service SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 7B-20 Air Conditioning System: Manual Type
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 directions 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.

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.
4
3
6
2
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Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-21
7) When refrigerant container (1) is emptied, use the
following procedure to replace it with a new
refrigerant container.
a) Close low pressure valve.
b) Replace empty container with a refrigerant
container which has been charged with
refrigerant. When using refrigerant container tap
valve (2), use the following procedure for
replacement.
i) Retract needle (3) and remove refrigerant
container tap valve by loosening its plate nut
(4).
ii) Install the refrigerant container tap valve to a
new refrigerant container.
c) Purge any air existing in center charging hose.
When using refrigerant container tap valve, use
the following procedure to purge air.
i) Once fully tighten refrigerant container tap
valve (1), and then loosen (open) plate nut
(2) slightly.
ii) Open low pressure side valve (3) of manifold
gauge set (4) a little.
iii) As soon as refrigerant comes out with a
“hiss” through a clearance between
refrigerant container and tap valve, tighten
plate nut as well as low pressure side valve.
iv) Turn handle of tap valve clockwise so that its
needle is screwed into the new container to
make a hole for refrigerant flow.8) After the system has been charged with specified
amount of refrigerant or when low pressure gauge
(1) and high pressure gauge (2) have indicated the
following specified value, close low pressure side
valve (3) on manifold gauge set (4).
Specified amount of refrigerant
430 ± 20 g (15.2 ± 0.7 oz))
Low side and high side pressure example
Removal of Manifold Gauge Set
WARNING!
High pressure side is under high pressure.
Therefore, be careful not to get injured
especially on your eyes and skin.

For the A/C system charged with the specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set.
(The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service
valves. This operation must be performed quickly.
5) Put caps on service valves.
I2RH01720018-01
I2RH01720019-01
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
Pressure
on high pressure gauge1130 – 1560 kPa
(11.4 – 15.6 kgf/cm
2)
(162.3 – 221.8 psi)
Pressure
on low pressure gauge270 – 390 kPa
(2.7 – 3.9 kgf/cm
2)
(38.8 – 56.0 psi)
4
2
1
3
I7RW01721013-02

Downloaded from www.Manualslib.com manuals search engine 7B-22 Air Conditioning System: Manual Type
Check A/C System for Refrigerant Leaks
Whenever a refrigerant leak is suspected in the system
or any service operation has been performed which may
result in malfunction of lines and connections, it is
advisable to check for leaks.
Common sense should be used during refrigerant leak
test, since the need and extent of any such test will, in
general, depend upon the nature of a complaint and the
type of a service performed on the system.
Liquid leak detector
WARNING!
• To prevent explosions and fires, make sure
that there are no flammables in the vicinity.
• When the refrigerant exposed to fire, it
turns into a poisonous gas (phosgene). Do
not inhale this gas.

There is a number of fittings and places throughout the
A/C system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question
with a swab, such as attached to the cap of a vial,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator
and condenser, an electronic (refrigerant) leak detector
is more practical for determining leaks.
Special tool
(A): 09990–86012
Condenser Cooling Fan Removal and
Installation
S6RW0D7216002
CAUTION!
Be careful not to damage fins of radiator. If
radiator fin is bent, straighten it by using flat
head screwdriver or pair of pliers.

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect condenser cooling fan motor coupler.
3) Remove reservoir (1) from radiator.
4) Remove condenser cooling fan (2) from radiator (3).
Installation
Reverse removal procedure to install condenser cooling
fan.
(A)
I5RW0A721054-01
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2
I5RW0A721017-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-37
Specifications
Tightening Torque SpecificationsS6RW0D7217001
NOTE
The specified tightening torque is also described in the following.
“A/C System Major Components Location”
“Compressor Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D7218001
NOTE
Required service material is also described in the following.
“HVAC Unit Components”
“Compressor Assembly Components”

Special ToolS6RW0D7218002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Expansion valve bolt 4.5 0.45 3.5)
A/C refrigerant pressure sensor 11 1.1 8.0)
Compressor mounting bolt 25 2.5 18.0)
Armature plate nut 16 1.6 11.5)
Relief valve 8 0.8 6.0)
Material SUZUKI recommended product or Specification Note
Compressor oil MATSUSHITADENKI GU10 P/No.: 99000–99015–
00A)
Silicon sealant SUZUKI SILICON SEALANT KE-
347W (100g)P/No.: 99000–34220)
09900–06107 09990–06020
Snap ring pliers (opening
type)Manifold gauge set (R134a)
) / ) / ) / ) / )1.Manifold gauge
2.Charging hoses 3.Quick
connector 4.Refrigerant
container tap valve
5.Refrigerant container T
joint 6.Packing sets 7.Case
)
09990–86012 09991–06310
Gas leak detector Armature plate holder
This kit includes following
items.1. Gas leak detector,
2. Instruction manual, 3.
Filter, 4. Sensor, 5. Dri-sell
battery (size D) ) / )) / )
12
34
5

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-85
Blower Motor Controller InspectionS6RW0D7226012
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 controller resistance
“1” – “2”: approximately 10 kΩ
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 bulb (3.4 W) (5) and service wire, connect
battery positive terminal to “3” terminal of blower
motor controller as shown in figure.
b) Using service wire, connect battery negative
terminal to “1” terminal of blower motor
controller.
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 terminal 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.
HVAC Control Module Removal and InstallationS6RW0D7226013
Removal
1) Remove audio unit from instrument panel referring to
“Audio Unit Removal and Installation (If Equipped) in
Section 9C”.
2) Remove HVAC control module (1) with its garnish (2)
from instrument panel.
3) Remove HVAC control module from garnish.
Installation
Reverse removal procedure.
Sunload Sensor Removal and InstallationS6RW0D7226014
Removal
1) Disconnect negative (–) cable at battery.
2) Remove combination meter from instrument panel
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).
21
43
3
1 2 4
5
6I7RW01722027-01
12
I5RW0A722024-02
1
2
I7RW01722028-01

Downloaded from www.Manualslib.com manuals search engine 7B-88 Air Conditioning System: Automatic Type
Special Tools and Equipment
Recommended Service MaterialS6RW0D7228001
NOTE
Required service material is also described in the following.
“HVAC Unit Components”

Special ToolS6RW0D7228002
SUZUKI scan tool
—
This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12. ) / )

Downloaded from www.Manualslib.com manuals search engine Table of Contents 8- i
8
Section 8
CONTENTS
Restraint
Precautions ................................................. 8-1
Precautions............................................................. 8-1
Precautions on Restraint ....................................... 8-1
Seat Belts ................................................. 8A-1
Precautions........................................................... 8A-1
Precautions on Service and Diagnosis of Seat
Belt .................................................................... 8A-1
General Description ............................................. 8A-2
Seat Belt Construction ........................................ 8A-2
Diagnostic Information and Procedures ............ 8A-3
Repair and Inspection Required after
Accident ............................................................ 8A-3
Repair Instructions .............................................. 8A-4
Front Seat Belt Components ............................... 8A-4
Front Seat Belt Removal and Installation ............ 8A-5
Front Seat Belt Inspection................................... 8A-6
Rear Seat Belt Components ............................... 8A-7
Rear Seat Belt Removal and Installation ............ 8A-8
Rear Seat Belt Inspection ................................... 8A-8
Specifications....................................................... 8A-8
Tightening Torque Specifications ........................ 8A-8
Air Bag System ........................................ 8B-1
Precautions........................................................... 8B-1
Precautions on Service and Diagnosis of Air
Bag System....................................................... 8B-1
Precautions on Handling and Storage of Air
Bag System Components ................................. 8B-1
Precautions on Disposal of Air Bag and Seat
Belt Pretensioner .............................................. 8B-5
General Description ............................................. 8B-5
Air Bag System Construction .............................. 8B-5
Air Bag System Block Diagram ........................... 8B-6
Air Bag System Input / Output Table .................. 8B-7
Schematic and Routing Diagram ........................ 8B-8
Air Bag System Wiring Circuit Diagram .............. 8B-8
Component Location ......................................... 8B-11
Air Bag System Components, Wiring and
Connectors Location ....................................... 8B-11
Diagnostic Information and Procedures .......... 8B-12
Air Bag Diagnostic System Check .................... 8B-12
Air Bag Diagnostic System Check Flow ............ 8B-13
DTC Table ......................................................... 8B-14DTC Check........................................................ 8B-18
DTC Clearance ................................................. 8B-18
Scan Tool Data ................................................. 8B-18
“AIR BAG” Warning Light Comes ON Steady ... 8B-19
“AIR BAG” Warning Light Does Not Come ON .. 8B-22
Serial Data Link Circuit Check .......................... 8B-23
DTC B1013: SDM Internal Failure .................... 8B-25
DTC B1014: “AIR BAG” Warning Light Circuit .. 8B-26
DTC B1016: Power Supply Voltage too High.... 8B-26
DTC B1017: Power Supply Voltage too Low .... 8B-27
DTC B1021: Front Air Bag Deployment
Record............................................................. 8B-28
DTC B1024 / B1025: Side Air-Bag
Deployment Record ........................................ 8B-29
DTC B1026: Seat Belt Pretensioner
Activation Record ............................................ 8B-29
DTC B1027: Number of Deployment Times
Exceeded Limit................................................ 8B-30
DTC B1031: Driver Air Bag Circuit High
Resistance ...................................................... 8B-31
DTC B1032: Driver Air Bag Circuit Low
Resistance ...................................................... 8B-33
DTC B1033: Driver Air Bag Circuit Shorted to
Ground ............................................................ 8B-35
DTC B1034: Driver Air Bag Circuit Shorted to
Power Supply .................................................. 8B-37
DTC B1041: Passenger Air Bag Circuit High
Resistance ...................................................... 8B-40
DTC B1042: Passenger Air Bag Circuit Low
Resistance ...................................................... 8B-43
DTC B1043: Passenger Air Bag Circuit
Shorted to Ground........................................... 8B-45
DTC B1044: Passenger Air Bag Circuit
Shorted to Power Supply ................................ 8B-46
DTC B1051 / B1055: Seat Belt Pretensioner
Circuit High Resistance ................................... 8B-48
DTC B1052 / B1056: Seat Belt Pretensioner
Circuit Low Resistance.................................... 8B-51
DTC B1053 / B1057: Seat Belt Pretensioner
Shorted to Ground........................................... 8B-52
DTC B1054 / B1058: Seat Belt Pretensioner
Circuit Shorted to Power Supply ..................... 8B-54
DTC B1061 / B1065: Side-Air Bag Circuit
High Resistance .............................................. 8B-55

Downloaded from www.Manualslib.com manuals search engine Precautions: 8-1
Restraint
Precautions
Precautions
Precautions on RestraintS6RW0D8000001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Fastener Caution
Refer to “Fastener Caution in Section 00”.
Precautions on Service and Diagnosis of Seat Belt
Refer to “Precautions on Service and Diagnosis of Seat Belt in Section 8A”.
Precautions on Service and Diagnosis of Air Bag System
Refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Precautions on Handling and Storage of Air Bag Components
Refer to “Precautions on Handling and Storage of Air Bag System Components in Section 8B”.
Precautions on Disposal of Air Bag and Seat Belt Pretensioner
Refer to “Precautions on Disposal of Air Bag and Seat Belt Pretensioner in Section 8B”.

Downloaded from www.Manualslib.com manuals search engine 8A-1 Seat Belts:
Restraint
Seat Belts
Precautions
Precautions on Service and Diagnosis of Seat BeltS6RW0D8100001
WARNING!
If replacing seat belt is necessary, replace buckle and seat belt together as a set. This is for the reason
of ensuring locking of tongue plate with buckle. If these parts are replaced individually, such a locking
condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle and seat
belt assembly in a set part.

Before servicing or replacing seat belts, refer to the following precautionary items.
• Seat belts should be normal relative to strap retractor and buckle portions.
• Keep sharp edges and damaging objects away from belts.
• Avoid bending or damaging any portion of belt buckle or latch plate.
• Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)
• When installing a seat belt anchor bolt, it should be tightened by hand at first to prevent cross-threading and then to
specified torque.
• Do not attempt any repairs on retractor mechanisms or retractor covers. Replace defective assemblies with new
replacement parts.
• Keep belts dry and clean at all times.
• If there exist any parts in question, replace such parts.
• Replace belts whose webbing is cut or otherwise damaged.
• Do not put anything into trim panel opening which seat belt webbing passes through.

Downloaded from www.Manualslib.com manuals search engine 8A-3 Seat Belts:
Seat Belt with ELR
The seat belt with emergency locking retractor (ELR) is
designed so that it locks immediately (to prevent the
webbing from being pulled out of the retractor any
further) when any of the following items is detected as
exceeding each set value;
• Speed at which the webbing is pulled out of the
retractor.
• Acceleration or deceleration of the vehicle speed.
• Inclination.
Seat Belt with A-ELR
The automatic and emergency locking retractor (A-ELR)
works as an Emergency Locking Retractor (ELR) till its
webbing is pulled all the way out and then on as an
Automatic Locking Retractor (ALR) till it is retracted fully.
ALR: Automatically locks when the webbing is pulled out
from the retractor and allowed to retract even a little.
Then the webbing can not be pulled out any further,
unless it is wound all the way back into the retractor,
which releases the lock and allows the webbing to be
pulled out.
Seat Belt with ELR and Pretensioner
The seat belt with ELR and a pretensioner has a
pretensioner mechanism which operates in linkage with
the air bag in addition to the described ELR.The pretensioner is incorporated in retractor and
controlled by SDM as one of air bag system
components. It will be activated at the same time as the
driver and passenger air bag module when an impact at
the front of vehicle exceeds the specified value.
When servicing seat belt (retractor) with pretensioner, be
sure to observe all WARNINGS and CAUTIONS and
“Precautions on Service and Diagnosis of Air Bag
System in Section 8B”.
CAUTION!
Do not reuse the seat belt pretensioner
(retractor) that has activated. Replace it with
a new seat belt and buckle together as a set.
For checking procedure of its activation,
refer to “Repair and Inspection Required after
Accident in Section 8B”.

Seat Belt Remainder
When driver’s seat belt is unfastened (under the
following conditions), seat belt reminder light inform that
driver’s seat belt is unfastened. Seat belt reminder light
located in combination meter located inside BCM
operate as follows:
• Seat belt reminder light comes on when driver’s seat
belt is unfastened while ignition key switch is at ON
position.
Diagnostic Information and Procedures
Repair and Inspection Required after AccidentS6RW0D8104001
After an accident, whether the seat belt pretensioner has been activated or not, be sure to perform checks and repairs
described on “Repair and Inspection Required after Accident in Section 8B”.