2006 SUZUKI SX4 Service Workshop Manual

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A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
S6RW0D7216014
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 kgf/cm2, 116 psi): 1.40 – 1.78 V
1.4 MPa (14 kgf/cm2, 203 psi): 2.18 – 2.64 V
1.6 MPa (16 kgf/cm2, 232 psi): 2.44 – 2.92 V
1.8 MPa (18 kgf/cm2, 261 psi): 2.70 – 3.21 V
A/C Refrigerant Pressure Sensor Removal and
Installation
S6RW0D7216015
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”.
A/C Switch InspectionS6RW0D7216016
• Check that there is continuity between terminal (1)
and terminal (2) when A/C switch is at ON position.
• Check that there is no continuity between terminal (1)
and terminal (2) when A/C switch is at OFF position.
If check result does not meet the above conditions,
replace HVAC control unit.
2
1
I5RW0A721029-01
(a)
I5RW0A721030-01
1
2
I5RW0A721031-01

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A/C System Relay InspectionS6RW0D7216017
NOTE
Do not use blue relay for the substitute of
white relay because internal durability of a
blue relay is different from the durability of a
white relay.

1) Disconnect negative (–) cable from battery.
2) Remove compressor relay (1) or condenser cooling
fan relay (2) from main fuse box (3).
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 and battery negative (–) terminal to terminal
“a” of relay, and then check continuity between
terminal “c” and “d”. If there is no continuity, replace
relay.
Compressor Drive Belt Inspection and
Adjustment
S6RW0D7216018
Inspection
• Check compressor drive belt (1) for wear, crack,
deformation and cleanliness. If any defect is found,
replace the belt with new one referring to
“Compressor Drive Belt Removal and Installation”.
• Check compressor drive belt tension by measuring
how much it deflects when pushed intermediate point
between magnet clutch pulley (6) and crankshaft
pulley (3) with about 100 N (10 kg) force after rotating
crankshaft pulley 360°. If belt tension is out of
specification, adjust belt tension referring to
“Adjustment”.
Compressor drive belt tension
“a”
: 7 – 8 mm (0.28 – 0.31 in.)
NOTE
When replacing drive belt, adjust drive belt
tension to the following specifications.

New compressor drive belt tension “a”
: 6 – 7 mm (0.24 – 0.28 in.)
Adjustment
1) Loosen tension pulley nut (4).
2) Adjust belt tension by tighten or loosen tension
pulley adjusting bolt (5).
3) Tighten tension pulley nut.
4) Rotate the crankshaft pulley 360°, and then recheck
belt tension.
3
1
2
“a”
“b”“c”
“d”
I5RW0B721023-01
2. Tension pulley
I5RW0A721033-01

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Compressor Drive Belt Removal and
Installation
S6RW0D7216019
Removal
1) Loosen tension pulley nut (1).
2) Loosen belt tension 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
S6RW0D7216020
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 from the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
5) Remove condenser cooling fan referring to
“Condenser Cooling Fan Removal and Installation”.
6) Remove compressor drive belt referring to
“Compressor Drive Belt Removal and Installation”.
7) Remove right side engine under cover.
8) Disconnect magnet clutch lead wire coupler (1).
9) Disconnect discharge hose (2) and suction hose (3)
from compressor (4).
NOTE
Cap open fittings immediately to keep
moisture out of the system.

10) 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 “Replenishing Compressor Oil” in
“Operation Procedure for Refrigerant Charge”.
• Tighten compressor mounting bolts to specified
torque.
Tightening torque
Compressor mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• 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 Inspection and Adjustment”.
I5RW0A721034-01
3
42 1
I7RW01721021-01
1
12
I7RW01721022-01

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Compressor Assembly ComponentsS6RW0D7216021
Magnet Clutch InspectionS6RW0D7216022
• Check armature plate and magnet clutch pulley for wear and oil soak respectively.
• Check magnet clutch pulley bearing for noise, wear and grease leakage.
• Measure magnet clutch coil for resistance at 20 °C (68 °F). If the measured resistance is out of specification,
replace magnet clutch assembly.
Magnet clutch coil resistance
Standard: 3.5 – 4.0 Ω
6
2
9
4
4 3
1
7
5 8(a)
(b)
10
I7RW01721023-01
1. Armature plate bolt 5. Shim 9. O-ring
: Apply compressor oil.: Do not reuse.
2. Compressor 6. Magnet clutch coil 10. Thermal switch
3. Relief valve 7. Magnet clutch pulley : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
4. Circlip 8. Armature plate : 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
I4RS0A720038-01

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Magnet Clutch Removal and InstallationS6RW0D7216023
Removal
1) Remove compressor from vehicle referring to
“Compressor Assembly Removal and Installation”.
2) Fix armature plate (1) with special tool and remove
armature plate bolt (2).
Special tool
(A): 09991–06310
3) Remove armature plate (1).
4) Remove shims from shaft.
5) Remove circlip (1) using special tool.
Special tool
(B): 09900–061076) Remove magnet clutch pulley (2).NOTE
• If it is difficult to remove magnet clutch
pulley by hand, use puller (1).
• Do not damage magnet clutch pulley when
using puller.

7) Remove thermal switch from compressor referring to
“Thermal Switch Removal and Installation”.
8) Remove circlip (1) by using special tool.
Special tool
(B): 09900–06107
9) Remove magnet clutch coil (2) from compressor (3).
2
1
(A)
I4RS0A720039-01
(B)
1
I4RS0A720040-01
1 2
I4RS0A720041-01
1 (B)
23
I4RS0A720042-01

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Installation
1) Install magnet clutch coil (2) fitting protrusion (4) of
magnet clutch coil onto hole (5) of compressor (3).
2) Install circlip (1) directing chamfer side (6)
downward.
Special tool
(B): 09900–06107
3) Install thermal switch to compressor referring to
“Thermal Switch Removal and Installation”.
4) Install magnet clutch pulley (1).
5) Install new circlip (2) directing chamfer side (3)
upward.
Special tool
(B): 09900–061076) Tighten new armature plate bolt to specified torque.
Tightening torque
Armature plate nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
Special tool
(A): 09991–06310
7) Adjust clearance between armature plate (1) and
magnet clutch pulley by putting shim(s) on
compressor shaft. To measure the clearance,
perform the following steps.
a) Put compressor in a vise (2).
b) Set dial gauge (3) on armature plate, and then
adjust its pointer at 0.
c) Connect battery positive terminal (+) to magnet
clutch coil lead wire.
d) Connect battery negative terminal (–) to
compressor body assembly. (At this point,
armature plate and magnet clutch pulley are kept
in contact.)
e) Disconnect battery negative terminal (–) to
compressor body assembly. (At this point,
armature plate and magnet clutch pulley are not
in contact.)
1(B)
2
34
56
I4RS0A720043-01
1
32(B)
I4RS0A720044-01
(a)
(A)
I4RS0A720045-01

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f) Read stroke of armature plate from dial gauge by
performing step d) and e) repeatedly. (Stroke of
armature plate is clearance between armature
plate and magnet clutch pulley.)
Standard clearance between armature plate
and magnet clutch pulley:
0.3 – 0.5 mm (0.012 – 0.020 in.)
Thermal Switch InspectionS6RW0D7216024
Measured thermal switch for resistance at 20 °C (68 °F)
Thermal switch resistance
Standard: 50 mΩ (DC 16 V, 5A at 20 °C (68 °F))
Thermal Switch Removal and InstallationS6RW0D7216025
Removal
1) Remove compressor from engine referring to
“Compressor Assembly Removal and Installation”.
2) Disconnect thermal switch connector.
3) Remove magnet clutch lead wire clamp.
4) Remove thermal switch (1) from compressor using
flat head (2).
Installation
Reverse removal procedure noting the following
instructions.
• Apply silicon sealant to contact face (2) of thermal
switch (1).
“A”: Silicon sealant 99000–34220 (SUZUKI
SILICON SEALANT KE-347W (100g))
• Install compressor to vehicle referring to “Compressor
Assembly Removal and Installation”.
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
213
I4RS0A720046-01
I7RW01721024-01
21
I5RS0C721011-01
3
2, “A”1
I5RS0C721012-02

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Relief Valve InspectionS6RW0D7216026
By using special tool, check is there is refrigerant
leakage.
If there is refrigerant leakage, replace the relief valve.
Special tool
(A) : 09990–86012
Relief valve Removal and InstallationS6RW0D7216027
Removal
1) Recover refrigerant from the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Remove right side engine under cover.
3) Remove relief valve (1) from compressor (2).Installation
Reverse removal procedure noting the following
instructions.
• Use new O-ring
• Apply compressor oil to O-ring.
• Tighten relief 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”.
(A)
I5RS0C721014-01
12I4RS0A720048-01
(a)I4RS0A720049-01