AIR SUZUKI SX4 2006 1.G Service Workshop Manual

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 Air Conditioning System: Automatic Type 7B-79
Reference waveform No. 1
Rear defogger switch or A/C switch signal (1)Reference waveform No. 2
Serial communication line of BCM (1)
A/C System Inspection at ECMS6RW0D7224030
When checking voltage at ECM terminals related to A/C system, refer to “Inspection of ECM and Its Circuits in Section
1A”.
Repair Instructions
Operation Procedure for Refrigerant ChargeS6RW0D7226001
Refer to “Operation Procedure for Refrigerant Charge”.Measurement terminal Rear defogger switch
CH1: “G20-4” to “G20-23” A/
C switch
CH1: “G20-21” to “G20-23”
Oscilloscope setting CH1: 5 V / DIV
TIME: 10 ms / DIV
Measurement condition Rear defogger switch:
• Ignition switch is at ON
position and rear defogger
switch is not pushed
A/C switch:
• Ignition switch is at ON
position and A/C switch is
not pushed
I7RW01722014-02
Measurement terminal CH1: “G20-13” to “G20-23”
Oscilloscope setting CH1: 5 V / DIV
TIME: 20 ms / DIV
Measurement condition Ignition switch is at ON
position
I7RW01722015-02

Downloaded from www.Manualslib.com manuals search engine 7B-80 Air Conditioning System: Automatic Type
HVAC Unit ComponentsS6RW0D7226002
1
10
1
29
9
8
3
29
21
3
20 20
20
19
23
22
5*
4
28*15 16*
30
29*
30
17*
18*2 1312 11
5*
26
2725
1424
29
67
*
I6RW0C722008-01
1. Blower upper case 9. Air intake control link 17. Expansion valve 25. Inside air temperature sensor
2. Blower lower case 10. Air intake control door 18. Expansion pipe 26. Aspirator
3. Heater unit upper case 11. Blower motor 19.Air flow control actuator 27. Aspirator hose
4. Heater unit lower case 12. Blower motor cap 20. Air flow control links 28. Drain hose
5. Foot duct 13. Blower motor controller 21. Air flow control door assembly 29. Packing
6. HVAC air filter (if equipped) 14. Heater core 22. Temperature control actuator 30. O-ring
: Apply compressor oil.
7. Cover (without HVAC air
filter)15. Evaporator 23. Temperature control link : Do not reuse.

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HVAC Unit Removal and InstallationS6RW0D7226003
Refer to “HVAC Unit Removal and Installation”.
Temperature Control Actuator Removal and
Installation
S6RW0D7226004
Removal
1) Disconnect negative (–) cable at battery.
2) Remove steering column hole cover from instrument
panel.
3) Remove driver side foot duct from HVAC unit.
4) Disconnect temperature control actuator connector
(1).
5) Remove temperature control actuator (2) from HVAC
unit by removing screws (3).Installation
Reverse removal procedure noting the following
instructions.
• Before installing actuator, make sure that position of
actuator lever is in between “MAX HOT” position and
“MAX COOL” position.
• Be sure to insert pin (1) of temperature control
actuator into the groove (2) of link.
Temperature Control Actuator and Its Circuit
Inspection
S6RW0D7226005
1) Remove temperature control actuator from HVAC
unit referring to “Temperature Control Actuator
Removal and Installation”.
2) Connect connector to temperature control actuator.
3) Set temperature selector to “MAX COOL” position
with ignition switch turned ON.
4) Connect voltage meter between terminal “2” and
body ground.
5) Turn temperature selector to “MAX HOT” position.
8. Air intake control actuator 16. Evaporator temperature
sensor24. Temperature control door
assembly
3
2
3
1
I7RW01722018-01
1
2
I7RW01722019-01

Downloaded from www.Manualslib.com manuals search engine 7B-82 Air Conditioning System: Automatic Type
6) Measure output voltage variation while temperature
control actuator is operated from “MAX COOL”
position (B) to “MAX HOT” position (A) as following
specification.
If measure voltage is out of specification or does not
vary linearly as the shown in graph, check related
wire circuit and HVAC control module. If wire circuits
and HVAC control module are OK, go to next step.
Temperature control actuator output voltage
0.48 – 4.53V (linear variation as following graph)
7) Set temperature selector of HVAC control module to
“MAX HOT” position with ignition switch turned ON,
and make sure if the position of actuator lever is
“MAX HOT” position (A).
8) Turn ignition switch to OFF position, and then
disconnect connector from temperature control
actuator.9) Measure resistance between terminal “1” and “2”.
Temperature control actuator resistance between
terminal “1” and “2” (MAX HOT position)
(Reference value)
Approx. 0.45 kΩ at 25 °C (77 °F)
10) Connect connector to temperature control actuator.
11) Set temperature selector of HVAC control module to
“MAX COOL” position with ignition switch turned ON,
and make sure if the position of actuator lever is
“MAX COOL” position (B).
12) Turn ignition switch to OFF position, and then
disconnect connector from temperature control
actuator.
13) Measure resistance between terminal “1” and “2”.
Temperature control actuator resistance between
terminal “1” and “2” (MAX COOL position)
(Reference value)
Approx. 4.3 kΩ at 25 °C (77 °F)
If measure resistance is out of specification, replace the
actuator with new one.[A]: MAX HOT
[B]: MAX COOL
[C]: Actuator lever position
123456
6
M5
3
2
1
AB
4.53
0.48 5.00(V)
[C]
[A] [B]
I7RW01722017-03
123456
6
M5
3
2
1
A
I7RW01722020-02
123456
6
M5
3
2
1
B
I7RW01722021-02

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-83
Air Flow Control Actuator Removal and
Installation
S6RW0D7226006
Removal
1) Disconnect negative cable at battery.
2) Remove steering column hole cover from instrument
panel.
3) Remove driver side foot duct from HVAC unit.
4) Disconnect air flow control actuator connector (2).
5) Remove air flow control actuator (1) from HVAC unit
by removing screws (3).
Installation
Reverse removal procedure noting the following
instructions.
• Before installing actuator, make sure that position of
actuator lever is in between “BENT” position and
“DEF” position.
• Be sure to insert pin (1) of air flow control actuator into
the groove (2) of link.
Air Flow Control Actuator and Its Circuit
Inspection
S6RW0D7226007
1) Remove air flow control actuator from HVAC unit
referring to “Air Flow Control Actuator Removal and
Installation”.
2) Connect connector to air flow control actuator.
3) Set air flow selector to “BENT” position with ignition
switch turned ON.
4) Connect voltage meter between terminal “2” and
body ground.
5) Turn air flow selector to “DEF” position.
6) Measure output voltage variation while air flow
control actuator is operated from “BENT” position (A)
to “DEF” position (B) as following specification.
If measure voltage is out of specification or does not
vary linearly as the shown in graph, check related
wire circuit and HVAC control module. If wire circuits
and HVAC control module are OK, go to next step.
Air flow control actuator output voltage
0.48 – 4.53 V (linear variation as following graph)
13
2
I7RW01722022-01
1
2
I7RW01722023-02
[A]: BENT [D]: FOOT
[B]: DEF [E]: DEF / FOOT
[C]: BI-LEVEL [F]: Actuator lever position
123456
6
M5
3
2
1 A
B
(V)
4.53
3.35
2.60
1.78
0.48
[A][B]
[C] [D] [E][F]5.00
I7RW01722024-02

Downloaded from www.Manualslib.com manuals search engine 7B-84 Air Conditioning System: Automatic Type
7) Set air flow selector of HVAC control module to
“DEF” position with ignition switch turned ON, and
make sure if the position of actuator lever is “DEF”
position (A).
8) Turn ignition switch to OFF position, and then
disconnect connector from air flow control actuator.
9) Measure resistance between terminal “1” and “2”.
Air flow control actuator resistance between
terminal “1” and “2” (DEF position) (Reference
value)
Approx. 0.45 kΩ at 25 °C (77 °F)
10) Connect connector to air flow control actuator.
11) Set air flow selector of HVAC control module to
“VENT” position with ignition switch turned ON, and
make sure if the position of actuator lever is “VENT”
position (B).
12) Turn ignition switch to OFF position, and then
disconnect connector from air flow control actuator.13) Measure resistance between terminal “1” and “2”.
Air flow control actuator resistance between
terminal “1” and “2” (VENT position) (Reference
value)
Approx. 4.3 kΩ at 25 °C (77 °F)
If measure resistance is out of specification, replace the
actuator with new one.
Air Intake Actuator Removal and InstallationS6RW0D7226008
Remove and install air intake actuator referring to “Air
Intake Control Actuator Removal and Installation in
Section 7A”.
Air Intake Actuator InspectionS6RW0D7226009
For inspection, refer to “Air Intake Control Actuator
Inspection in Section 7A”.
Actuator Linkage InspectionS6RW0D7226010
• 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
S6RW0D7226011
Refer to “Blower Motor Resistor Removal and
Installation in Section 7A”.
123456
6
M5
3
2
1 A
I7RW01722025-01
123456
6
M5
3
2
1 B
I7RW01722026-01

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-86 Air Conditioning System: Automatic Type
Installation
Reverse removal procedure noting the following
instructions.
• Install sunload sensor (1) to instrument panel fitting
tab (2) of sunload sensor into the groove (3) of
instrument panel as shown in figure.
Sunload Sensor InspectionS6RW0D7226015
1) Light over sunload sensor vertically with an
incandescent light of approximately 100 W. The
distance between sunload sensor and light should
be approximately 100 mm (3.94 in.).
2) Measure voltage between terminals “a” and “b” of
sunload sensor as shown in figure.
If check result is not satisfactory, replace sunload
sensor with new one.
Sunload sensor voltage specification
“a” – “b”: Approx. 0.38 – 0.42 V
Outside Air Temperature Sensor Removal and
Installation
S6RW0D7226016
Refer to “Outside Air Temperature Sensor Removal and
Installation (If Equipped) in Section 9C”.
Outside Air Temperature Sensor InspectionS6RW0D7226017
Refer to “Outside Air Temperature Sensor Inspection (If
Equipped) in Section 9C”.
Inside Air Temperature Sensor Removal and
Installation
S6RW0D7226018
Removal
1) Disconnect negative (–) cable at battery.
2) Remove audio unit from instrument panel referring to
“Audio Unit Removal and Installation (If Equipped) in
Section 9C”.
3) Remove combination meter from instrument panel
referring to “Combination Meter Removal and
Installation in Section 9C”.
4) Remove connector (3) and aspirator hose (1) from
inside air temperature sensor (2).
5) Remove inside air temperature sensor (2) from
instrument panel by removing screw (4).
Installation
Reverse removal procedure.
Inside Air Temperature Sensor InspectionS6RW0D7226019
Measure resistance between each connector terminal
with an ohmmeter.
If resistance is incorrect, replace inside air temperature
sensor with new one.
Inside air temperature sensor resistance
2.2 ± 0.07 kΩ at 25 °C (77 °F)
F: Vehicle forward
2
F
1
3
I7RW01722029-01
“b” “a”I5JB0A720053-01
1
23 4
I7RW01722031-01
I7RW01722030-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-87
Condenser Cooling Fan Relay InspectionS6RW0D7226020
Refer to “A/C System Relay Inspection”.
Condenser Cooling Fan Removal and
Installation
S6RW0D7226021
Refer to “Condenser Cooling Fan Removal and
Installation”.
Condenser Cooling Fan InspectionS6RW0D7226022
Refer to “Condenser Cooling Fan Inspection”.
Condenser Assembly On-Vehicle InspectionS6RW0D7226023
Refer to “Condenser Assembly On-Vehicle Inspection”.
Condenser Assembly Removal and InstallationS6RW0D7226024
Refer to “Condenser Assembly Removal and
Installation”.
Evaporator InspectionS6RW0D7226025
Refer to “Evaporator Inspection”.
Evaporator Temperature Sensor Removal and
Installation
S6RW0D7226026
Refer to “Evaporator Temperature Sensor Removal and
Installation”.
Evaporator Temperature Sensor InspectionS6RW0D7226027
Refer to “Evaporator Temperature Sensor Inspection”.
Expansion Valve Removal and InstallationS6RW0D7226028
Refer to “Expansion Valve Removal and Installation”.
Expansion Valve InspectionS6RW0D7226029
Refer to “Expansion Valve Inspection”.
A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
S6RW0D7226030
Refer to “A/C Refrigerant Pressure Sensor and Its Circuit
Inspection”.
A/C Refrigerant Pressure Sensor Removal and
Installation
S6RW0D7226031
Refer to “A/C Refrigerant Pressure Sensor Removal and
Installation”.
Compressor Relay InspectionS6RW0D7226032
Refer to “A/C System Relay Inspection”.
Compressor Drive Belt Inspection and
Adjustment
S6RW0D7226033
Refer to “Compressor Drive Belt Inspection and
Adjustment”.
Compressor Drive Belt Removal and
Installation
S6RW0D7226034
Refer to “Compressor Drive Belt Removal and
Installation”.
Compressor Assembly Removal and
Installation
S6RW0D7226035
Refer to “Compressor Assembly Removal and
Installation”.
Compressor Assembly ComponentsS6RW0D7226036
Refer to “Compressor Assembly Components”.
Magnet Clutch Removal and InstallationS6RW0D7226037
Refer to “Magnet Clutch Removal and Installation”.
Magnet Clutch InspectionS6RW0D7226038
Refer to “Magnet Clutch Inspection”.
Thermal Switch InspectionS6RW0D7226039
Refer to “Thermal Switch Inspection”.
Thermal Switch Removal and InstallationS6RW0D7226040
Refer to “Thermal Switch Removal and Installation”.
Relief Valve InspectionS6RW0D7226041
Refer to “Relief Valve Inspection”.