2006 SUZUKI SX4 Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-41
P/S Control Module Removal and InstallationS6RW0D6306011
Removal
1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connectors (1) from P/S control module.
4) Remove P/S control module and bracket (2) from
floor panel.
5) Separate P/S control module and bracket.
Installation
Reverse removal procedure.
Torque Sensor and Its Circuit InspectionS6RW0D6306012
1) Check that torque sensor circuit is in good condition
referring to Step 2 to 3 of “DTC C1111 / C1113 /
C1115: Torque Sensor Circuit Failure”. If check result
is not satisfactory, repair torque sensor circuit.
2) Remove console box.
3) With ignition switch turned OFF, connect scan tool to
DLC or connect voltage tester between “E11-18” –
“E11-9” (main sensor) or “E11-10” – “E11-9” (sub
sensor) with connected connector to P/S control
module.
4) Set torque wrench to steering wheel referring to
“Steering Force Check” for checking steering force.
1
2
I5RW0A630027-01
[A]: Main sensor [B]: Sub sensor
E11
1818
E11
10
[A]
[B]
9 9
I7RW01632021-01
I3RM0A630022-01

Downloaded from www.Manualslib.com manuals search engine 6C-42 Power Assisted Steering System:
5) Turn ON ignition switch without engine running and
select scan tool “Data List” mode due to checking
“Sensor (Main) Torque” and “Sensor (Sub) Torque”
displayed on scan tool when steering wheel turned
left and right (if used).
6) Check that characteristic of torque sensor (main and
sub) output voltage or scan tool data and steering
force is as following graph when steering wheel is
turned left and right. If sensor voltage or scan tool
data is out of specified value or does not vary linearly
as the following graph, check EPS control module
and its circuit referring to “Inspection of P/S Control
Module and Its Circuits”.
If they are OK, replace steering gear case assembly.P/S Motor and Its Circuit InspectionS6RW0D6306013
1) Check motor circuit referring to Step 2 to 3 of “DTC
C1141 / C1142 / C1143 / C1145: Motor Circuit
Failure”. If check result is not satisfactory, repair
motor circuit.
2) Disconnect motor connector from steering gear case
assembly with ignition switch turned OFF.
3) Check for resistance between terminals of motor
connector.
If check result is not as specified, check P/S motor
harness for continuity. If it is OK, replace steering
gear case assembly.
Motor circuit resistance
4) Check for insulation between each terminal of motor
connector and body ground.
If check result is not as specified, check P/S motor
harness for insulation. If it is OK, replace steering
gear case assembly.
Motor circuit resistance
5) Hoist vehicle
6) Check that steering wheel turns to left and right
smoothly. If steering wheel does not turn smoothly,
inspect and repair defective steering and suspension
parts.
7) Connect “E12” connector with ignition switch turned
OFF.
[A]: Main sensor
[B]: Sub sensor
[C]: Steering force at left turn
[D]: Steering force at right turn
[E]: Steering wheel at free
[F]: “Sensor (Main) Torque” in “Data List” displayed on scan tool
[G]: “Sensor (Sub) Torque” in “Data List” displayed on scan tool
0
[E][N.m]
MAX
MAX [D] [C]
[E][D] [C]
2.33 - 2.68[V] [F]
[G] [A]
[B]
66
1.65 - 1.9
(1.0 - 1.3)3.0 - 3.4 (3.7 - 4.0)
0 5
2.33 - 2.681.65 - 1.9
(1.0 - 1.3)3.0 - 3.4 (3.7 - 4.0)
0 5
0
[N.m]
MAX
MAX
[V]
6 11.76 11.7611.76 11.766
0 11.5
-12.00 -12.0
11.5
I7RW01632011-02
“E12-1” and “E12-2” (For motor) Approx. 1 Ω
Each terminal and body ground No continuity
[A]: Motor connector “E12” (viewed from harness side)
12
[A]
I6RW0C630012-02

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-43
8) Using ammeter (2), check that P/S motor current (1)
is as following table with idling engine. If check result
is not satisfactory, check P/S control module for
torque sensor signal and P/S motor output referring
to “Inspection of P/S Control Module and Its
Circuits”. If they are OK, replace steering gear case
assembly.
NOTE
When P/S motor is cold condition (that is,
armature coil of P/S motor is not heated),
motor current in the following table can be
measured

Motor current at hoisted vehicle (reference
value)
Specifications
Tightening Torque SpecificationsS6RW0D6307001
NOTE
The specified tightening torque is also described in the following.
“Steering Gear Case Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. ConditionWhen
steering
wheel is left
at straight
position: [A]When steering
wheel is turned
left or right by
turning speed
with 90° /sec:
[B]When
steering
wheel is
kept fully
turned left
or right
until it
stops.: [C]
Motor
currentApprox. 0 A Approx. 0 – 5 AApprox.
45 – 60 A
3. P/S control module
1
32
E12-1
E12-2
[C][A]
[B] [B]
I7RW01632012-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Tie-rod end nut 45 4.5 32.5)
Tie-rod end lock nut 45 4.5 32.5)
Wheel bolt 85 8.5 61.5)
Steering gear case mounting bolt 70 7.0 51.0)
Steering lower shaft assembly upper joint bolt 25 2.5 18.5)
Steering lower shaft assembly lower joint bolt 25 2.5 18.5)
Tie-rod 75 7.5 54.5)
Earth cable bolt 4.0 0.4 2.8)
Rack damper screw Tighten 25 N⋅m (2.5 kgf-m, 18.0 lb-ft) and
loosen 180° and then tighten 3.9 N⋅m (0.39
kgf-m, 3.0 lb-ft) and turn it back by 10° or
less by the specified procedure.)
Rotation torque of pinion 2.2 0.22 1.5)
Steering rack damper lock nut 60 6.0 43.5)

Downloaded from www.Manualslib.com manuals search engine 6C-44 Power Assisted Steering System:
Special Tools and Equipment
Recommended Service MaterialS6RW0D6308001
NOTE
Required service material is also described in the following.
“Steering Gear Case Assembly Components”

Special ToolS6RW0D6308002
Material SUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease E P/No.: 99000–25050)
Water tight sealant SUZUKI Bond No.1207F P/No.: 99000–31250)
09944–18220 SUZUKI scan tool
Pinion torque checking
socket—
)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 Table of Contents 7- i
7
Section 7
CONTENTS
HVAC
Precautions ................................................. 7-1
Precautions............................................................. 7-1
Precautions on HVAC ........................................... 7-1
Heater and Ventilation............................. 7A-1
General Description ............................................. 7A-1
Heater and Ventilation Construction ................... 7A-1
Schematic and Routing Diagram ........................ 7A-2
Heater and Ventilation Wiring Circuit Diagram .... 7A-2
Component Location ........................................... 7A-2
Electronic Control System Components
Location ............................................................ 7A-2
Diagnostic Information and Procedures ............ 7A-3
Heater and Ventilation Symptom Diagnosis........ 7A-3
Repair Instructions .............................................. 7A-4
HVAC Unit Components ..................................... 7A-4
HVAC Unit Removal and Installation (Non-A/
C) ...................................................................... 7A-4
Blower Motor Removal and Installation............... 7A-4
Blower Motor Inspection ..................................... 7A-4
Blower Motor Resistor Removal and
Installation ......................................................... 7A-5
Blower Motor Resistor Inspection ....................... 7A-5
Blower Motor Relay Inspection ........................... 7A-6
HVAC Control Unit Components ......................... 7A-6
HVAC Control Unit Removal and Installation ...... 7A-7
Blower Speed Selector Inspection ...................... 7A-9
Air Intake Selector Inspection ............................. 7A-9
Air Intake Control Actuator Removal and
Installation ......................................................... 7A-9
Air Intake Control Actuator Inspection .............. 7A-10
Center Ventilation Louver Removal and
Installation ....................................................... 7A-11
Side Ventilation Louver Removal and
Installation ....................................................... 7A-11
Rear Duct Removal and Installation (If
Equipped)........................................................ 7A-12
HVAC Air Filter Removal and Installation (If
Equipped)........................................................ 7A-12
HVAC Air Filter Inspection (If Equipped) ........... 7A-12
Air Conditioning System......................... 7B-1
Manual Type ............................................................ 7B-1
Precautions........................................................... 7B-1A/C System Caution ............................................ 7B-1
Precautions on Servicing A/C System ................ 7B-1
General Description .............................................7B-2
Sub-Cool A/C System Description ...................... 7B-2
Manual A/C Electronic Input Output Table .......... 7B-3
A/C Operation Description at ECM ..................... 7B-3
Schematic and Routing Diagram ........................7B-4
A/C System Air Flow Diagram............................. 7B-4
A/C System Wiring Diagram ............................... 7B-5
Component Location ...........................................7B-6
A/C System Major Components Location ........... 7B-6
Electronic Control System Components
Location............................................................. 7B-7
Diagnostic Information and Procedures ............7B-8
A/C System Performance Inspection .................. 7B-8
Trouble Diagnosis for Abnormal Pressure ........ 7B-11
A/C System Inspection at ECM ......................... 7B-12
A/C System Symptom Diagnosis ...................... 7B-13
Abnormal Noise Symptom Diagnosis of A/C
System ............................................................ 7B-15
Repair Instructions ............................................7B-17
Operation Procedure for Refrigerant Charge .... 7B-17
Condenser Cooling Fan Removal and
Installation ....................................................... 7B-22
Condenser Cooling Fan Inspection ................... 7B-23
Condenser Assembly On-Vehicle Inspection .... 7B-23
Condenser Assembly Removal and
Installation ....................................................... 7B-23
Desiccant Removal and Installation .................. 7B-24
HVAC Unit Components ................................... 7B-25
HVAC Unit Removal and Installation ................ 7B-26
Evaporator Inspection ....................................... 7B-27
Evaporator Temperature Sensor Removal
and Installation ................................................ 7B-27
Evaporator Temperature Sensor Inspection ..... 7B-28
Expansion Valve Removal and Installation ....... 7B-28
Expansion Valve Inspection .............................. 7B-28
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection............................................. 7B-29
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................ 7B-29
A/C Switch Inspection ....................................... 7B-29
A/C System Relay Inspection............................ 7B-30
Compressor Drive Belt Inspection and
Adjustment ...................................................... 7B-30

Downloaded from www.Manualslib.com manuals search engine 7-ii Table of Contents
Compressor Drive Belt Removal and
Installation ....................................................... 7B-31
Compressor Assembly Removal and
Installation ....................................................... 7B-31
Compressor Assembly Components................. 7B-32
Magnet Clutch Inspection.................................. 7B-32
Magnet Clutch Removal and Installation........... 7B-33
Thermal Switch Inspection ................................ 7B-35
Thermal Switch Removal and Installation ......... 7B-35
Relief Valve Inspection...................................... 7B-36
Relief valve Removal and Installation ............... 7B-36
Specifications .....................................................7B-37
Tightening Torque Specifications ...................... 7B-37
Special Tools and Equipment ...........................7B-37
Recommended Service Material ....................... 7B-37
Special Tool ...................................................... 7B-37
Automatic Type .....................................................7B-38
Precautions.........................................................7B-38
A/C System Caution .......................................... 7B-38
Precautions in Diagnosing Trouble ................... 7B-38
Precautions on Servicing A/C System .............. 7B-38
General Description ...........................................7B-39
Auto A/C System Description ............................ 7B-39
HVAC Control Description................................. 7B-40
Sub-Cool A/C System Description .................... 7B-40
On-Board Diagnostic System Description ......... 7B-41
Schematic and Routing Diagram ......................7B-41
A/C System Air Flow Diagram........................... 7B-41
A/C System Wiring Diagram ............................. 7B-42
Component Location .........................................7B-43
A/C System Major Components Location ......... 7B-43
Electronic Control System Components
Location .......................................................... 7B-44
Diagnostic Information and Procedures ..........7B-45
Air Conditioning System Check......................... 7B-45
A/C System Symptom Diagnosis ...................... 7B-47
Abnormal Noise Symptom Diagnosis of A/C
System ............................................................ 7B-49
DTC Check........................................................ 7B-49
DTC Clearance ................................................. 7B-51
DTC Table ......................................................... 7B-52
Fail-Safe Table .................................................. 7B-54
Scan Tool Data ................................................. 7B-55
Visual Inspection ............................................... 7B-57
DTC B1502: Inside Air Temperature Sensor
Circuit Malfunction .......................................... 7B-57
DTC B1503: Evaporator Temperature Sensor
Circuit Malfunction .......................................... 7B-59
DTC B1504: Sunload Sensor Circuit
Malfunction ...................................................... 7B-60
DTC B1511: Temperature Control Actuator
(Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-61
DTC B1512: Air flow Control Actuator
(Position Sensor) and/or Its Circuit
Malfunction ...................................................... 7B-63
DTC B1513: Temperature Control Actuator
(Motor) and/or Its Circuit Malfunction .............. 7B-65DTC B1514: Air Flow Control Actuator (Motor)
and/or Its Circuit Malfunction........................... 7B-67
DTC B1520 / B1521 / B1522: Temperature /
Blower Speed / Air Flow Selector
Malfunction ...................................................... 7B-68
DTC B1541: Back-Up Power Supply Circuit
Malfunction ...................................................... 7B-69
DTC B1546: A/C Refrigerant Pressure
Malfunction ...................................................... 7B-70
DTC B1551: Serial Communication Circuit
Malfunction ...................................................... 7B-70
DTC B1552: HVAC Control Module Check
Sum Error ........................................................ 7B-72
DTC B1553: CAN Communication Circuit
Malfunction ...................................................... 7B-72
DTC B1557: VSS Signal Failure ....................... 7B-73
DTC B1561: ECT Signal Failure ....................... 7B-73
DTC B1562: Outside Air Temperature Signal
Failure ............................................................. 7B-74
DTC B1563: A/C Refrigerant Pressure Signal
Failure ............................................................. 7B-74
DTC B1570: Engine Type Signal Failure .......... 7B-75
DTC B1571: Combination Meter Spec Signal
Failure ............................................................. 7B-75
Inspection of HVAC Control Module and Its
Circuit .............................................................. 7B-76
A/C System Inspection at ECM ......................... 7B-79
Repair Instructions ............................................7B-79
Operation Procedure for Refrigerant Charge .... 7B-79
HVAC Unit Components ................................... 7B-80
HVAC Unit Removal and Installation ................ 7B-81
Temperature Control Actuator Removal and
Installation ....................................................... 7B-81
Temperature Control Actuator and Its Circuit
Inspection ........................................................ 7B-81
Air Flow Control Actuator Removal and
Installation ....................................................... 7B-83
Air Flow Control Actuator and Its Circuit
Inspection ........................................................ 7B-83
Air Intake Actuator Removal and Installation .... 7B-84
Air Intake Actuator Inspection ........................... 7B-84
Actuator Linkage Inspection.............................. 7B-84
Blower Motor Controller Removal and
Installation ....................................................... 7B-84
Blower Motor Controller Inspection ................... 7B-85
HVAC Control Module Removal and
Installation ....................................................... 7B-85
Sunload Sensor Removal and Installation ........ 7B-85
Sunload Sensor Inspection ............................... 7B-86
Outside Air Temperature Sensor Removal
and Installation ................................................ 7B-86
Outside Air Temperature Sensor Inspection ..... 7B-86
Inside Air Temperature Sensor Removal and
Installation ....................................................... 7B-86
Inside Air Temperature Sensor Inspection ........ 7B-86
Condenser Cooling Fan Relay Inspection......... 7B-87
Condenser Cooling Fan Removal and
Installation ....................................................... 7B-87
Condenser Cooling Fan Inspection ................... 7B-87
Condenser Assembly On-Vehicle Inspection .... 7B-87

Downloaded from www.Manualslib.com manuals search engine Table of Contents 7-iii
Condenser Assembly Removal and
Installation ....................................................... 7B-87
Evaporator Inspection ....................................... 7B-87
Evaporator Temperature Sensor Removal
and Installation ................................................ 7B-87
Evaporator Temperature Sensor Inspection ..... 7B-87
Expansion Valve Removal and Installation ....... 7B-87
Expansion Valve Inspection .............................. 7B-87
A/C Refrigerant Pressure Sensor and Its
Circuit Inspection ............................................ 7B-87
A/C Refrigerant Pressure Sensor Removal
and Installation ................................................ 7B-87
Compressor Relay Inspection ........................... 7B-87
Compressor Drive Belt Inspection and
Adjustment ...................................................... 7B-87Compressor Drive Belt Removal and
Installation ....................................................... 7B-87
Compressor Assembly Removal and
Installation ....................................................... 7B-87
Compressor Assembly Components................. 7B-87
Magnet Clutch Removal and Installation........... 7B-87
Magnet Clutch Inspection.................................. 7B-87
Thermal Switch Inspection ................................ 7B-87
Thermal Switch Removal and Installation ......... 7B-87
Relief Valve Inspection...................................... 7B-87
Special Tools and Equipment ...........................7B-88
Recommended Service Material ....................... 7B-88
Special Tool ...................................................... 7B-88

Downloaded from www.Manualslib.com manuals search engine 7-1 Precautions:
HVAC
Precautions
Precautions
Precautions on HVACS6RW0D7000001
Air Bag Warning
Refer to “Air Bag Warning in Section 00”.
A/C System Caution
Refer to “A/C System Caution in Section 7B” or “A/C System Caution in Section 7B”.
Precautions on Servicing A/C System
Refer to “Precautions on Servicing A/C System in Section 7B” or “Precautions on Servicing A/C System in Section
7B”.
Precaution in Diagnosing Trouble (Automatic Type)
Refer to “Precautions in Diagnosing Trouble in Section 7B”.