Hvac SUZUKI SX4 2006 1.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-81
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
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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
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0.48 5.00(V)
[C]
[A] [B]
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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)
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[A]: BENT [D]: FOOT
[B]: DEF [E]: DEF / FOOT
[C]: BI-LEVEL [F]: Actuator lever position
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4.53
3.35
2.60
1.78
0.48
[A][B]
[C] [D] [E][F]5.00
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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”.
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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).
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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 8B-9 Air Bag System:
Terminal arrangement of SDM (viewed from harness side)
[A]: Shorting bar 11. BCM 25. Driver seat belt pretensioner
[B]: Connector 12. Combination meter 26. Passenger seat belt pretensioner
[C]: Junction block with BCM model 13. “AIR BAG” warning light27. Driver side-air bag (inflator) module (8-channel system)
[D]: Junction block without BCM model 14. Light driver 28. Passenger side-air bag (inflator) module (8-channel system)
1. Battery 15. SDM 29. Driver side curtain-air bag (inflator) module (8-channel
system)
2. Main fuse 16. To HVAC control module (auto A/C model) 30. Passenger side curtain-air bag (inflator) module (8-channel
system)
3. Fuse 17. Data link connector (DLC) 31. Safing power driver
4. Individual circuit fuse box No.1 18. Forward impact-sensor 32. X-Y-G (longitudinal / lateral acceleration)
5. “IGN” fuse 19. Driver side impact-sensor (8-channel
system)33. DC / DC converter
6. Ignition switch 20. Passenger side impact-sensor (8-channel
system)34. Mechanical longitudinal G sensor (switch)
7. Junction block assembly 21. Ground for air bag system 35. Back up capacitor
8. “DOME” fuse 22. Contact coil assembly
9. “METER” fuse 23. Driver air bag (inflator) module
10. “A/B” fuse 24. Passenger air bag (inflator) module
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1. SDM Connector “L04”

Downloaded from www.Manualslib.com manuals search engine 8B-23 Air Bag System:
Serial Data Link Circuit CheckS6RW0D8204051
Wiring Diagram
1
2
3
3
18
12V
RED 7
14 9
10
“L313”
“G273”
YEL/BLKL04-2
L04-27 “L04”
PPL/WHT
“G04”L04-3212V
8
GRN
15
+BB
56WHTWHT
4
BLUBLU
BLK
16
11
12
“G241”
13
BLK
L04-28
RED/BLK
WHT/REDYEL/BLK
BLK“G271”
“G272”
WHT/RED
BLK/
ORNBLK
B
C
A A
A
17
[A]
A
[B]
12V
PPL/WHTYEL14
17A
A
YELL04-37
12V
I6RW0C820006-01
[A]: Junction block with BCM model 4. Individual circuit fuse box No.1 12. “METER” fuse
[B]: Junction block without BCM model (That
is, TAIWAN spec model)5. “IGN” fuse 13. “A/B” fuse
A: Serial data circuit 6. Ignition switch 14. BCM
B: DLC power supply circuit 7. Combination meter 15. Data link connector (DLC)
C: DLC ground circuit 8. “AIR BAG” warning light 16. Ground for air system
1. Battery 9. Light driver 17. To HVAC control module (auto A/C model)
2. Main fuse 10. Junction block assembly 18. SDM
3. Fuse 11. “DOME” fuse

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-24
Troubleshooting
Step Action Yes No
1“AIR BAG” warning light check
1) Turn ignition switch to ON position.
Does “AIR BAG” warning light come ON steady?Go to ““AIR BAG”
Warning Light Comes
ON Steady”.Go to Step 2.
2Scan tool condition check
1) Make sure that SUZUKI scan tool is as follows.
• Correct PCMCIA card (software) is used.
• There are no deformation and wear for DLC cable
terminals.
• Connection for DLC cable terminals is in good
condition.
Are they OK?Go to Step 3. Repair or replace
defective part.
3Scan tool operation check
1) Check DLC terminal for deformation and wear.
2) If it is in good condition, connect SUZUKI scan tool to
DLC with ignition switch turned OFF.
3) Check if communication is possible by making
communication with other control modules (BCM, ABS
control module, HVAC control module (auto A/C model)
or P/S control module).
Is it possible to communicate with the other control
modules?Go to Step 4. Go to Step 6.
4Serial communication circuit check
1) With ignition switch turned OFF, disconnect SDM
connector “L04” and check for proper connection at
SDM connector terminal.
2) If connections are OK, check that “Serial data circuit” is
as follows.
• Wiring resistance of “Serial data circuit” wire between
DLC and SDM connector is less than 1 Ω.
Is it resistance less than 1
Ω?Go to Step 5. “Serial data circuit” is
open or high resistance.
5SDM power and ground circuit check
1) Check power supply circuit and ground circuit for SDM
referring to “SDM Power Supply and Ground Circuit
Check”.
Is check result in good condition?Substitute a known-
good SDM and recheck.Repair or replace
defective circuit.
6DLC power and ground circuit check
1) Check power supply circuit and ground circuit for DLC as
follows.
• Voltage of “DLC power supply circuit” between DLC
terminal and vehicle body ground is 10 – 14 V with
ignition switch turned ON.
• Wire resistance of each “DLC ground circuit” between
DLC terminal and vehicle body ground is less than
1Ω.
Is check result in good condition?Go to Step 7. Repair or replace
defective circuit.

Downloaded from www.Manualslib.com manuals search engine Glass / Windows / Mirrors: 9E-18
Rear Door Window Regulator Removal and
Installation
S6RW0D9506015
Removal
1) Remove door glass referring to “Rear Door Glass
Removal and Installation”.
2) Disconnect power window motor lead wire at
coupler.
3) Loosen regulator mounting screws, and then remove
rear window regulator (1).
Installation
Reverse removal procedure noting the following.
• Apply grease to sliding and rotating portions of
window regulator.
: Grease 99000–25011 (SUZUKI Super Grease A)
• Tighten rear door window regulator attaching screws.
Rear door window regulator screw tightening
order
(1) → (2)
Rear Door Window Regulator InspectionS6RW0D9506016
Check the following point:
• Check regulator sliding and rotating parts.
• Check rollers for wear and damage.
Rear End Door Window Defogger Switch
Inspection
S6RW0D9506017
1) Check rear end door window defogger switch for
operation as follows.
a) Rear end door window defogger switch is built in
HVAC control unit.
Remove HVAC control module (unit) referring to
“HVAC Control Unit Removal and Installation in
Section 7A” or “HVAC Control Module Removal
and Installation in Section 7B”.
b) Check that there is continuity between terminal
(1) and terminal (2) of HVAC control module
(unit) when rear end door window defogger
switch is at ON position. (Rear end door window
defogger switch is kept in push.)
c) Check that there is no continuity between
terminal (1) and terminal (2) of HVAC control
module (unit) when rear end door window
defogger switch is at OFF position.
If check result does not meet the above conditions,
replace HVAC control module (unit).
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[B]: Auto A/C model
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