2005 SUZUKI SWIFT air cond

Downloaded from www.Manualslib.com manuals search engine 7-ii Table of Contents
Recommended Service Material ....................... 7B-33
Special Tool ...................................................... 7B-33
Automatic Type .................... .................................7B-34
Precautions.........................................................7B-34 A/C System Caution .......................................... 7B-34
Precautions in Diagnosing Trouble ................... 7B-34
Precautions on Servicing A/C System .............. 7B-34
General Description .......... .................................7B-34
Auto A/C System Descript ion ............................ 7B-34
HVAC Control Module Operation Description ... 7B-36
Refrigerant Type Identifica tion .......................... 7B-36
Sub-Cool A/C System Description .................... 7B-36
A/C Operation Description ................................ 7B-36
On-Board Diagnostic System Description ......... 7B-37
Schematic and Routing Diagram ......................7B-37 Major Components of A/C System .................... 7B-37
A/C System Wiring Diagra m ............................. 7B-38
Diagnostic Information and Procedures ..........7B-39 A/C System Symptom Diagnosis ...................... 7B-39
Abnormal Noise Sympto m Diagnosis of A/C
System ............................................................ 7B-42
DTC Check........................................................ 7B-42
DTC Clearance ................................................. 7B-43
DTC Table ......................................................... 7B-44
Fail-Safe Table ................. ................................. 7B-45
Scan Tool Data ................................................. 7B-46
Air Conditioning System Check......................... 7B-47
Visual Inspection ............................................... 7B-49
DTC B1502: Inside Air Temperature Sensor and/or Its Circuit Malfunction .......................... 7B-49
DTC B1503: A/C Evaporator Air Temperature Sensor and/or Its Circuit Malfunction .............. 7B-50
DTC B1504: Sunload Sensor and/or Its Circuit Malfunction ......... ................................. 7B-52
DTC B1511: Temperature Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-53
DTC B1512: Air flow Control Actuator (Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-55
DTC B1513: Temperature Control Actuator and/or Its Circuit Malfunction .......................... 7B-57
DTC B1514: Air Flow Co ntrol Actuator and/or
Its Circuit Malfunction ...................................... 7B-60
DTC B1541: HVAC Control Module Back-Up Power Supply Malfunction .............................. 7B-62
DTC B1546: A/C Refrigerant Pressure Malfunction ...................................................... 7B-63
DTC B1551: Serial Communication Circuit Malfunction ...................................................... 7B-63
DTC B1552: Serial Communication Signal Malfunction ...................................................... 7B-64
DTC B1553: CAN Communication Signal Malfunction ...................................................... 7B-65
DTC B1557: Vehicle Speed Sensor Signal Malfunction ...................................................... 7B-65
DTC B1561: Engine Coolant Temperature Sensor Signal Malfunctio n .............................. 7B-66 DTC B1562: Outside Air Temperature Sensor
Signal Malfunction ........................................... 7B-66
DTC B1563: A/C Refr igerant Pressure
Sensor Signal Malfunction .............................. 7B-66
Inspection of HVAC Control Module and Its Circuit .............................................................. 7B-67
A/C System Performance Inspection ................ 7B-70
A/C System Inspection at ECM ......................... 7B-70
Repair Instructions ............ ................................7B-71
Operation Procedure for Refrigerant Charge .... 7B-71
HVAC Unit Components ................................... 7B-72
HVAC Unit Removal and In stallation ................ 7B-73
Temperature Control Actuator Removal and Installation ....................................................... 7B-73
Temperature Control Actuat or Inspection ......... 7B-73
Air Flow Control Actuator Removal and Installation ....................................................... 7B-74
Air Flow Control Actuator Inspection ................. 7B-74
Air Intake Control Actuator Removal and Installation ....................................................... 7B-75
Air Intake Control Actuator Inspection............... 7B-75
Actuator Linkage Inspection .............................. 7B-76
Blower Motor Controller Removal and Installation ....................................................... 7B-76
Blower Motor Controller Inspection ................... 7B-76
HVAC Control Module Removal and Installation ....................................................... 7B-77
Sunload Sensor Removal and Installation ........ 7B-77
Sunload Sensor Inspection ............................... 7B-77
Outside Air Temperature Sensor Removal and Installation ................................................ 7B-77
Outside Air Temperature Sensor Inspection ..... 7B-77
Inside Air Temperature Sensor Removal and Installation ....................................................... 7B-78
Inside Air Temperature Sens or Inspection ........ 7B-78
Condenser Assembly On-Vehicle Inspection .... 7B-78
Condenser Assembly Removal and Installation ....................................................... 7B-78
Receiver/Dryer Removal and Installation .......... 7B-78
Evaporator Inspection ....................................... 7B-78
Evaporator Temperature Sensor Removal and Installation ................................................ 7B-78
Evaporator Temperature Se nsor Inspection ..... 7B-78
Expansion Valve Removal an d Installation ....... 7B-78
Expansion Valve Inspection .............................. 7B-78
A/C Refrigerant Pressure Sensor and Its Circuit Inspection............................................. 7B-78
A/C Refrigerant Pressu re Sensor Removal
and Installation ................................................ 7B-78
Compressor Relay Inspection .
.......................... 7B-78
Compressor Drive Belt Inspection and Adjustment ...................................................... 7B-78
Compressor Drive Belt Removal and Installation ....................................................... 7B-79
Compressor Assembly Removal and Installation ....................................................... 7B-79
Compressor Assembly Components................. 7B-79
Magnet Clutch Removal and Installation........... 7B-79
Magnet Clutch Inspection.................................. 7B-79
Relief Valve Inspection...................................... 7B-79

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-3
Diagnostic Information and Procedures
Heater and Ventilation Symptom DiagnosisS7RS0B7104001
ConditionPossible cause Correction / Reference Item
Blower motor does not
operate with blower
speed selector ON Fuse blown
Check related fuses, and then check for short
circuit to ground.
Blower motor relay faulty Check blower motor relay referring to “Blower
Motor Relay Inspection”.
Blower motor resistor faulty Check blower motor resistor referring to
“Blower Motor Resistor Inspection”.
Blower speed selector faulty Check blower speed selector referring to
“Blower Speed Selector Inspection”.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection”.
Wiring or grounding faulty Repair as necessary.
Incorrect temperature
output Temperature control cable broken or
bent (manual A/C) Check temperature control cable.
Temperature control lever faulty (manual
A/C) Check temperature control lever.
Incorrect installation of temperature
control cable (manual A/C) Check position and adjust it as necessary.
Temperature control door assembly
broken Repair temperature control door assembly.
Air ducts clogged Repair air ducts.
Heater core leaked or clogged Replace heater core.
Heater hoses leaked or clogged Replace heater hoses.
Thermostat faulty Check thermostat referring to “Thermostat
Inspection in Section 1F”.
Temperature control actuator faulty
(automatic A/C) Check temperature control actuator referring to
“Temperature Control Actuator Inspection in
Section 7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air outlet port does not
change or does not agree
with air flow selector’s
position even if air flow
selector is changed Air flow control cable broken or bent
(manual A/C)
Check air flow control cable.
Air flow control lever faulty (manual A/C) Check air flow control lever.
Incorrect installation of air flow control
cable (manual A/C) Check position and adjust it as necessary.
Air flow control door assembly broken Repair air flow control door assembly.
Air ducts leaked or clogged Repair air ducts.
Air flow control actuator faulty
(automatic A/C) Check air flow control actuator referring to “Air
Flow Control Actuator
Inspection in Section
7B”.
HVAC control module faulty (automatic
A/C) Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (automatic A/
C) Repair as necessary.
Air intake door does not
change even if air intake
mode is changed Air intake door broken
Repair air intake door.
Air intake control actuator faulty Check air intake control actuator referring to
“Air Intake Control Actuator Inspection”.
Air intake selector faulty Check air intake selector referring to “Air Intake
Selector Inspection”.
Wiring or grounding faulty Repair as necessary.

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-9
Blower Speed Selector InspectionS7RS0B7106010
Check blower speed selector for each terminal to
terminal continuity. If check result does not meet the
following conditions, replace HVAC control unit.
Air Intake Selector InspectionS7RS0B7106011
• Check that there is continuity between terminal (1) and terminal (2) when air intake selector is at fresh
position.
• Check that there is no continuity between terminal (1) and terminal (2) when air intake selector is at
recirculation position.
If check result does not meet the above conditions,
replace HVAC control unit.
Air Intake Control Actuator Removal and
Installation
S7RS0B7106012
Removal
1) Remove instrument panel from vehicle body referring to “Instrum ent Panel Removal and
Installation in Section 9C”.
2) Remove screws (1).
3) Remove air intake control actuator (2) from HVAC unit.
Installation
Reverse removal procedure noting the following
instruction.
• Be sure to insert the linkage pin (1) into the groove (2) of air intake control actuator.
IHMH
GND LML
PositionTerminalI
OFF 1
2
3
4 LMLMHHGND
I4RS0A710019-01
1
2
I5RS0A710001-01
1 1
2
I4RS0A710021-01
1
2
I4RS0A710022-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-1
HVAC
Air Conditioning System
Manual Type
Precautions
A/C System CautionS7RS0B7210001
CAUTION!
• The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Be sure to check which refrigerant is used be fore any service work including inspection and
maintenance. For identification between these two types, refer to “Refrigerant Type Identification”.
When replenishing or changing refrigerant and comp ressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being
serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
• When servicing the compressor, keep dirt or foreign material away from getting on or into the compressor parts and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any “On
vehicle” repair or before removal of the compressor. The parts must be kept clean at all times and
any parts to be reassembled should be cleaned with trichloromethane, naphtha, kerosene or
equivalent solvent and dried with dry air. Use only lint free cloths to wipe parts.
• When compressor is removed from the vehicle for servicing, the oil remaining in the compressor
should be discarded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair
procedures require that the system be discharged of refrigerant.

Precautions on Servicing A/C SystemS7RS0B7210002
WARNING!
Should refrigerant HFC-134a (R-134a) is exposed to your eye(s), consult a doctor immediately.
• Do not use your hand to rub affected eye(s). Instead, use fresh cold water to splash it over affected area to thus gradually raise its temperature above the freezing point.
• Obtain proper treatment as soon as possible from a doctor or eye specialist. Should liquid refrigerant HFC-134a (R-134a) is exposed to your skin, such affected part should be treated in the
same manner as when skin is frostbitten or frozen.

Handling Refrigerant HFC-134a (R-134a)
• Always wear goggles to protect your eyes.
• Avoid direct contact to liquid refrigerant.
• Do not heat refrigerant container higher than 40 °C (104 ° F).
• Do not discharge refrigerant into atmosphere.
• Do not expose bright metals to liquid refrigerant. Refrig erant combined with moisture is corrosive and tarnishes
surfaces of bright metals including chrome.

Downloaded from www.Manualslib.com manuals search engine 7B-2 Air Conditioning System: Manual Type
Refrigerant Line
• Never use heat for bending pipes. When bending a pipe , try to make its bending angle as smooth as possible.
• Keep internal parts of air conditioning free from moistu re and dirt. When disconnecting any line from system, install
a blind plug or cap to the fitting immediately.
• When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to O-ring.
• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
• Check local governmental regulations regarding working with refrigerator systems and its tooling.
• Route drain hose so that drained water does not make any contact to vehicle components.
• If pipes or hoses are replaced, replenish specified amount of compressor oil to compre ssor suction side referring to
“Replenishing Compressor Oil” in “Operation Procedure for Refrigerant Charge”.
Refrigerant Recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a (R-1 34a) into atmosphere would cause adverse effect to
environments.
NOTE
When handling recovery and recycling equipment, be sure to follow the instruction manual for the
equipment.

Refrigerant Charge
After performing compressor oil replenishment and evacuat ion, charge a proper amount of refrigerant to A/C system
referring to “Charge” in “Operation Procedure for Refrigerant Charge”.
3
1
2
4
5
I4RS0B720001-02
1. Suction hose : Apply compressor oil (refrigerant oil) to O-ring. 4. Expansion valve
: Apply compressor oil (refrigerant oil) to O-ring.
2. Discharge hose : Apply compressor oil (refrigerant oil) to O-ring. 5. A/C refrigerant pressure sensor
: Apply compressor oil (refrigerant oil) to O-ring.
3. Liquid pipe : Apply compressor oil (refrigerant oil) to O-ring.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-3
General Description
Refrigerant Type IdentificationS7RS0B7211001
Whether the A/C system in the vehicle uses HFC-134a (R-134a) or CFC-12 (R-12) is indicated on label (1) on the
compressor. Also, it can be checked by th e shape of the service (charge) valve (2).
[A]: HFC-134a (R-134a) [B]: CFC-12 (R-12)
I4RS0A720002-01

Downloaded from www.Manualslib.com manuals search engine 7B-4 Air Conditioning System: Manual Type
Sub-Cool A/C System DescriptionS7RS0B7211003
In the sub-cool A/C system (condenser integrated with receiver/dryer), the inside of the condenser is divided into the
condensation part and the sub-cooler part, and the receiver/dryer is located between those. In the receiver/dryer, the
refrigerant is separated into the vapor refrigerant and the liqui d refrigerant. Only the liquid refrigerant is delivered to the
sub-cooler part of the condenser. The refrigerant is supercooled by the sub-cooler part of the condenser.
A/C Operation DescriptionS7RS0B7211004
ECM controls the radiator fan relay and the compressor relay by following signals.
• ON/OFF signal of A/C switch
• A/C refrigerant pressure sensor
• Evaporator thermistor (evaporator temperature sensor)
• ECT sensor
NOTE
The signal of A/C swit ch is fed from BCM to ECM usin g CAN communication system. For CAN
communication system, refer to “CAN Communication System Description in Section 1A”.

I7RS0A721001-01
[A]: Liquid 2. Magnet clutch 6. Expansion valve10. Desiccant
[B]: Vapor 3. Condenser 7. A/C evaporator11. Filter
[C]: Superheated vapor 4. Receiver/dryer (Modulator) 8. Condensation part12. Vapor refrigerant
1. Compressor 5. Refrigerant pressure sensor 9. Sub-cooler part 13. Liquid refrigerant

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-5
Schematic and Routing Diagram
Major Components of A/C SystemS7RS0B7212001
Airflow diagram
Major components of A/C system
I4RS0A720003-01
7
2
34
1 8
6
5
I4RS0B720002-01
1. HVAC unit 5. Discharge hose9. Side ventilation air 13. Side defroster air
2. Compressor 6. Suction hose10. Center ventilation air 14. Fresh air
3. Condenser assembly 7. Liquid pipe11. Foot air 15. Recirculation air
4. Receiver/dryer (Modulator) 8. Expansion valve12. Front defroster air 16. Evaporator