Motor SUZUKI SX4 2006 1.G Service Workshop Manual

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HVAC
Heater and Ventilation
General Description
Heater and Ventilation ConstructionS6RW0D7101001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

I6RW0C710001-02
A: Air flow 7. Defroster air 15. Rear duct (if equipped)
B: Water flow 8. Demister air 16. Foot duct
1. HVAC unit 9. Fresh air 17. Engine
2. Ventilator duct 10. Recirculation air 18. Radiator
3. Defroster duct and demister duct 11. Center ventilation air 19. Reservoir
4. Heater core 12. Air intake door 20. Temperature control door
5. Side ventilation air 13. Blower motor 21. Air flow control door
6. Foot air 14. Resistance board (non-A/C) or evaporator (A/C)

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Schematic and Routing Diagram
Heater and Ventilation Wiring Circuit DiagramS6RW0D7102001
Non–A/C
Manual A/C
Refer to “A/C System Wiring Diagram in Section 7B”.
Auto A/C
Refer to “A/C System Wiring Diagram in Section 7B”.
Component Location
Electronic Control System Components LocationS6RW0D7103001
Refer to “Electronic Control System Components Location in Section 7B” (non-A/C and manual A/C) or “Electronic
Control System Components Location in Section 7B” (auto A/C).
5V
BLK
RED/BLK3
5 72
G154-3
G154-4
G154-7
G154-8
G154-10
G154-13
G155-2
G155-3
G155-7
G155-6
G155-1
G154-9
G154-14
BLK/WHT
YEL
BLU/WHT
RED
RED/BLKRED
GRN
GRN/YEL
RED/YEL
RED/BLU
BLK/ORN
46
8
BLU
YELGRN
WHT
13
1514
[A]21
BLK/RED
12V
BLK/YELBLK/WHTM
BLK
1IG1
IG2
12
BLK/RED
M 10
11
11
BLU/WHT 19
16
17
18 9 20
I6RW0C710003-01
[A]: Illumination control model 6. Blower motor resistor 12. Main fuse box 18. Illumination light
1. Ignition switch 7. Junction block assembly 13. Blower speed selector 19. Rear defogger relay
2. Blower motor 8. BCM 14. Air intake selector 20. Rear defogger
3. HVAC control unit 9. ECM 15. Rear defogger switch 21. Tail light
4. Lighting switch 10. Air intake control actuator 16. “REC” indicator light
5. Blower motor relay 11. To BCM 17. Rear defogger indicator

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Diagnostic Information and Procedures
Heater and Ventilation Symptom DiagnosisS6RW0D7104001
Condition Possible cause Correction / Reference Item
Blower motor does not
operate with blower
speed selector ONFuse blownCheck related fuses, and then check for short
circuit to ground.
Blower motor relay faultyCheck blower motor relay referring to “Blower
Motor Relay Inspection”.
Blower motor resistor faultyCheck blower motor resistor referring to
“Blower Motor Resistor Inspection”.
Blower speed selector faultyCheck blower speed selector referring to
“Blower Speed Selector Inspection”.
Blower motor faultyCheck blower motor referring to “Blower Motor
Inspection”.
Wiring or grounding faultyRepair as necessary.
Incorrect temperature
outputTemperature control cable broken or
bent (non-A/C and manual A/C)Check temperature control cable.
Temperature selector faulty (non-A/C
and manual A/C)Check temperature selector.
Incorrect installation of temperature
control cable (non-A/C and manual A/C)Check position and adjust it as necessary.
Temperature control door assembly
brokenRepair temperature control door assembly.
Air ducts cloggedRepair air ducts.
Heater core leaked or cloggedReplace heater core.
Heater hoses leaked or cloggedReplace heater hoses.
Thermostat faultyCheck thermostat referring to “Thermostat
Inspection in Section 1F”.
Temperature control actuator faulty
(auto A/C)Check temperature control actuator referring to
“Temperature Control Actuator and Its Circuit
Inspection in Section 7B”.
HVAC control module faulty (auto A/C)Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (auto 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 changedAir flow control cable broken or bent
(non-A/C and manual A/C)Check air flow control cable.
Air flow selector faulty (non-A/C and
manual A/C)Check air flow selector.
Incorrect installation of air flow control
cable (non-A/C and manual A/C)Check position and adjust it as necessary.
Air flow control door assembly brokenRepair air flow control door assembly.
Air ducts leaked or cloggedRepair air ducts.
Air flow control actuator faulty (auto A/C)Check air flow control actuator referring to “Air
Flow Control Actuator and Its Circuit Inspection
in Section 7B”.
HVAC control module faulty (auto A/C)Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (auto A/C)Repair as necessary.
Air intake door does not
change even if air intake
mode is changedAir intake door brokenRepair air intake door.
Air intake control actuator faultyCheck air intake control actuator referring to
“Air Intake Control Actuator Inspection”.
Air intake selector faultyCheck air intake selector referring to “Air Intake
Selector Inspection”.
Wiring or grounding faultyRepair as necessary.

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Repair Instructions
HVAC Unit ComponentsS6RW0D7106001
For non-A/C and manual A/C, refer to “HVAC Unit
Components in Section 7B”.
For auto A/C, refer to “HVAC Unit Components in
Section 7B”.
HVAC Unit Removal and Installation (Non-A/C)S6RW0D7106002
For manual A/C and auto A/C, refer to “HVAC Unit
Removal and Installation in Section 7B”.
Removal
1) Drain engine coolant referring to “Cooling System
Draining in Section 1F”, and then disconnect heater
hoses from HVAC unit.
2) Remove cowl top cover from vehicle body referring
to “Cowl Top and Front Lower Crossmember
Components in Section 9K”.
3) Remove instrument panel from vehicle body
referring to “Instrument Panel Removal and
Installation in Section 9C”.
4) Remove HVAC unit (1) from vehicle body by
removing nuts (2).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 Removal and Installation”.
• Refill cooling system with coolant referring to “Cooling
System Flush and Refill in Section 1F”.
Blower Motor Removal and InstallationS6RW0D7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect connector (1) from blower motor (2).
3) Remove blower motor (2) from HVAC unit as follows.
a) Remove screws (4).
b) Release tub (3) to arrow direction.
c) Hold Step b) and turn blower motor (2) to arrow
direction.
Installation
Reverse removal procedure.
Blower Motor InspectionS6RW0D7106004
• Check blower motor for resistance between two
terminals as shown.
If there is no continuity, replace blower motor.
2
2
2
1
I7RW01710003-01
3
2
b)
c)
1
4
4I7RW01710004-02
I7RW01710005-01

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• Check for operation and current.
a. Put blower motor (1) in a soft-jawed vise.
b. Connect battery to blower motor as shown.
c. Check if blower motor operates smoothly without
noise.
d. Check if ammeter indicates the specified current.
If measured current is out of specification, replace
blower motor.
Blower motor specified current at 12 V
18.5 A maximum at 20 – 25 °C (68 – 77 °F)
Blower Motor Resistor Removal and InstallationS6RW0D7106005
Removal
1) Disconnect negative (–) cable from battery.
2) Remove glove box from instrument panel.
3) Remove passenger side foot duct (1) from HVAC
unit by removing screw (2).4) Disconnect connector (1) from blower motor resistor
(2), and then remove blower motor resistor from
HVAC unit by removing screws (3).
Installation
Reverse removal procedure.
Blower Motor Resistor InspectionS6RW0D7106006
Measure each terminal-to-terminal resistance. If
measured resistance is out of specification, replace
blower motor resistor.
Blower motor resistor resistance
“H” – “MH”: Approx. 0.43 Ω at 20 – 25 °C (68 – 77 °F)
“MH” – “ML”: Approx. 0.6 Ω at 20 – 25 °C (68 – 77 °F)
“ML” – “L”: Approx. 2.0 Ω at 20 – 25 °C (68 – 77 °F)
1
I7RW01710006-01
1
2
I7RW01710007-01
2
3
1
I7RW01710008-01
I7RW01710009-02

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Blower Motor Relay InspectionS6RW0D7106007
1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air
Bag System in Section 8B”.
3) Remove junction block assembly (2).
4) Disconnect blower motor relay (1) from junction
block assembly (2).
5) Check that there is no continuity between terminal
“C” and “D”. If there is continuity, replace relay.
6) Connect battery positive (+) terminal to terminal “B”
of relay. Connect battery negative (–) terminal “A” of
relay.
Check continuity between terminal “C” and “D”.
If there is no continuity when relay is connected to
the battery, replace relay.
HVAC Control Unit ComponentsS6RW0D7106008
“D” “B”“A”“C”
1
2
I4RS0B710008-01
1. Heater control body assembly 4. Bulb 7. Air intake selector 10. Rear defogger switch
2. Air flow selector 5. Temperature control cable 8. Temperature selector
3. Blower speed selector 6. Air flow control cable 9. A/C switch (if equipped)
7
10
9
2
3 8
45
61
I5RW0A710005-01

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Installation
Reverse removal procedure noting the following
instruction.
• Be sure to insert the linkage rod (1) into the hole (2) of
air intake control actuator.Air Intake Control Actuator InspectionS6RW0D7106013
Check air intake control actuator as follows:
1) Using service wire, connect battery positive terminal
to “d” terminal and battery negative terminal to
terminal “a”. And, check if air intake selector link
operates smoothly and it stops at “FRE” position (1).
2) Using service wire, connect battery positive terminal
to “d” terminal and battery negative terminal to
terminal “c”. And, check if air intake selector link
operates smoothly and it stops at “REC” position (2).
3) For auto A/C model, using service wire, connect
battery positive terminal to “d” terminal and battery
negative terminal to “b” terminal. And, check air
intake selector link operates smoothly and it stops at
MIX position (3).
If malfunction is found, replace air intake control
actuator.
21
I7RW01710017-02
4. Motor rotation direction
“a” “b” “c” “d”
1 3
2
4“a”
“b”
“c” “d”
I7RW01710018-05

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Manual A/C Electronic Input Output TableS6RW0D7211002
A/C Operation Description at ECMS6RW0D7211003
ECM controls the A/C compressor relay and condenser cooling fan relay according to signals from HVAC control unit,
A/C refrigerant pressure sensor, ECT sensor and evaporator temperature sensor. The A/C switch ON signal from
HVAC control unit is transmitted to ECM through BCM. For CAN communication system, refer to “CAN
Communication System Description in Section 1A”.
ECM turns ON the A/C compressor relay when the vehicle state satisfy conditions described below.
• A/C switch ON signal is inputted from HVAC control unit
• A/C refrigerant pressure is within specified range
• Evaporator temperature is within specified range
• Engine speed is within specified range
• Engine coolant temperature is lower than specified value
• Throttle opening is lower than specified value
• Vehicle is not in either state of starting or quick acceleration
• ECT sensor malfunction is not detected
• A/C refrigerant pressure sensor malfunction is not detected
Condenser Cooling Fan Relay Control
ECM turn ON the condenser cooling fan relay at the same time when ECM turn ON the A/C compressor relay.
ECM
BCM
A/C switch Air intake selector
A/C refrigerant pressure sensor
A/C evaporator temperature sensorCompressor relay
ECT sensor
Condensor cooling fan relay
*
Wheel speed sensor (VSS)
HVAC control unit
Blower motor Blower motor resistor
Air intake control actuator
*Blower speed selector
ABS control module
I6RW0C721001-01
*: CAN communication

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A/C System Wiring DiagramS6RW0D7212002
[A]
7
WHT
GRN5YELBLK
3
G154-3
G154-4
G154-7
G154-8
G154-10
G154-13
G154-5
G154-6
G155-5
G155-2
G155-3
G155-7
G155-6
G155-1
G154-9
G154-14
BLK/WHT
YEL
BLU/WHT
RED
BRN
GRN/WHT
RED/BLK
RED
GRN
GRN/YEL
RED/YEL
RED/BLU
20
21
23 22
BLK/RED
6 2
MBLK/WHTBLK/YEL
M
11
4RED/YEL 1
E01-49
12
E01-16
GRY 13
12V
BLU/WHTE01-3510
E01-48
18
19RED/BLK
BLK/RED
BLK/RED
BRN/WHTE01-60
E01-1
E01-29BLK/WHT
M
BLU/YELBLK/YEL
5V5V 5V
WHT/BLK
9
ORN
14E01-36
C01-12C01-14GRY/REDRED/BLU
E01-41
RED/BLK
RED
WHT
8
BLK
BLK/ORN
BLU IG1
IG2
5V
17
28
29
31
2726 2524
16
16
30
34
33E01-4 E01-19WHTRED
C01-50C01-49WHTRED
32
LT GRN
C01-57
C01-2415
GRY/BLU5V
I6RW0C721002-01
[A]: Illumination control model 9. A/C refrigerant pressure
sensor18. Condenser cooling fan relay 27. Illumination light
1. Ignition switch 10. ECM 19. Condenser cooling fan motor 28. Rear defogger relay
2. Blower motor 11. Air intake control actuator 20. Blower speed selector 29. Rear defogger
3. HVAC control unit 12. Compressor relay 21. A/C switch 30. Main relay
4. Lighting switch 13. Compressor 22. Air intake selector 31. Tail light
5. Blower motor relay 14. Evaporator temperature
sensor23. Rear defogger switch 32. TCM
6. Blower motor resistor 15. ECT sensor 24. “A/C” indicator light 33. To other control module and DLC
7. Junction block assembly 16. To BCM 25. “REC” indicator light 34. ABS control module
8. BCM 17. Main fuse box 26. Rear defogger indicator

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Electronic Control System Components LocationS6RW0D7213002
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

[A]
8*
9* 10*
11
1
5
7*
6
7*
12
13
14
1715
1642
3
I6RW0C721003-01
[A]: Junction block assembly viewed from relay side 6. Blower motor relay 12. Air intake selector
1. A/C refrigerant pressure sensor 7. Junction block assembly 13. Rear defogger switch
2. Compressor relay 8. Air intake actuator 14. Temperature selector
3. Condenser cooling fan relay 9. Blower motor 15. Blower speed selector
4. ECT sensor 10. Blower motor resistor 16. Air flow selector
5. Condenser cooling fan 11. HVAC control unit 17. A/C switch