tail SUZUKI SX4 2006 1.G Service Owner's Guide

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Terminal Arrangement of P/S Control Module Coupler (Viewed from Harness Side)
Diagnostic Information and Procedures
EPS System CheckS6RW0D6304001
WARNING!
Carry out test drive in light traffic area to prevent an accident.

Refer to the following items for the details of each step.Terminal Circuit Terminal Circuit
E11-1Ignition switch signal for P/S control
moduleE11-13 —
E11-2 — E11-14 P/S active signal (idle up signal)
E11-3 — E11-15 —
E11-4 Vehicle speed signal E11-16 —
E11-5 “EPS” warning Light E11-17 —
E11-6 — E11-18 Torque sensor signal (Main)
E11-7 — E11-19 Ground for shield wire
E11-8 9 V power supply for torque sensor E11-20Reference sensor power supply for
torque sensor
E11-9 Ground for torque sensors E12-1 Motor output 1
E11-10 Torque sensor signal (Sub) E12-2 Motor output 2
E11-11Serial communication circuit for data
link connectorE13-1Main power supply for internal
memory and EPS motor
E11-12 Engine speed signal E13-2 Ground for P/S control module
Step Action Yes No
1) Customer complaint analysis
1) Perform customer complaint analysis referring to
“Customer Complaint Analysis”.
Was customer complaint analysis performed?Go to Step 2. Perform customer
complaint analysis.
2) DTC check, record and clearance
1) Check for DTC (including pending DTC) referring to
“DTC Check, Record and Clearance”.
Is there any DTC(s)?Print DTC or write them
down and clear them by
referring to “DTC
Clearance”, and go to
St ep 3 .Go to Step 4.
3) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition?Repair or replace
malfunction part, and go
to Step 11.Go to Step 5.
4) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition?Repair or replace
malfunction part, and go
to Step 11.Go to Step 8.
5) Trouble symptom confirmation
1) Confirm trouble symptom referring to “Trouble Symptom
Confirmation”.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 8.
7) Rechecking and record of DTC
1) Recheck for DTC referring to “DTC Check”.
Is there any DTC(s)?Go to Step 9. Go to Step 10.

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Step 1: Customer Complaint Analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose,
use of such an inspection form will facilitate collecting information to the point required for proper analysis and
diagnosis. Check if the problem described in “Customer questionnaire” actually occurs in the vehicle if necessary.
(This step should be performed with the customer if possible)
Customer questionnaire (Example)
NOTE
This form is a standard sample. It should be modified according to conditions characteristic of each
market.

Step 2: DTC check, record and clearance
First, referring to “DTC Check”, check DTC (including
pending DTC). If DTC exists, print or write down DTC
and then clear them by referring to “DTC Clearance”.
DTC indicates malfunction in the system but it is not
possible to know from it whether the malfunction is
occurring now or it occurred in the past and normal
condition has been restored. In order to know that, check
symptom in question according to Step 5 and then
recheck DTC according to Step 6 and 7.
Diagnosing a trouble based on the DTC in this step only
or failure to clear the DTC in this step may result in an
faulty diagnosis, trouble diagnosis of a normal circuit or
difficulty in troubleshooting which is otherwise
unnecessary.Step 3 and Step 4: Visual inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the P/S system
referring to “Visual Inspection”.
Step 5: Trouble Symptom Confirmation
Based on information obtained in “Step 1: Customer
Complaint Analysis:” and “Step 2: DTC Check, Record
and Clearance:”, confirm trouble symptoms. Also,
reconfirm trouble symptom by performing test drive and
turning steering wheel fully to right and left at stopped
vehicle.
Step 6 and 7: Rechecking and Record of DTC
Refer to “DTC Check” for checking procedure.
I7RW01632004-02

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Step 8: Steering Symptom Diagnosis and P/S
System Symptom Diagnosis
Perform basic steering system check according to
“Steering Symptom Diagnosis in Section 6A” first. When
the end of the flow has been reached, check the parts of
the system suspected as a possible cause referring to
“P/S System Symptom Diagnosis” and based on
symptoms appearing on the vehicle (symptoms obtained
through steps of customer complaint analysis, trouble
symptom confirmation and/or basic P/S system check)
and repair or replace faulty parts, if any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, P/S control module or other part and
repair or replace faulty parts.
Step 10: Intermittent Problems Check
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of DTC recorded in Step 2.
Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and the P/
S system is free from any abnormal conditions. If what
has been repaired is related to the DTC, clear the DTC
once, perform DTC confirmation procedure and confirm
that no DTC is indicated.
“EPS” Warning Light CheckS6RW0D6304002
1) Turn ignition switch to ON position (but without
running engine) and check if the “EPS” warning light
(1) lights up. If the light dose not light up, go to
““EPS” Warning Light Does Not Come ON with
Ignition Switch Turned ON before Engine Starts” of
the diagnostic flows.
2) Start engine and check that “EPS” warning light turns
OFF. If light remains ON and no DTC is stored in P/S
control module, go to ““EPS” Warning Light Remains
ON Steady after Engine Starts” for troubleshooting.
DTC CheckS6RW0D6304003
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool
3) Start engine.
4) Read DTC according to the instructions displayed on
SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
NOTE
• If communication between SUZUKI scan
tool and the vehicle can not be
established, perform “DLC and Its
Communication Check (No communication
to P/S Control Module)”.
• DTC C1122 (engine speed signal failure) is
indicated when ignition switch is at ON
position and engine is not running, but it
means there is nothing abnormal if
indication changes to a normal one when
engine is started.

5) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
1
I7RW01632002-01
(A)
1I5RW0A630004-01

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DTC ClearanceS6RW0D6304004
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(DLC) (1) located on underside of instrument panel
at driver’s seat side.
Special tool
(A): SUZUKI scan tool3) Turn ignition switch to ON position.
4) Erase DTC according to the instructions displayed
on SUZUKI scan tool. For further details, refer to
operator’s manual for SUZUKI scan tool.
5) After completing the clearance, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
DTC TableS6RW0D6304005
CAUTION!
Be sure to perform the “EPS System Check” before starting troubleshooting corresponding to each
DTC.

(A)
1I5RW0A630004-01
DTC No. Detecting itemDetecting condition
(DTC will set when detecting)Trouble area DTC“EPS”
warning
light
No
CODESNormal — — — —
) C1111Steering torque sensor
(Main) circuit voltageCircuit voltage of sensor main is
more than 4.5 V or less than 0.5
V
• Torque sensor signal
circuit
• Torque sensor
• P/S control module1 driving
cycle1 driving
cycle
)
C1113Steering torque sensor
(Main and Sub) circuit
correlationDifference between steering
torque calculated based on
sensor main signal and steering
torque calculated based on
sensor sub signal is more than
4.9 N⋅m
or
Difference between
instantaneous value and average
value of steering torque
calculated based on sensor main
signal and steering torque
calculated based on sensor sub
signal is more than 2.94 N⋅m1 driving
cycle1 driving
cycle
)
C1115Steering torque sensor
(Sub) circuit voltageCircuit voltage of sensor sub
signal is more than 4.5 V or less
than 0.5 V1 driving
cycle1 driving
cycle
)
C1116Steering torque sensor
power supply circuit Circuit voltage of torque sensor 9
V power supply is less than 7 V• Torque sensor 9 V
power supply circuit
• Torque sensor
• P/S control module1 driving
cycle1 driving
cycle

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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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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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Thermometer at center ventilation louver
Trouble Diagnosis for Abnormal PressureS6RW0D7214002
NOTE
Normal pressure values on high side and low side in following table are measured when the ambient
temperature is 30 °C. As normal pressure values on high side and low side vary depending on the
ambient temperature, be sure to perform following steps first when diagnosing troubles.
1. Measure the ambient temperature and using that value, read the normal value from the graph given
in Step 10 of “A/C System Performance Inspection”.
2. Put that value in place of the normal pressure in following table.

Condition Possible cause Correction
Crossing point is higher
than acceptable range
(“E” area)Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in
cooling (heater) unitRepair or replace.
Compressor malfunction Check compressor.
Crossing point is lower
than acceptable range
(“F” area)Insufficient air volume from center duct (Heater
blower malfunction)Check blower motor and fan.
Compressor malfunction Check compressor.
Condition
Possible cause Correction Manifold gauge MPa (kgf/cm2) (psi)
Detail
Lo Hi
0.27 – 0.39
(2.7 – 3.9)
(38.8 – 56.0)1.13 – 1.56
(11.4 – 15.6)
(162.3 – 221.8)Normal condition
——
Negative pressure 0.5 – 0.6
(5 – 6)
(71.2 – 85.3)The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.
Presence of frost around
tubing to and from
receiver/dryer and
expansion valve.Dust particles or water
droplets are either
stuck or frozen inside
expansion valve,
preventing the
refrigerant from
flowing.Replace expansion
valve.
Replace desiccant and
cap with filter.
Evacuate the A/C
system and recharge
with fresh refrigerant.
Normal:
0.27 – 0.39
(2.7 – 3.9)
(38.8 – 56.0)
↑ ↓
Abnormal:
Negative pressureNormal:
1.13 – 1.56
(11.4 – 15.6)
(162.3 – 221.8)
↑ ↓
Abnormal:
0.7 – 1.0
(7 – 10)
(100 – 142)During A/C operation, the
low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.Expansion valve is
frozen due to moisture
in the system, and
temporarily shuts off
the refrigeration cycle.Replace expansion
valve.
Replace desiccant and
cap with filter.
Evacuate A/C system
and recharge with
fresh refrigerant.

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A/C System Inspection at ECMS6RW0D7214003
When checking voltage at ECM terminals related to A/C system, refer to “Inspection of ECM and Its Circuits in Section
1A”.0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3)0.7 – 1.0
(7 – 10)
(100 – 142)Both low and high
pressure sides indicate
low readings.
Output air is slightly cold.Insufficient refrigerant
in system
(Refrigerant leaking).Using leak detector,
check for leaks and
repair as necessary.
Recharge refrigerant to
a specified amount.
If the pressure reading
is almost 0 when the
manifold gauges are
attached, check for any
leaks, repair them, and
evacuate the system.
0.4 – 0.6
(4 – 6)
(56.9 – 85.3)Pressure on low pressure
side is high.
Pressure on high pressure
side is low.
Both pressure becoming
equal right after A/C is
turned OFF.Internal leak in
compressor.Inspect compressor
and repair or replace
as necessary.
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 condenser
cooling fan operation.Inspect and repair
condenser 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 desiccant and
cap with filter.
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 (kgf/cm
2) (psi)
Detail
Lo Hi

Downloaded from www.Manualslib.com manuals search engine 7B-40 Air Conditioning System: Automatic Type
HVAC Control DescriptionS6RW0D7221002
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, ECT 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, ECT 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 air flow control
actuator so that the current air flow control 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)A/C Compressor Relay Control
HVAC control module outputs A/C switch ON signal to
ECM via BCM when the vehicle state satisfy conditions
described below.
• A/C switch is ON
• Evaporator temperature is higher than specified value
• Evaporator temperature sensor malfunction is not
detected
Communication of ECM and BCM is established by CAN
(Controller Area Network). (For more detail of CAN
communication, 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
• A/C refrigerant pressure 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.
Sub-Cool A/C System DescriptionS6RW0D7221003
Refer to “Sub-Cool A/C System Description”.

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On-Board Diagnostic System DescriptionS6RW0D7221004
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 detects malfunctions, which may
occur in the following area.
• Inside air temperature sensor
• Evaporator temperature sensor
• Sunload sensor
• Temperature control actuator
• Air flow control actuator
• Temperature selector of HVAC control module
• Air flow selector of HVAC control module
• Blower speed selector of HVAC control module
• Back-up power supply circuit of HAVC control module
• Serial communication line between BCM and HVAC
control module• Received data from BCM as follows
– Outside air temperature sensor signal
– ECT sensor signal
– A/C refrigerant pressure sensor signal
– VSS signal
– Engine type signal
– Combination meter spec signal
– CAN communication circuit failure signal
When HVAC control module detects malfunction, the “A/
C” indicator light (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
A/C System Air Flow DiagramS6RW0D7222001
Refer to “A/C System Air Flow Diagram”.
1
I5RW0A722002-01