2005 SUZUKI SWIFT reverse

Downloaded from www.Manualslib.com manuals search engine 7B-26 Air Conditioning System: Manual Type
Expansion Valve Removal and InstallationS7RS0B7216010
Removal1) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Loosen a bolt (1) and remove pipes from expansion valve (2).
3) Loosen bolts (3) and remove expansion valve.
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of expansion valve and pipes.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Tightening torque
Expansion valve mount bolt: 3.5 N·m (0.35 kgf-m,
2.5 lb-ft)
Expansion Valve InspectionS7RS0B7216011
Refer to “A/C System Performance Inspection”.
A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
S7RS0B7216012
1) Disconnect A/C refrigerant pressure sensor connector.
2) Turn ignition switch to ON position.
3) Check if voltage between “RED” wire terminal and “ORN” wire terminal of A/C refrigerant pressure
sensor connector is 4.75 V to 5.25 V.
If not, check A/C refrigerant pressure sensor circuit.
4) Connect A/C refrigerant pressure sensor connector with ignition switch turned OFF.
5) Connect manifold gauge set to the charging valves.
6) Check A/C refrigerant pressure sensor voltage of ECM connector referring to “A/C System Inspection
at ECM”.
If voltage is not as specified below, replace A/C
refrigerant pressure sensor. A/C refrigerant pressure sensor voltage
specifications (A/C refrigerant pressure measured
by manifold gauge)
0.8 MPa (8.0 kg/cm2, 116 psi): 1.46 – 1.71 V
1.4 MPa (14 kg/cm2, 203 psi): 2.28 – 2.53 V
1.6 MPa (16 kg/cm2, 232 psi): 2.55 – 2.80 V
1.8 MPa (18 kg/cm2, 261 psi): 2.82 – 3.03 V
A/C Refrigerant Pressure Sensor Removal and
Installation
S7RS0B7216013
Removal
1) Recover refrigerant from the A/C system with the recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Disconnect negative (–) cable from battery.
3) Disconnect A/C refrigerant pressure sensor connector.
4) Remove A/C refrigerant pressure sensor (1) from liquid pipe (2).
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of A/C refrigerant
pressure sensor.
• Tighten A/C refrigerant pressure sensor to specified torque.
Tightening torque
A/C refrigerant pressure sensor (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
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2 2
3
I4RS0A720028-01
1 2I4RS0A720029-01
(a)I4RS0A720031-01

Downloaded from www.Manualslib.com manuals search engine 7B-28 Air Conditioning System: Manual Type
Compressor Drive Belt Removal and
Installation
S7RS0B7216017
Removal1) Loosen tension pulley nut (1).
2) Loosen belt tension by loosening tension pulley adjusting bolt (2).
3) Remove compressor drive belt (3).
Installation
Reverse removal procedure noting the following
instruction.
• Adjust belt tension referring to “Compressor Drive Belt Inspection and Adjustment”.
Compressor Assembly Removal and
Installation
S7RS0B7216018
Removal
1) Run engine at idle speed with A/C ON for 10 minutes.
2) Stop the engine.
3) Disconnect negative (–) cable from battery.
4) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
5) Remove compressor drive belt referring to “Compressor Drive Belt Re moval and Installation”.
6) Remove right side engine under cover.
7) Disconnect magnet clutch lead wire coupler (1).
8) Disconnect discharge hose (2) and suction hose (3) from compressor (4).
NOTE
Cap open fittings immediately to keep
moisture out of the system.

9) Remove compressor mounting bolts (1), and then remove compressor (2 ) from its bracket.
Installation
Reverse removal procedure noting the following
instructions.
• If compressor is replaced, pour new compressor oil referring to “Replenishi ng Compressor Oil” in
“Operation Procedure for Refrigerant Charge”.
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Adjust drive belt tension referring to “Compressor Drive Belt Inspecti on and Adjustment”.
I4RS0A720034-01
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4 2
1
I7RS0A721009-01
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1 2
I7RS0A721010-02

Downloaded from www.Manualslib.com manuals search engine 7B-32 Air Conditioning System: Manual Type
Relief Valve Removal and InstallationS7RS0B7216030
Removal1) Recover refrigerant fr om the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Remove relief valve (1) from compressor (2). Installation
Reverse removal procedure nothing the following
instructions.
• Use new O-ring.
• Apply compressor oil to O-ring.
• Tighten relive valve to the specified torque.
Tightening torque
Relief valve (a): 8 N·m (0.8 kgf-m, 6.0 lb-ft)
• Evacuate and charge the A/C system referring to “Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Specifications
Tightening Torque SpecificationsS7RS0B7217001
NOTE
The specified tightening torque is also described in the following.
“Compressor Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
12I4RS0A720048-01
(a)I4RS0A720049-01
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Receiver/dryer bolt 10 1.0 7.5 )
Expansion valve mount bolt 3.5 0.35 2.5 )
A/C refrigerant pressure sensor 11 1.1 8.0 )
Armature plate bolt 15 1.5 11.0 )
Relief valve 8 0.8 6.0 )

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-73
HVAC Unit Removal and InstallationS7RS0B7226003
Refer to “HVAC Unit Removal and Installation”.
Temperature Control Actuator Removal and
Installation
S7RS0B7226004
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hol e cover from instrument
panel.
3) Remove foot duct from HVAC unit.
4) Disconnect temperature control actuator connector (1).
5) Detach temperature control actuator rods (2) from linkage (3).
6) Remove temperature control actuator (4) from HVAC unit.
Installation
Reverse removal procedure.
Temperature Control Actuator InspectionS7RS0B7226005
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 of HVAC control module to MAX HOT position with ignition switch ON, and
make sure if the position of actuator lever is MAX
HOT position (A).
4) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
5) Measure resistance between terminal “3” and “5”.
Temperature control actuator resistance between
terminal “3” and “5” (MAX HOT position)
Approximately 2.5 k Ω at 25 °C (77 °F) 6) Connect connector to tem
perature control actuator.
7) Set temperature selector of HVAC control module to MAX COOL position with ignition switch ON, and
make sure if the position of actuator lever is MAX
COOL position (B).
8) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
9) Measure resistance between terminal “3” and “5”
Temperature control actuator resistance between
terminal “3” and “5” (MAX COOL position)
Approximately 4.8 k Ω at 25 °C (77 °F)
If check result is not satisfactory, replace the actuator
with new one.
2. Blower upper case 9. Blower motor controller 16. Evaporator 23. Temperature control actuator
3. Air intake control actuator 10. Blower lower case 17. O-ring24. Air flow control actuator
4. Air filter (if equipped) 11. Blower motor 18. Expansion valve25. Inside air temperature sensor
5. Heater unit upper case 12. Heater unit lower case 19. Evaporator temperature sensor 26. Aspirator hose
6. Foot duct 13. Heater core 20. Packing : Do not reuse.
7. Air flow control door assembly 14. Temperature control links 21. Filter cover
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2
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3
4
I5RS0A722020-02
I5RS0A722021-03
I5RS0A722022-03

Downloaded from www.Manualslib.com manuals search engine 7B-74 Air Conditioning System: Automatic Type
Air Flow Control Actuator Removal and
Installation
S7RS0B7226006
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hol e cover from instrument
panel.
3) Remove foot duct from HVAC unit.
4) Disconnect air flow contro l actuator connector (2).
5) Remove air flow control actuator (1) from HVAC unit, and then detach air flow actuator rod from linkage.
Installation
Reverse removal procedure.
Air Flow Control Actuator InspectionS7RS0B7226007
1) Remove air flow control actuator from HVAC unit referring to “Air Flow C ontrol Actuator Removal and
Installation”.
2) Connect actuator connector to the actuator.
3) Set air flow selector of HVAC control module to DEF position with ignition switch ON, and make sure if the
position of actuator lever is DEF position (8).
4) Turn ignition switch OFF, and then disconnect connector from air flow control actuator.
5) Measure resistance between terminal “3” and “5”
Air flow control actuator resistance between
terminal “3” and “5” (DEF position)
Approximately 4.8 k Ω at 25 °C (77 °F)
I5RS0A722023-03
[A]: LH steering vehicle [B]: RH steering vehicle
8
[A]
[B]
8
7654 321
I5RS0C722004-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-77
HVAC Control Module Removal and InstallationS7RS0B7226013
Removal1) Disconnect negative (–) cable at battery.
2) Disable air bag system referring to “Disabling Air Bag System in Section 8B”.
3) Remove passenger air bag module from instrument panel referring to “Passenger Air Bag (Inflator)
Module Removal and Installation in Section 8B”.
4) Remove radio assembly from instrument panel referring to “Rear Speaker Removal and Installation
in Section 9C”.
5) Remove two connectors fr om HVAC control module.
6) Remove HVAC control modu le (1) from instrument
panel.
NOTE
Be careful not to damage HVAC control
module and instrument panel by using rag.

Installation
Reverse removal procedure noting the following
instructions.
Enable air bag system referring to “Enabling Air Bag
System in Section 8B”.
Sunload Sensor Removal and InstallationS7RS0B7226014
Removal
1) Disconnect negative (–) cable at battery.
2) Remove combination meter 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). Installation
Reverse removal procedure.
Sunload Sensor InspectionS7RS0B7226015
1) Light over sunload sensor vertically with an
incandescent lamp of approximately 100 W. The
distance between sunload sensor and lamp should
be approximately 100 mm (3.94 in.).
2) Measure voltage between terminals of sunload sensor as shown.
If check result is not satisfactory, replace sunload
sensor with new one.
Sunload sensor voltage specification
0.4 V or more
Outside Air Temperature Sensor Removal and
Installation
S7RS0B7226016
Refer to “Instrument Panel Re moval and Installation in
Section 9C”.
Outside Air Temperature Sensor InspectionS7RS0B7226017
Refer to “Information Display (Clock) Removal and
Installation in Section 9C”.
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I4RH01722036-01

Downloaded from www.Manualslib.com manuals search engine 7B-78 Air Conditioning System: Automatic Type
Inside Air Temperature Sensor Removal and
Installation
S7RS0B7226018
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hole cover.
3) Remove connector and aspirator hose (1) from inside air temperature sensor (2).
4) Remove inside air temperature sensor from instrument panel while releas ing lock of both sides of
inside air temperature sensor.
Installation
Reverse removal procedure.
Inside Air Temperature Sensor InspectionS7RS0B7226019
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
1.7 k Ω ± 0.085 k Ω at 25 °C (77 ° F)
Condenser Assembly On-Vehicle InspectionS7RS0B7226020
Refer to “Condenser Assembly On-Vehicle Inspection”.
Condenser Assembly Removal and InstallationS7RS0B7226021
Refer to “Condenser Assembly Removal and
Installation”.
Receiver/Dryer Removal and InstallationS7RS0B7226022
Refer to “Receiver/Dryer Removal and Installation”.
Evaporator InspectionS7RS0B7226023
Refer to “Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Evaporator Temperature Sensor Removal and
Installation
S7RS0B7226024
Refer to “Evaporator Thermistor (Evaporator
Temperature Sensor) Removal and Installation”.
Evaporator Temperature Sensor InspectionS7RS0B7226025
Refer to “Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Expansion Valve Removal and InstallationS7RS0B7226026
Refer to “Expansion Valve Removal and Installation”.
Expansion Valve InspectionS7RS0B7226027
Refer to “Expansion Valve Inspection”.
A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
S7RS0B7226028
Refer to “A/C Refrigerant Pressure Sensor and Its Circuit
Inspection”.
A/C Refrigerant Pressure Sensor Removal and
Installation
S7RS0B7226029
Refer to “A/C Refrigerant Pressure Sensor Removal and
Installation”.
Compressor Relay InspectionS7RS0B7226030
Refer to “Compressor Relay Inspection”.
Compressor Drive Belt Inspection and
Adjustment
S7RS0B7226031
Refer to “Compressor Drive Belt Inspection and
Adjustment”.
12I5RS0A722028-01
Temperature
Resistance
1.7
0
32 25
77
F
5.5
I5RS0A722029-01

Downloaded from www.Manualslib.com manuals search engine Seat Belts: 8A-4
Front Seat Belt Removal and InstallationS7RS0B8106002
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor
assembly). 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. Ne glecting them may result in
personal injury or una ctivation of the seat
belt pretensioner when necessary.

Removal
1) Disconnect negative (–) cable at battery.
2) Disable air bag system. Refer to “Disabling Air Bag System in Section 8B”.
3) Remove center pillar lower trim.
4) Disconnect Yellow connector (1) from seat belt pretensioner (2).
a) Release locking of lock button (3).
b) After unlocked, disconnect to connector.
5) Remove front seat belts from the vehicle.
Installation
Install in reverse order of removal, noting the following.
• Seat belt anchor bolts should have an unified fine thread (7/16-20 UNF). Under no circumstances
should any different sized or metric screw threads be
used.
• Connect Yellow connector (1) to seat belt pretensioner securely.
a. Connect connector.
b. Lock connector with lock slider (2). • Enable air bag system. Refer to “Enabling Air Bag
System in Section 8B”.
Front Seat Belt InspectionS7RS0B8106003
WARNING!
• Never attempt to disassemble or repair the seat belt pretensioner (retractor
assembly). 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.
• Never measure resistance of pretensioner or disassemble it. Otherwise, personal
injury may result.

CAUTION!
If seat belt pretensioner (retractor assembly)
was dropped from a height of 30 cm (1 ft) or
more, it should be replaced.

Seat belts and attaching parts can affect the vital
components and systems of a vehicle.
Therefore, they should be inspected carefully and
replaced with genuine parts only.
a
b
21 3I6RS0B810003-01
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1
2
b)
a)
I6RS0B810004-01
I2RH01810004-01