steering wheel is
turned left and right. If sensor voltage or scan tool
data is out of specified value or does not vary linearly
as the following graph, check P/S control module
and its circuit.
If they are OK, replace steering gear case assembly.
1
(a)
2
3
(b)
I7RS0A630020-01
[A]: Steering force at left turn
[B]: Steering force at right turn
[C]: Steering wheel at free
[D]: “TQS Main Torque”, “TQS Sub Torque” and “Assist Torque” in “Data List” displayed on scan tool
E52
18
9
6
9
6 18
1
I6RS0C630024-01
I3RM0A630022-01
0
[C] [N.m]
MAX MAX
[B]
[A]
2.33 - 2.68 [V]
[D]
0.65 - 0.72
(0 - 0.4)
4.21 - 4.41
(5.1 - 5.6)
6.86
-6.86
0
6.86
- 6.86
I6RS0C630021-04

Downloaded from www.Manualslib.com manuals search engine 7B-10 Air Conditioning System: Manual Type
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

Downloaded from www.Manualslib.com manuals search engine 7B-26 Air Conditioning System: Manual Type
Expansion Valve Removal and InstallationS7RS0B7216010
Removal1) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Loosen a bolt (1) and remove pipes from expansion valve (2).
3) Loosen bolts (3) and remove expansion valve.
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of expansion valve and pipes.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Tightening torque
Expansion valve mount bolt: 3.5 N·m (0.35 kgf-m,
2.5 lb-ft)
Expansion Valve InspectionS7RS0B7216011
Refer to “A/C System Performance Inspection”.
A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
S7RS0B7216012
1) Disconnect A/C refrigerant pressure sensor connector.
2) Turn ignition switch to ON position.
3) Check if voltage between “RED” wire terminal and “ORN” wire terminal of A/C refrigerant pressure
sensor connector is 4.75 V to 5.25 V.
If not, check A/C refrigerant pressure sensor circuit.
4) Connect A/C refrigerant pressure sensor connector with ignition switch turned OFF.
5) Connect manifold gauge set to the charging valves.
6) Check A/C refrigerant pressure sensor voltage of ECM connector referring to “A/C System Inspection
at ECM”.
If voltage is not as specified below, replace A/C
refrigerant pressure sensor. A/C refrigerant pressure sensor voltage
specifications (A/C refrigerant pressure measured
by manifold gauge)
0.8 MPa (8.0 kg/cm2, 116 psi): 1.46 – 1.71 V
1.4 MPa (14 kg/cm2, 203 psi): 2.28 – 2.53 V
1.6 MPa (16 kg/cm2, 232 psi): 2.55 – 2.80 V
1.8 MPa (18 kg/cm2, 261 psi): 2.82 – 3.03 V
A/C Refrigerant Pressure Sensor Removal and
Installation
S7RS0B7216013
Removal
1) Recover refrigerant from the A/C system with the recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Disconnect negative (–) cable from battery.
3) Disconnect A/C refrigerant pressure sensor connector.
4) Remove A/C refrigerant pressure sensor (1) from liquid pipe (2).
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of A/C refrigerant
pressure sensor.
• Tighten A/C refrigerant pressure sensor to specified torque.
Tightening torque
A/C refrigerant pressure sensor (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
1
2 2
3
I4RS0A720028-01
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(a)I4RS0A720031-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-49
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
7812910
65 431516 14 13 12 11
G52
789101920121112
65 431718 16 15 14 13
G51
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.

Downloaded from www.Manualslib.com manuals search engine 7B-62 Air Conditioning System: Automatic Type
DTC B1541: HVAC Control Module Back-Up Power Supply MalfunctionS7RS0B7224017
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting11
Position sensor circuit check
1) Check air flow control actuator position sensor circuit
referring to Step 1 to Step 5 and Step 10 to Step 11 of
“DTC B1512: Air flow Control Actuator (Position Sensor)
and/or Its Circuit Malfunction”.
Is it in good condition? Go to Step 12. Repair circuit.
12 Air flow control actuator check
1) Check air flow control actuator referring to “Air Flow
Control Actuator Inspection”.
Is it in good condition? HVAC control module
faulty.
Air flow control actuator
faulty.
Step Action Yes No
WHT/RED
2 17812910
65 431516 14 13 12 11
G52
789101920121112
65 431718 16 15 14 13
G51
3
G52-16
I5RS0A722015-01
1. HVAC control module
2. Junction block assembly 3. Circuit fuse
DTC Detecting Condition Trouble Area
Back-up power supply voltage is lo wer than specified value continuously. • Battery voltage supply circuit
• HVAC control module
StepAction YesNo
1 DTC check
1) Turn ON ignition switch for 20 sec. or more.
2) Ignition switch turned OF F and connect scan tool to
DLC.
3) Turn ON ignition switch and check DTC.
Is there DTC B1541? Go to Step 2.
Intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection
Inspection in Section
00”.
2 Battery voltage 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 “G52-16” terminal.
3) If OK, measure voltage between “G52-16” terminal of HVAC control module connector and vehicle body
ground.
Is voltage 10 – 14 V? HVAC control module
faulty.
Circuit fuse blown and/
or “WHT/RED” wire
circuit open or short.

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-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 7B-76 Air Conditioning System: Automatic Type
Actuator Linkage InspectionS7RS0B7226010
• Check if each actuator linkage operates smoothly.
• Check actuator rod for bend.
• Check each actuator linkage for breakage.
• Make sure if there is not any obstruction in operating range of actuator linkage.
If any malfunction is found, repair or replace faulty
part(s).
Blower Motor Controller Removal and
Installation
S7RS0B7226011
Refer to “Blower Motor Resistor Removal and
Installation in Section 7A”.
Blower Motor Controller InspectionS7RS0B7226012
1) Check internal circuit of controller for resistance as follows.
a) Measure resistance between “1” terminal and “2” terminal of blower motor controller.
Blower motor cont roller resistance
“1” – “2”: approximately 10 k Ω at 25 °C (77 °F)
If resistance does not meet above specification,
replace blower motor controller.
b) Using ohmmeter, connect its positive terminal to “3” terminal of blower motor controller and
negative terminal to “1” terminal of blower motor
controller and check that there is no continuity.
2) Check controller for operation as follows. a) Using service wire, connect battery positive terminal to “3” terminal of blower motor controller
and battery negative terminal to “1” terminal of
blower motor controller.
b) Using bulb (3.4 W) (5) and service wire, connect battery positive terminal to “3” terminal of blower
motor controller as shown figure.
c) Arrange 3 new 1.5 V batteries (6) in series (check that total voltage is 4.5 – 5.0 V) and
connect its positive term inal to “2” terminal of
blower motor controller and negative terminal to
“1” terminal of blower motor controller.
Then, check that bulb lights. If bulb does not light
under the above conditions, replace blower
motor controller.
3
1
2
4
2
1
3
4
5
6I5RS0A722026-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-77
HVAC Control Module Removal and InstallationS7RS0B7226013
Removal1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove passenger air bag module from instrument panel referring to “Passenger Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Remove radio assembly from instrument panel referring to “Rear Speaker Removal and Installation
in Section 9C”.
5) Remove two connectors fr om HVAC control module.
6) Remove HVAC control modu le (1) from instrument
panel.
NOTE
Be careful not to damage HVAC control
module and instrument panel by using rag.

Installation
Reverse removal procedure noting the following
instructions.
Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Sunload Sensor Removal and InstallationS7RS0B7226014
Removal
1) Disconnect negative (–) cable at battery.
2) Remove combination meter referring to “Combination Meter Removal and Installation in
Section 9C”.
3) Remove sunload sensor (1) from instrument panel by depressing tab and pushing sensor upward from
underneath.
4) Disconnect sunload sensor connector (2). Installation
Reverse removal procedure.
Sunload Sensor InspectionS7RS0B7226015
1) Light over sunload sensor vertically with an
incandescent lamp of approximately 100 W. The
distance between sunload sensor and lamp should
be approximately 100 mm (3.94 in.).
2) Measure voltage between terminals of sunload sensor as shown.
If check result is not satisfactory, replace sunload
sensor with new one.
Sunload sensor voltage specification
0.4 V or more
Outside Air Temperature Sensor Removal and
Installation
S7RS0B7226016
Refer to “Instrument Panel Re moval and Installation in
Section 9C”.
Outside Air Temperature Sensor InspectionS7RS0B7226017
Refer to “Information Display (Clock) Removal and
Installation in Section 9C”.
1
I5RS0A722030-01
1
2
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