SUZUKI SX4 2006 1.G Service Workshop Manual

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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

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A/C System Wiring DiagramS6RW0D7222002
1913
15
16
10
11
12
5V
12V
WHT/BLU
RED
GRY/BLU
BRN/WHT
GRY/RED
BRN/YEL
PNK
BLK/ORN
RED/BLKRED/BLK
RED/BLK
14
REDWHT
WHT/RED
BLU
YEL
WHT
WHT/BLUGRNWHT
G20-18
G20-7
23 1
24
6 17
24
5V
5V
5V
5V5V
12V
12V
ORN
ORN
ORN
ORN
ORN
PNK/BLK
WHT/BLK
GRN/REDGRN
WHT
WHT
ORN
WHT
YEL
G20-10
G20-17G20-19
G20-12
G20-27
G20-24
G20-22
G20-15
G20-16
G20-28
G20-2G20-1
5V
G20
G20-26
G20-13
G20-23
BLK/RED
YEL/REDYEL/BLK
YEL
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
28 27
G20-9
G20-25
[A]
G20-6RED/YEL33
34 29
30 35
41
42
43
31G20-5[B]:BLK/YEL
[C]:RED/BLU
12V
3912V
40
5V
44 38
5V
3612V
12VG20-21GRN/WHT
5VG20-4GRN/YEL
5
RED/YELBRN
BLK
BLK/RED
31
5V
5V 5V
ORN
GRY
12V
BLU/WHT
LT GRN
REDWHT
RED/BLK
ORN
GRY/REDRED/BLU
BLK/RED
BLK/RED
BRN/WHT
BLK/WHT
RED
WHT
20
BLU/YEL
BLK/WHT
BLK/YEL
7
8
G20-29
BLU/RED
GRY
G20-30G20-8
BLU/YEL
9
+BB
12V
G20-3BLU
12V
BLK
5V IG1
IG2
4521
2218
26
25
32
337
[C]
[B]
I6RW0C722002-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-43
Component Location
A/C System Major Components LocationS6RW0D7223001
Refer to “A/C System Major Components Location”.
[A]: Illumination control model 10. Air intake actuator 22. Compressor 34. “A/C” indicator light
[B]: Junction block with BCM 11. Air flow control actuator 23. HVAC control module 35. Rear defogger switch
[C]: Junction block without BCM 12. Temperature control actuator 24. BCM 36. Rear defogger indicator
1. Main fuse box 13. Inside air temperature sensor 25. A/C refrigerant pressure sensor 37. To other control module
2. Ignition switch 14. Outside air temperature sensor 26. Condenser cooling fan relay 38. Indicator light, switch,
selector
3. CAN junction connector 15. Evaporator temperature sensor 27. Information display 39. “FRE” indicator light
4. Rear defogger relay 16. Sunload sensor 28. Lighting switch 40. “REC” indicator light
5. Rear defogger 17. Junction block assembly 29. A/C switch 41. Temperature selector
6. Blower motor relay 18. ECM 30. Air intake selector 42. Blower speed selector
7. Blower motor 19. ECT sensor 31. To BCM 43. MODE (air flow) selector
8. Blower motor controller 20. Condenser cooling fan motor 32. ABS control module 44. Tail light
9. DLC 21. Compressor relay 33. Illumination light 45. Main relay

Downloaded from www.Manualslib.com manuals search engine 7B-44 Air Conditioning System: Automatic Type
Electronic Control System Components LocationS6RW0D7223002
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

[A]
2
3
5
1
4
78*
18
19
20
23
22 219*
10*
11*
12*
13*
15* 16* 17
14*
8*6
I6RW0C722003-01
[A]: Junction block assembly viewed from relay
side8. Junction block assembly 16. Blower motor controller
1. A/C refrigerant pressure sensor 9. Sunload sensor 17. HVAC control module
2. Compressor relay 10. Inside air temperature sensor 18. Temperature selector
3. Condenser cooling fan relay 11. Air flow control actuator 19. Blower speed selector
4. Outside air temperature sensor 12. Temperature control actuator 20. MODE (air flow) selector
5. ECT sensor 13. Evaporator temperature sensor 21. A/C switch
6. Condenser cooling fan 14. Air intake actuator 22. Air intake selector
7. Blower motor relay 15. Blower motor 23. Rear defogger switch

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Diagnostic Information and Procedures
Air Conditioning System CheckS6RW0D7224001
Step Action Yes No
1Customer complaint analysis
1) Perform )”Customer complaint analysis”.
Was customer complaint analysis performed?Go to Step 2. Perform customer
complaint analysis.
2Visual inspection
1) Perform ) “Visual inspection”.
Is there any faulty condition?Repair or replace
malfunction part.Go to Step 3.
3DTC check
1) Perform ) “DTC check”.
Is there any DTC code?Go to Step 4. Go to Step 5.
4DTC troubleshooting
1) Perform ) “DTC Troubleshooting”.
Is there any faulty condition?Repair or replace
malfunction part, and go
to Step 7.Go to Step 5.
5A/C system performance inspection
1) Perform ) “A/C system performance inspection”.
Is there any faulty condition?Repair or replace
malfunction part, and go
to Step 8.Go to Step 6.
6Perform A/C system symptom diagnosis
1) Inspect and repair referring to “A/C System Symptom
Diagnosis”.
Is there any faulty condition?Repair or replace
malfunction part, and go
to Step 7.Go to Step 8.
7Check for intermittent problem
1) Check for intermittent troubles referring to “Intermittent
and Poor Connection Inspection in Section 00”.
Is there any faulty condition?Repair or replace
malfunction part, and go
to Step 8.Go to Step 8.
8Final confirmation test
1) Perform ) “Final confirmation test”.
Is there any malfunction code?Go to Step 4. End.

Downloaded from www.Manualslib.com manuals search engine 7B-46 Air Conditioning System: Automatic Type
Description for Each Step
Step 1. Customer complaint analysis
Talk to customer, and then record details of the problem.
Customer questionnaire (Example)
NOTE
The form is a standard sample. It should be modified according to conditions characteristic of each
market.

Step 2. Visual inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the air
conditioning system referring to “Visual Inspection”.
Step 3. DTC check
Check DTC referring to “DTC Check”.
Step 4. DTC troubleshooting
Based on the DTC, perform an applicable DTC
diagnostic flow and locate the cause of the trouble,
namely in a sensor, wire harness, connector, actuator,
HVAC control module or other part and repair faulty
parts.
Step 5. A/C system performance inspection
Inspect A/C system suspected to be a possible cause
referring to “A/C System Performance Inspection”.Step 6. A/C system symptom diagnosis
Check any part or system suspected to be a possible
cause referring to “A/C System Symptom Diagnosis”.
Step 7. Check for intermittent problem
Check any part 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 trouble cord recorded.
Step 8. Final confirmation test
Confirm if the problem symptom is troubleshoot and the
A/C system is free from any abnormal conditions. If there
existed DTC, clear the DTC. Then, check if the DTC is
still detected and if there is any other DTC.
I4RH01722014-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-47
A/C System Symptom DiagnosisS6RW0D7224002
Condition Possible cause Correction / Reference Item
No cool air comes out (A/
C system does not
operate)No refrigerantPerform recovery, evacuation and charge
referring to “Operation Procedure for
Refrigerant Charge”.
Fuse blownCheck related fuses, and then check for short
circuit to ground.
A/C switch faultyCheck A/C switch referring to “Inspection of
HVAC Control Module and Its Circuit”.
Evaporator temperature sensor faultyCheck evaporator temperature sensor
referring to “Evaporator Temperature Sensor
Inspection”.
A/C refrigerant pressure sensor faultyCheck A/C refrigerant pressure sensor
referring to “A/C Refrigerant Pressure Sensor
and Its Circuit Inspection”.
Wiring or grounding faultyRepair as necessary.
ECM faultyCheck ECM referring to “A/C System
Inspection at ECM”.
HVAC control module faultyCheck HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
Magnet clutch faultyCheck magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor drive belt loosened or
brokenAdjust or replace drive belt.
Compressor faultyCheck compressor.
Compressor relay faultyCheck compressor relay referring to “A/C
System Relay Inspection”.
BCM faultyCheck BCM referring to “Inspection of BCM
and Its Circuits in Section 10B”.
No cool air comes out
(radiator cooling fan
motor does not operate)Fuse blownCheck related fuses, and then check for short
circuit to ground.
Wiring or grounding faultyRepair as necessary.
Condenser cooling fan motor relay faultyCheck condenser cooling fan motor relay
referring to “A/C System Relay Inspection”.
Condenser cooling fan motor faultyCheck condenser cooling fan motor referring to
“Condenser Cooling Fan Inspection”.
ECM faultyCheck ECM referring to “A/C System
Inspection at ECM”.
HVAC control module faultyCheck HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
No cool air comes out
(blower motor does not
operate)Fuse blownCheck related fuses, and then check for short
circuit to ground.
Blower motor controller faultyCheck blower motor controller referring to
“Blower Motor Controller Inspection”.
HVAC control module faultyCheck HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
Wiring or grounding faultyRepair as necessary.
Blower motor faultyCheck blower motor referring to “Blower Motor
Inspection in Section 7A”.
Blower motor relay faultyCheck blower motor relay referring to “Blower
Motor Relay Inspection in Section 7A”.

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 Air Conditioning System: Automatic Type 7B-49
Abnormal Noise Symptom Diagnosis of A/C
System
S6RW0D7224003
Refer to “Abnormal Noise Symptom Diagnosis of A/C
System”.
DTC CheckS6RW0D7224004
Using SUZUKI Scan Tool
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) Light over sunload sensor vertically with an
incandescent light of approximately 100 W apart
from about 100 mm (3.94 in.).
NOTE
If sunload sensor is not lighted over with an
incandescent light, DTC B1504 is detected
even though there is not any malfunction.

4) Turn ignition switch to ON position.
5) Read DTC displayed on SUZUKI scan tool.
NOTE
To know how to use SUZUKI scan tool, refer
to operator’s manual for SUZUKI scan tool.

6) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
data link connector (DLC). Insufficient air flow of
cooled airA/C evaporator clogged or frostedCheck A/C evaporator and evaporator
temperature sensor referring to “Evaporator
Inspection” and “Evaporator Temperature
Sensor Inspection”.
Air leaking from HVAC unit or air ductRepair as necessary.
Blower motor faultyCheck blower motor referring to “Blower Motor
Inspection in Section 7A”.
Wiring or grounding faultyRepair as necessary. Condition Possible cause Correction / Reference Item(A)
1I5RW0A722004-01

Downloaded from www.Manualslib.com manuals search engine 7B-50 Air Conditioning System: Automatic Type
Not Using SUZUKI Scan Tool
NOTE
In case of malfunction of temperature
selector, blower speed selector and air flow
selector, DTC can not be checked by the
following procedure. Use SUZUKI scan tool
for DTC check.

1) Light over sunload sensor vertically with an
incandescent light of approximately 100 W apart
from about 100 mm (3.94 in.).
NOTE
If sunload sensor is not lighted over with an
incandescent light, DTC of sunload sensor is
detected as current DTC even though there is
not any malfunction.

2) Set the following selectors to specified positions
below respectively with ignition switch off position.
• Temperature selector (1) is maximum cool
position
• Blower speed selector (2) is OFF position
• Air flow selector (3) is AUTO position
3) While pressing A/C switch (4) and air intake selector
(5) simultaneously, turn ignition switch to ON
position.
4) Wait for about 5 seconds (start of diagnosis).
5) Read flashing pattern of “FRE” (6) and “REC” (7)
indicator lights which represents DTC and write it
down.
NOTE
• When 2 or more current DTCs are
detected, only DTC having the highest
priority is indicated. Therefore, after
troubleshooting the malfunction, DTC
check has to be performed again to see if
any other DTC(s) is detected.
• Pressing “A/C” switch alternates display
of current DTC and history DTC. “A/C”
indicator light (8) remains off when display
is in current DTC mode and it lights up
when display is in history DTC mode.
• When a history DTC is indicated while 2 or
more history DTCs are detected, it is
possible to have other history DTC(s)
stored in HVAC control module displayed
by pressing the air intake selector.

Example: When inside air temperature sensor
circuit malfunction (Open) is set
Example: When VSS signal failure (Data error) is
set
6) After completing above check, turn ignition switch to
“OFF” position.
[A]: “REC” indicator light L: OFF
[B]: “FRE” indicator light a. About 0.5 seconds
H: ON b. About 2 seconds
[A]: “REC” indicator light a. About 0.5 seconds
[B]: “FRE” indicator light b. About 3 seconds
H: ON c. About 1.5 seconds
L: OFF
123
458
6
7I5RW0A722005-01
[A]
[B]H
L
H
L [B]
[A]
ab
aI5RW0A722006-02
[A]
[B]H
L
H
L [B]
[A]
ab
aaaa
c
I5RW0A722025-01