engine mount SUZUKI SX4 2006 1.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-39
General Description
Auto A/C System DescriptionS6RW0D7221001
The automatic type air conditioning system (auto A/C) is provided with the function to automatically control the inside
air temperature, fan speed, air flow outlet direction and air intake position by HVAC control module in addition to
functions of the manual type air conditioning system (manual 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 air temperature, amount of sunlight and engine coolant
temperature detected respectively by the inside air temperature sensor, outside air temperature sensor, sunload
sensor and ECT sensor. For the electronic control system components location, refer to “Electronic Control System
Components Location”. For the A/C system components location, refer to “A/C System Major Components Location”.
Auto A/C Electronic Control Input / Output Table
Temperature selector
MODE (air flow) selector
Blower speed selector
Air intake selector
AUTO switch A/C switch
Outside air
temperature
sensor
A/C refrigerant pressure sensor
Compressor relay
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
Sunload sensor
Inside air temperature sensor
Evaporator temperature sensor
Condenser cooling fan relay
Wheel
speed
sensor
*
*
*
Combination meterABS control module
I6RW0C722001-01
*: CAN communication

Downloaded from www.Manualslib.com manuals search engine 7B-48 Air Conditioning System: Automatic Type
Cool air does not come
out or insufficient cooling
(A/C compressor normal
operation)Insufficient or excessive charge of
refrigerantCheck the amount of refrigerant and system
for leaks.
Condenser cloggedCheck condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
A/C evaporator clogged or frostedCheck A/C evaporator and evaporator
temperature sensor referring to “Evaporator
Inspection” and “Evaporator Temperature
Sensor Inspection”.
Evaporator temperature sensor faultyCheck evaporator temperature sensor
referring to “Evaporator Temperature Sensor
Inspection”.
Expansion valve faultyCheck expansion valve referring to “Expansion
Valve Inspection”.
Desiccant cloggedCheck desiccant and cap with filter.
Compressor drive belt loosened or
brokenAdjust or replace drive belt.
Magnet clutch faultyCheck magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor faultyCheck compressor.
Air in A/C systemReplace condenser, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Air leaking from HVAC unit or air ductRepair as necessary.
Heater and ventilation system faultyCheck HVAC unit.
HVAC control module faultyCheck HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
Temperature control actuator faultyCheck temperature control actuator referring to
“Temperature Control Actuator and Its Circuit
Inspection”.
Blower motor faultyCheck blower motor referring to “Blower Motor
Inspection in Section 7A”.
Excessive compressor oil in A/C systemDrain excessive compressor oil from A/C
system circuit and compressor.
Cool air does not come
out only intermittentlyWiring connection faultyRepair as necessary.
Expansion valve faultyCheck expansion valve referring to “Expansion
Valve Inspection”.
Excessive moisture in A/C systemReplace condenser, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Magnet clutch faultyCheck magnet clutch referring to “Magnet
Clutch Inspection”.
Excessive amount of refrigerantCheck the amount of refrigerant.
Cool air comes out only at
high speedCondenser cloggedCheck condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
Insufficient charge of refrigerantCheck the amount of refrigerant and system
for leaks.
Air in A/C systemReplace condenser, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Compressor drive belt loosened or
brokenAdjust or replace drive belt.
Compressor faultyCheck compressor.
Cool air does not come
out only at high speedExcessive amount of refrigerantCheck the amount of refrigerant.
A/C evaporator frostedCheck A/C evaporator and evaporator
temperature sensor referring to “Evaporator
Inspection” and “Evaporator Temperature
Sensor Inspection”. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 7B-54 Air Conditioning System: Automatic Type
DTC of A/C System detected by ECM
NOTE
When no DTC is detected, “FRE” [A] and “REC” [B] indicator lights on HVAC control module flash at
the same time in specific pattern.

Fail-Safe TableS6RW0D7224007
When any of the following malfunctions (DTCs) is detected, fail-safe mode is activated.
However, when HVAC control module detects normal operation of A/C system, fail-safe mode is canceled. DTC No. Detection itemDetecting condition
(DTC will set when detecting)MIL
P0481 Fan 2 Control Circuit
Refer to “Fail-Safe Table in Section 1A”. P0532A/C Refrigerant Pressure
Sensor Circuit Low
P0533A/C Refrigerant Pressure
Sensor Circuit High
H: ON a. About 3 seconds
L: OFF b. About 1 seconds
DTC No. Trouble AreaFail-Safe Operation
When ignition switch is turned ON
after malfunction is already detectedWhen malfunction is detected during
ignition switch is ON
) B1502Inside air temperature
sensor circuitHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that inside air temperature is
25 °C (77 °F).
) B1503A/C evaporator
temperature sensor
circuitHVAC control module assuming that
evaporator temperature is 0 °C (32 °F).• HVAC control module turns off A/C
switch signal.
• HVAC control module controls
actuators assuming that evaporator
temperature is 0 °C (32 °F).
) B1504 Sunload sensor circuitHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that amount of sunlight is 0 W/
m
2.
) B1520Temperature selector
malfunctionHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that setting of temperature
selector is 25 °C (77 °F) position.
) B1521Blower speed selector
malfunctionHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that setting of blower speed
selector is low (1st) position.
) B1522Air flow selector
malfunctionHVAC control module maintains last
normal value.HVAC control module controls actuators
assuming that setting of air flow selector
is DEF position.
[A]
[A]H
L
H
L [B]
[B]
baaba
baaba
I5RW0A722008-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-57
SUN LOAD (W/m2): This parameter indicates the
amount of sunlight detected by sunload sensor.
MODE CONT SWITCH (Air flow selector position,
AUTO, FACE, B/L, FOOT, D/F, DEF): This
parameter indicates the selected position of air flow
selector.
FAN CONT SWITCH (Blower speed selector, AUTO,
OFF, 1st – 8th): This parameter indicates the
selected position of blower speed selector.
FAN DESIRE VOLT (Fan desired voltage, V): This
parameter indicates the consumption voltage of
blower motor.
AIR MIX POS SENSOR (Temperature control
actuator position sensor, V): This parameter
indicates the input signal from position sensor in
temperature control actuator.
MODE POS SENSOR (Air flow control actuator
position sensor, V): This parameter indicates the
input signal from position sensor in air flow control
actuator.
A/C CONT SIG (A/C control signal, ON, OFF): This
parameter indicates the state of A/C switch.BLOWER LOAD SIG (Blower fan load signal, ON,
OFF): ON: Position of blower speed selector is 1st
position or more.
OFF: Position of blower speed selector is OFF
position.
AIR INTAKE MODE (Air intake selector position,
AUTO, FRE, REC): This parameter indicates the
selected position of air intake selector.
REFRIGERANT PRESSURE (A/C refrigerant absolute
pressure, kPa): This parameter indicates the A/C
refrigerant absolute pressure calculated by ECM
A/C COMP CLUCH (A/C compressor magnet clutch,
ON, OFF): This parameter indicates the state of the
A/C compressor magnet clutch.
VEHICLE SPEED (km/h, mph): This parameter
indicates the vehicle speed calculated by ECM.
ENGINE TYPE (Engine type signal, J20, M16 or
M15): This parameter indicates the engine type
signal transmitted by ECM.
METER SPEC (Combination meter spec signal, EU,
UK, US, Canada, DOM): This parameter indicates
the combination meter spec signal transmitted by
combination meter.
Visual InspectionS6RW0D7224009
Check visually the following parts and systems.
DTC B1502: Inside Air Temperature Sensor Circuit MalfunctionS6RW0D7224010
Wiring DiagramInspection item Correction
• Refrigerant leakage and amount
• A/C pipe or hose disconnection,
looseness and
deterioration
• A/C compressor drive belt looseness and damageRefer to “Compressor Drive Belt Inspection
and Adjustment”.
• Battery fluid level and corrosion
of terminal
• Connectors of electric wire harness disconnection and
friction
• Fuses burning
• Parts installation and damage
• Other parts that can be checked visually
5V
G20
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30
ORNORNPNK/BLKG20-10
21
3 [S]
[G]
G20-24
I7RW01722004-01
[S]: Inside air temperature sensor signal circuit 1. HVAC control module 3. To other sensors
[G]: Inside air temperature sensor ground circuit 2. Inside air temperature sensor

Downloaded from www.Manualslib.com manuals search engine 7B-70 Air Conditioning System: Automatic Type
DTC B1546: A/C Refrigerant Pressure MalfunctionS6RW0D7224019
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
DTC B1551: Serial Communication Circuit MalfunctionS6RW0D7224020
Wiring DiagramDTC detecting condition Trouble area
• A/C refrigerant pressure sensor signal voltage is lower than specified value
even though outside air temperature is higher than specified value for
specified time continuously.
• Insufficient refrigerant in A/C system• Insufficient of refrigerant
• A/C refrigerant pressure sensor
• Outside air temperature sensor
• HVAC control module
Step Action Yes No
1Was “Air Conditioning System Check” performed?Go to Step 2. Go to “Air Conditioning
System Check”.
2DTC check
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ignition switch to ON position and check DTC in
BCM.
Is DTC B1141 or B1142 (BCM) detected?Go to applicable DTC
diag. flow.Go to Step 3.
3DTC check
Check DTC in ECM.
Is DTC P0532 or P0533 detected?Go to applicable DTC
diag. flow.Go to Step 4.
4A/C refrigerant pressure and outside air temperature
data check
1) Start engine and select “DATA LIST” mode on scan tool.
2) Check “Refrigerant Pressure” and “Outside Air Temp”
displayed on scan tool.
Are values of A/C refrigerant pressure sensor and outside air
temperature within specified ranges indicated in “Scan Tool
Data”?Substitute a known-
good HVAC control
module and recheck.Check the amount of
refrigerant and system
for leaks.
12V
G20
G20-13YEL
1 2 3 4 5 6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 24 23 22 25 26 27 28 29 30
1
2 3
[S]WHT/REDWHTG20-7
12V5V
[B]4 4
I7RW01722012-02
[B]: Back-up power supply circuit 1. HVAC control module 3. Information display
[S]: Serial communication circuit 2. BCM 4. Circuit fuse

Downloaded from www.Manualslib.com manuals search engine 7B-78 Air Conditioning System: Automatic Type
G20-25 PNK Sunload sensor signalApprox. 3.5 VIgnition switch turned ON, amount of insolation is
500 W/m2
Approx. 5 VIgnition switch turned ON, amount of insolation is 0
W/m2
G20-26 BLK/RED Rear defogger indicator0 – 1 V Ignition switch turned ON, rear defogger switch OFF
10 – 14 V Ignition switch turned ON, rear defogger switch ON
G20-27 YELTemperature control
actuator position sensor
signalApprox. 0.5 VIgnition switch turned ON, temperature selector
“MAX COOL” position
Approx. 4.5 VIgnition switch turned ON, temperature selector
“MAX HOT” position
G20-28 WHT/BLUAir flow control actuator
position sensor signalApprox. 0.5 VIgnition switch turned ON, air flow selector “FACE”
position
Approx. 4.5 VIgnition switch turned ON, air flow selector “DEF”
position
G20-29 GRY Blower motor controller0 – 1 VIgnition switch turned ON, blower speed selector
OFF position
2 – 3.5 VIgnition switch turned ON, blower speed selector
between 1st and 6th position
Approx. 10.0
VIgnition switch turned ON, blower speed selector 7th
and HIGH position
G20-30 BLU/REDBlower motor control
voltage feedback10 – 14 VIgnition switch turned ON, blower speed selector
OFF position
Approx. 8.1 VIgnition switch turned ON, blower speed selector 1st
position
Approx. 6.8 VIgnition switch turned ON, blower speed selector 2nd
position
Approx. 5.5 VIgnition switch turned ON, blower speed selector 3rd
position
Approx. 4.0 VIgnition switch turned ON, blower speed selector 4th
position
Approx. 2.6 VIgnition switch turned ON, blower speed selector 5th
position
Approx. 1.2 VIgnition switch turned ON, blower speed selector 6th
position
Approx. 0.2 VIgnition switch turned ON, blower speed selector 7th
and HIGH position Terminal Wire Color CircuitNormal
Vo l ta g eCondition

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-4
Repair Instructions
Front Seat Belt ComponentsS6RW0D8106001
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor). If any abnormality is
found, be sure to replace it with new one as an assembly.
• Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and
observe every precaution during work. Neglecting them may result in personal injury or
unactivation of the seat belt pretensioner when necessary.

I7RW01810002-01
1. Sash guide 10. Buckle mounting bolt
2. Anchor plate 11. Sash guide bolt
: Tighten sash guide bolt first, then tighten anchor bolt.
3. Retractor 12. Spacer
4. Buckle 13. Washer
5. Yellow connector (for seat belt pretensioner) 14. Spring washer
6. Retractor mounting bolt 15. Wave washer
7. Shoulder adjuster : 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
8. Shoulder adjuster bolt
: Tighten upper bolt first, then tighten lower bolt.: 5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)
9. Anchor bolt
: Tighten sash guide bolt first, then tighten anchor
bolt.

Downloaded from www.Manualslib.com manuals search engine 8A-7 Seat Belts:
Rear Seat Belt ComponentsS6RW0D8106004
WARNING!
Be sure to read “Precautions on Service and Diagnosis of Seat Belt” before starting to work and
observe every precaution during work.

I6RW0C810002-01
[A]: A-ELR rear center seat belt model 9. Anchor bolt
: Tighten retractor mounting bolts and sash guide bolt first, then tighten
anchor bolt.
[B]: Non-A-ELR rear center seat belt model 10. Buckle bolt
1. Sash guide 11. Center retractor
2. Anchor plate 12. Center retractor mounting bolt
: Tighten lower bolt first, then tighten upper bolt.
3. Side retractor 13. Sash guide bolt
: Tighten sash guide bolt first, then tighten side retractor mounting bolt.
4. Center seat belt 14. Spring washer
5. Buckle for seat belt 15. Washer
6. Buckle for center seat belt 16. Spacer
7. Seat belt: 43 N⋅m (4.3 kgf-m, 31.5 lb-ft)
8. Side retractor mounting bolt
: Tighten sash guide bolt first, then tighten side retractor mounting bolt.:5.5 N⋅m (0.55 kgf-m, 4.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-2
• Never attempt disassembly of SDM.
• When storing SDM, select a place where neither high
temperature nor high humidity is anticipated and oil,
water and dust are kept off.
• If SDM has been dropped, replace it with a new one.
• If SDM installation part of floor was damaged, repair
that part completely before reinstallation.
• All SDM and mounting bracket fasteners must be
carefully torqued and the arrow must be pointed
toward the front of the vehicle to ensure proper
operation of the air bag system.
Live (Undeployed) Air Bag (Inflator) Modules
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) modules.
The rapid gas generation produced during deployment
of the air bag could cause the air bag (inflator) module,
or an object in front of the air bag (inflator) module, to be
thrown through the air in the unlikely event of an
accidental deployment.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver module,
passenger module and side modules and
curtain modules). It is very dangerous as the
electric current from the tester may deploy
the air bag.

• Never attempt disassembly of the air bag (inflator)
modules.
• If any abnormality is found, be sure to replace it with
new one as an assembly.
• When an abnormality is noted as existing in the live
(undeployed) air bag (inflator) module, be sure to
deploy it before discarding it.
• When grease, cleaning agent, oil, water, etc., got on
the air bag (inflator) modules (driver and passenger),
wipe it off immediately with a dry cloth.
• If air bag (inflator) module was dropped from a height
of 90 cm (3 ft) or more, it should be replaced with a
new one as an assembly.
I5RW0A820001-03
I7RW01821001-01
I6RW0B820001-01

Downloaded from www.Manualslib.com manuals search engine 8B-21 Air Bag System:
NOTE
Upon completion of inspection and repair work, perform the following items.
• Reconnect all air bag system components and ensure all components are properly mounted.
• Repeat “Air Bag Diagnostic System Check” to confirm that the trouble has been corrected.

5“AIR BAG” warning light circuit check
1) Connect SDM connector “L04” and combination meter
connector “G241”.
2) With ignition switch turned ON, measure voltage
between “G241-5” terminal and body ground.
Special tool
(A): 09932–76010
Is measured voltage in 8 – 12 V?Replace combination
meter.Go to Step 6.
6“AIR BAG” warning light circuit check
1) Disconnect combination meter connector “G241”.
2) Measure voltage between “G241-5” terminal and body
ground.
Special tool
(A): 09932–76010
Is measured voltage in 10 – 14 V?Replace combination
meter.Replace SDM. Step Action Yes No
“G241-5”(A)
I7RW01822008-01
“G241-5”(A)
I7RW01822008-01