2006 SUZUKI SWIFT Air flow

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Blower Motor Relay InspectionS7RS0B7106007
1) Remove junction block assembly referring to “BCM (Included in Junction Block Assembly) Removal and
Installation in Section 10B”.
2) Disconnect blower motor relay (1) from junction block assembly (2).
3) Check that there is no continuity between terminal “C” and “D”. If there is continuity, replace relay.
4) Connect battery positive (+ ) terminal to terminal “B”
of relay. Connect battery negative (–) terminal “A” of
relay.
Check continuity between terminal “C” and “D”.
If there is no continuity wh en relay is connected to
the battery, replace relay.
HVAC Control Unit ComponentsS7RS0B7106008
“D”
“B” “A”
“C”
1
2
I4RS0B710008-01
45
61
7
10
9
238
I4RS0B710009-01
1. Heater control body assembly 4. Bulb 7. Air intake selector10. Rear defogger switch (if equipped)
2. Air flow selector 5. Temperature control cable 8. Temperature selector
3. Blower speed selector 6. Air flow control cable9. A/C switch (if equipped)

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HVAC Control Unit Removal and InstallationS7RS0B7106009
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 “Audio Unit Re moval and Installation in
Section 9C”.
5) Remove driver side foot duct (1) from HVAC unit by removing screw (2).
6) Disconnect temperature control cable (1) and air flow control cable (2) from HVAC unit. 7) Remove two connectors from HVAC control unit.
8) Remove HVAC control unit (1) from instrument
panel.
NOTE
Be careful not to damage HVAC control unit
and instrument panel by using rag.

Installation
Reverse removal procedure noting the following
instructions.
• Connect temperature control cable and air flow control
cable of HVAC control unit to links of HVAC unit.
a. For LH steering vehicle, set air flow selector (1) to “DEF” position and temperature selector (2) to
“MAX HOT” position.
For RH steering vehicle, set air flow selector (1) to
“VENT” position and temperature selector (2) to
“MAX COOL” position.
[A]: LH steering vehicle [B]: RH steering vehicle
2
1
I4RS0B710010-01
2
1
1
2
[B] [A]
I4RS0B710011-01
1
I4RS0B710012-01
12I4RS0B710013-01
12I4RS0A710016-01

Downloaded from www.Manualslib.com manuals search engine 7A-8 Heater and Ventilation:
b. Move temperature control lever (1) and air flow control plate (2) fully to the arrow direction. c. Fix temperature control inner cable (1) to pin of
temperature control lever and air flow control inner
cable (2) to pin of air fl ow control plate, and then
fix each outer cable (3) to each cable lock clamp.
NOTE
After installing control cables, make sure that
control lever and plate move smoothly and
stop at proper position.

• Enable air bag system referring to “Enabling Air Bag System in Section 8B”.
• Make sure that air flow outlet changes correctly as air flow selector is changed.
[A]: LH steering vehicle [B]: RH steering vehicle
1
2
[A]
[B]
1
2
I4RS0B710014-01
[A]: LH steering vehicle [B]: RH steering vehicle
1
2
[B] [A] 3
3
1
3
23
I4RS0B710015-01

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

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Abnormal Noise Symptom Diagnosis of A/C SystemS7RS0B7214002
Abnormal Noise from Compressor
Abnormal Noise from Magnetic Clutch
Abnormal Noise from Tubing
Abnormal Noise from Condenser Assembly
Abnormal Noise from Crankshaft PulleyInsufficient airflow of
cooled air
A/C evaporator clogged or frosted
Check A/C evaporator and evaporator
thermistor (evaporator temperature sensor)
referring to “Evaporator Inspection” and
“Evaporator Thermistor (Evaporator
Temperature Sensor) Inspection”.
Air leaking from HVAC unit or air duct Repair as necessary.
Blower motor faulty Check blower motor referring to “Blower Motor
Inspection in Section 7A”.
Wiring or grounding faulty Repair as necessary.
Condition Possible cause Correction / Reference Item
Condition
Possible cause Correction / Reference Item
During compressor
operation, a rumbling
noise is heard
proportional to engine
revolutions Inadequate clearance in scroll area
Replace compressor.
A loud noise is heard at a
certain rpm,
disproportionately to
engine revolution Loose or faulty compressor drive belt
Adjust drive belt tension or replace drive belt.
Loose compressor mounting bolts Retighten mounting bolts.
A loud rattle is heard at
low engine rpm Loose compressor clutch plate bolt
Retighten clutch plate bolt.
Replace compressor if it was operated in this
condition for a long time.
Condition Possible cause Correction / Reference Item
A rumbling noise is heard
when compressor is not
in operation Worn or damaged bearings
Replace magnet clutch assembly.
A chattering noise is
heard when compressor
is in operation Faulty magnet clutch clearance
(excessive clearance)
Adjust magnet clutch clearance.
Worn magnet clutch friction surface Replace magnet clutch assembly.
Compressor oil leaked from shaft seal,
contaminating the friction surface Replace compressor body assembly.
Condition
Possible cause Correction / Reference Item
A droning noise is heard
from inside of the vehicle,
but not particularly
noticeable in engine
compartment Faulty tubing clamps
Reposition clamps or increase the number of
clamps.
Resonance caused by pulsation from
variations in re frigerant pressure Attach a silencer to tubing, or modify its
position and length.
Condition
Possible cause Correction / Reference Item
Considerable vibration in
condenser assembly Resonance from condenser assembly
bracket and body Firmly insert a silenc
er between condenser
assembly bracket and body.
Condition Possible cause Correction / Reference Item
A large rattling noise is
heard at idle or sudden
acceleration Loosen crankshaft pulley bolt
Retighten bolt.

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Abnormal Noise from Tension Pulley
Abnormal Noise from A/C Evaporator
Abnormal Noise from Blower Motor
A/C System Performance InspectionS7RS0B7214003
1) Confirm that vehicle and environmental conditions are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 35 °C (77 – 95
° F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal.
• Blower motor is normal.
• There is no air leakage from air ducts.
• Condenser fins are clean.
• Air filter in HVAC unit is not clogged with dirt and
dust.
• Battery voltage is about 12 V.
• Radiator cooling fan operates normally.
2) Make sure that high pressure valve (1) and low pressure valve (2) of manifold gauge are firmly
closed.
3) Connect high pressure charging hose (3) to high pressure service valve (5) on vehicle and low
pressure charging hose (4) to low pressure service
valve (6).
4) Bleed the air in charging hoses (3) and (4) by loosening their nuts respectively utilizing the
refrigerant pressure. When a hissing sound is heard,
immediately tighten nut.
CAUTION!
Do not connect high and low pressure
charging hoses in reverse.

Condition Possible cause Correction / Reference Item
Clattering noise is heard
from pulley Worn or damaged bearing
Replace tension pulley.
Pulley cranks upon
contact Cracked or loose bracket
Replace or retighten bracket.
ConditionPossible cause Correction / Reference Item
Whistling sound is heard
from A/C evaporator Depending on the combination of the
interior / exterior temperatures, engine
rpm and refrigerant pressure, the
refrigerant flowing out of the expansion
valve may, under certain conditions,
make a whistling sound At times, slightly decrea
sing refrigerant volume
may stop this noise.
Inspect expansion valve and replace if faulty.
Condition Possible cause Correction / Reference Item
Blower motor emits a
chirping sound in
proportion to its speed of
rotation Worn or damaged motor brushes or
commutator
Replace blower motor.
Fluttering noise or large
droning noise is heard
from blower motor Leaves or other debris introduced from
fresh air inlet to blower motor
Remove debris and make sure that the screen
at fresh air inlet is intact.
53
2
1
4 6
I4RS0A720006-01

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5) Warm up engine to the normal operating temperature and keep it at the specified idle speed.
6) Turn A/C switch ON, set blower speed selector at maximum speed position, temperature selector at
maximum cold position, airflow selector at face
position, and air intake switch at recirculation
position. (Confirm that A/C compressor and
condenser fans are working.)
7) Wait for ten minutes to stabilize the A/C operation.
8) Open front windows, front doors and engine hood.
9) With about 20 mm (0.8 in.) of dry bulb thermometer
(1) put right in front of center ventilation louver and a
wet and dry bulb thermometer (2) near air inlet of
HVAC unit. 10) Check for each pressure of low side and high side if
it is within shaded range of graph. If each gauge
reading is out of specified pressure, correct defective
part referring to the following table.
NOTE
Pressure registered on gauge varies with
ambient temperature. Therefore, use the
graphs when determining if pressures are
normal or not.

Low side and high side pressure example,
Gauges should read as follows when ambient
temperature is 30 °C (86 °F)
Pressure on high pressure gauge (HI): 1590 –
1940 kPa (15.9 – 19.4 kg/cm2)
Pressure on low pressure gauge (LO): 270 – 430
kPa (2.7 – 4.3 kg/cm
2)
2
1
I4RS0B720004-01
[A]: Pressure of high pressure gauge
[B]: Pressure of low pressure gauge
[C]: Ambient temperature
[D]: Humidity [E]: Acceptable range
22
312.9 2200
0 1
2 3 30 70 30 70 %
4 5 6 7 8 9
10
11 12 13 14 15
16 17
18
19 21
298.7 2100
20
14.2 28.4 42.7 56.9 71.1 85.3 99.5
113.8 128.0 142.2
151.4
170.6
184.9 199.1
213.3 227.5
241.7
256.0
270.2
284.4
100 200 300 400 500 600 700 800 900
1000 1100 1200
1300
1400 1500 1600
1700 1800
1900
2000
25 30 35
77 86 95
psi kPa kg/cm
2
C
F
“A”
“B”
“C”
“D”
23
2300
327.1
[A]
[B]
[C][D][E]
[E]
I7RS0A721006-01

Downloaded from www.Manualslib.com manuals search engine 7B-14 Air Conditioning System: Manual Type
ConditionPossible cause Correction
Manifold gauge MPa (kg/cm2) (psi)
Detail
Lo Hi
0.27 – 0.43
(2.7 – 4.3)
(38 – 61) 1.59 – 1.94
(15.9 – 19.4)
(226 – 276)
Normal condition — —
Negative pressure 0.5 – 0.6
(5 – 6)
(71.2 – 85.3) The low pressure side
reads a negative
pressure, and the high
pressure side reads an
extremely low pressure.
Presence of frost around
tubing to and from
receiver/dryer and
expansion valve. Dust particles or water
droplets are either
stuck or frozen inside
expansion valve,
preventing the
refrigerant from
flowing.Clean expansion
valve.
Replace it if it cannot
be cleaned.
Replace receiver/
dryer.
Evacuate the A/C
system and recharge
with fresh refrigerant.
Normal:
0.27 – 0.43
(2.7 – 4.3)
(38 – 61)
↑ ↓
Abnormal:
Negative pressure Normal:
1.59 – 1.94
(15.9 – 19.4)
(226 – 276)
↑
↓
Abnormal:
0.7 – 1.0
(7 – 10)
(100 – 142) During A/C operation, the
low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.
Expansion valve is
frozen due to
moisture in the
system, and
temporarily shuts off
the refrigeration cycle.
Replace expansion
valve.
Replace receiver/
dryer.
Evacuate A/C system
and recharge with
fresh refrigerant.
0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3) 0.7 – 1.0
(7 – 10)
(100 – 142) Both low and high
pressure sides indicate
low readings.
Output air is slightly cold.
Insufficient refrigerant
in system
(Refrigerant leaking).Using leak detector,
check for leaks and
repair as necessary.
Recharge refrigerant
to a specified amount.
If the pressure reading
is almost 0 when the
manifold gauges are
attached, check for
any leaks, repair
them, and evacuate
the system.
0.4 – 0.6
(4 – 6)
(56.9 – 85.3) Pressure on low pressure
side is high.
Pressure on high
pressure side is low.
Both pressure becoming
equal right after A/C is
turned OFF.
Internal leak in
compressor.
Inspect compressor
and repair or replace
as necessary.