2006 SUZUKI SX4 Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-77
G20-8 BLU/WHTElectric load signal for
blower motor10 – 14 V• Ignition switch turned ON, blower speed selector
OFF or 1st position
• Ignition switch turned ON, blower speed selector
from 1st to 2nd position
0 – 2 V• Ignition switch turned ON, blower speed selector
between 3rd and HIGH position
• Ignition switch turned ON, blower speed selector
from 3rd to 2nd position
G20-9 WHT/BLKEvaporator temperature
sensor signalApprox. 2.6 VIgnition switch turned ON, evaporator temperature 0
°C (32 °F)
Approx. 1.7 VIgnition switch turned ON, evaporator temperature
15 °C (59 °F)
Approx. 1.0 VIgnition switch turned ON, evaporator temperature
30 °C (86 °F)
G20-10 PNK/BLKInside air temperature
sensor signalApprox. 2.5 VIgnition switch turned ON, room temperature 25 °C
(77 °F)
Approx. 3.7 VIgnition switch turned ON, room temperature 0 °C
(32 °F)
G20-11 — — —
G20-12 WHTOutput of 5 V power
source for air flow control
actuator position sensor
and temperature control
actuator position sensor4 – 6 V Ignition switch turned ON
G20-13 YELSerial communication line
of BCMRefer to “Reference waveform No. 2: Automatic Type”.
G20-14 — — — —
G20-15 BRN/YELAir flow control actuator
(FACE)10 – 14 VIgnition switch turned ON, air flow control actuator is
working in operation from “DEF” to “FACE” position
0 – 1 VIgnition switch turned ON, except the above
condition
G20-16 BRN/WHTAir flow control actuator
(DEF)10 – 14 VIgnition switch turned ON, air flow control actuator is
working in operation from “FACE” to “DEF” position
0 – 1 VIgnition switch turned ON, except the above
condition
G20-17 GRNAir intake actuator
(FRESH AIR)0 – 1 VIgnition switch turned ON, air intake selector “FRE”
position
10 – 14 VIgnition switch turned ON, air intake selector “REC”
position
G20-18 REDAir intake actuator
(RECIRCULATION AIR)0 – 1 VIgnition switch turned ON, air intake selector “REC”
position
10 – 14 VIgnition switch turned ON, air intake selector “FRE”
position
G20-19 GRN/REDAir intake actuator (MIX
AIR)10 – 14 VIgnition switch turned ON, air intake selector “FRE”
or “REC” position
0 – 1 VIgnition switch turned ON, air intake selector is
working in operation from “FRE” to “REC” or “REC”
to “FRE” position
G20-20 — — — —
G20-21 GRN/WHT A/C switch signal Refer to “Reference waveform No. 1: Automatic Type”.
G20-22 RED/BLK Electric power source 10 – 14 V Ignition switch turned ON
G20-23 BLK/ORNGround for HVAC control
moduleBelow 0.5 V Ignition switch turned ON
G20-24 ORN Ground for sensors Below 0.5 V Ignition switch turned ON Terminal Wire Color CircuitNormal
Vo l ta g eCondition

Downloaded from www.Manualslib.com manuals search engine 7B-78 Air Conditioning System: Automatic Type
G20-25 PNK Sunload sensor signalApprox. 3.5 VIgnition switch turned ON, amount of insolation is
500 W/m2
Approx. 5 VIgnition switch turned ON, amount of insolation is 0
W/m2
G20-26 BLK/RED Rear defogger indicator0 – 1 V Ignition switch turned ON, rear defogger switch OFF
10 – 14 V Ignition switch turned ON, rear defogger switch ON
G20-27 YELTemperature control
actuator position sensor
signalApprox. 0.5 VIgnition switch turned ON, temperature selector
“MAX COOL” position
Approx. 4.5 VIgnition switch turned ON, temperature selector
“MAX HOT” position
G20-28 WHT/BLUAir flow control actuator
position sensor signalApprox. 0.5 VIgnition switch turned ON, air flow selector “FACE”
position
Approx. 4.5 VIgnition switch turned ON, air flow selector “DEF”
position
G20-29 GRY Blower motor controller0 – 1 VIgnition switch turned ON, blower speed selector
OFF position
2 – 3.5 VIgnition switch turned ON, blower speed selector
between 1st and 6th position
Approx. 10.0
VIgnition switch turned ON, blower speed selector 7th
and HIGH position
G20-30 BLU/REDBlower motor control
voltage feedback10 – 14 VIgnition switch turned ON, blower speed selector
OFF position
Approx. 8.1 VIgnition switch turned ON, blower speed selector 1st
position
Approx. 6.8 VIgnition switch turned ON, blower speed selector 2nd
position
Approx. 5.5 VIgnition switch turned ON, blower speed selector 3rd
position
Approx. 4.0 VIgnition switch turned ON, blower speed selector 4th
position
Approx. 2.6 VIgnition switch turned ON, blower speed selector 5th
position
Approx. 1.2 VIgnition switch turned ON, blower speed selector 6th
position
Approx. 0.2 VIgnition switch turned ON, blower speed selector 7th
and HIGH position Terminal Wire Color CircuitNormal
Vo l ta g eCondition

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-79
Reference waveform No. 1
Rear defogger switch or A/C switch signal (1)Reference waveform No. 2
Serial communication line of BCM (1)
A/C System Inspection at ECMS6RW0D7224030
When checking voltage at ECM terminals related to A/C system, refer to “Inspection of ECM and Its Circuits in Section
1A”.
Repair Instructions
Operation Procedure for Refrigerant ChargeS6RW0D7226001
Refer to “Operation Procedure for Refrigerant Charge”.Measurement terminal Rear defogger switch
CH1: “G20-4” to “G20-23” A/
C switch
CH1: “G20-21” to “G20-23”
Oscilloscope setting CH1: 5 V / DIV
TIME: 10 ms / DIV
Measurement condition Rear defogger switch:
• Ignition switch is at ON
position and rear defogger
switch is not pushed
A/C switch:
• Ignition switch is at ON
position and A/C switch is
not pushed
I7RW01722014-02
Measurement terminal CH1: “G20-13” to “G20-23”
Oscilloscope setting CH1: 5 V / DIV
TIME: 20 ms / DIV
Measurement condition Ignition switch is at ON
position
I7RW01722015-02

Downloaded from www.Manualslib.com manuals search engine 7B-80 Air Conditioning System: Automatic Type
HVAC Unit ComponentsS6RW0D7226002
1
10
1
29
9
8
3
29
21
3
20 20
20
19
23
22
5*
4
28*15 16*
30
29*
30
17*
18*2 1312 11
5*
26
2725
1424
29
67
*
I6RW0C722008-01
1. Blower upper case 9. Air intake control link 17. Expansion valve 25. Inside air temperature sensor
2. Blower lower case 10. Air intake control door 18. Expansion pipe 26. Aspirator
3. Heater unit upper case 11. Blower motor 19.Air flow control actuator 27. Aspirator hose
4. Heater unit lower case 12. Blower motor cap 20. Air flow control links 28. Drain hose
5. Foot duct 13. Blower motor controller 21. Air flow control door assembly 29. Packing
6. HVAC air filter (if equipped) 14. Heater core 22. Temperature control actuator 30. O-ring
: Apply compressor oil.
7. Cover (without HVAC air
filter)15. Evaporator 23. Temperature control link : Do not reuse.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-81
HVAC Unit Removal and InstallationS6RW0D7226003
Refer to “HVAC Unit Removal and Installation”.
Temperature Control Actuator Removal and
Installation
S6RW0D7226004
Removal
1) Disconnect negative (–) cable at battery.
2) Remove steering column hole cover from instrument
panel.
3) Remove driver side foot duct from HVAC unit.
4) Disconnect temperature control actuator connector
(1).
5) Remove temperature control actuator (2) from HVAC
unit by removing screws (3).Installation
Reverse removal procedure noting the following
instructions.
• Before installing actuator, make sure that position of
actuator lever is in between “MAX HOT” position and
“MAX COOL” position.
• Be sure to insert pin (1) of temperature control
actuator into the groove (2) of link.
Temperature Control Actuator and Its Circuit
Inspection
S6RW0D7226005
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 to “MAX COOL” position
with ignition switch turned ON.
4) Connect voltage meter between terminal “2” and
body ground.
5) Turn temperature selector to “MAX HOT” position.
8. Air intake control actuator 16. Evaporator temperature
sensor24. Temperature control door
assembly
3
2
3
1
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1
2
I7RW01722019-01

Downloaded from www.Manualslib.com manuals search engine 7B-82 Air Conditioning System: Automatic Type
6) Measure output voltage variation while temperature
control actuator is operated from “MAX COOL”
position (B) to “MAX HOT” position (A) as following
specification.
If measure voltage is out of specification or does not
vary linearly as the shown in graph, check related
wire circuit and HVAC control module. If wire circuits
and HVAC control module are OK, go to next step.
Temperature control actuator output voltage
0.48 – 4.53V (linear variation as following graph)
7) Set temperature selector of HVAC control module to
“MAX HOT” position with ignition switch turned ON,
and make sure if the position of actuator lever is
“MAX HOT” position (A).
8) Turn ignition switch to OFF position, and then
disconnect connector from temperature control
actuator.9) Measure resistance between terminal “1” and “2”.
Temperature control actuator resistance between
terminal “1” and “2” (MAX HOT position)
(Reference value)
Approx. 0.45 kΩ at 25 °C (77 °F)
10) Connect connector to temperature control actuator.
11) Set temperature selector of HVAC control module to
“MAX COOL” position with ignition switch turned ON,
and make sure if the position of actuator lever is
“MAX COOL” position (B).
12) Turn ignition switch to OFF position, and then
disconnect connector from temperature control
actuator.
13) Measure resistance between terminal “1” and “2”.
Temperature control actuator resistance between
terminal “1” and “2” (MAX COOL position)
(Reference value)
Approx. 4.3 kΩ at 25 °C (77 °F)
If measure resistance is out of specification, replace the
actuator with new one.[A]: MAX HOT
[B]: MAX COOL
[C]: Actuator lever position
123456
6
M5
3
2
1
AB
4.53
0.48 5.00(V)
[C]
[A] [B]
I7RW01722017-03
123456
6
M5
3
2
1
A
I7RW01722020-02
123456
6
M5
3
2
1
B
I7RW01722021-02

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-83
Air Flow Control Actuator Removal and
Installation
S6RW0D7226006
Removal
1) Disconnect negative cable at battery.
2) Remove steering column hole cover from instrument
panel.
3) Remove driver side foot duct from HVAC unit.
4) Disconnect air flow control actuator connector (2).
5) Remove air flow control actuator (1) from HVAC unit
by removing screws (3).
Installation
Reverse removal procedure noting the following
instructions.
• Before installing actuator, make sure that position of
actuator lever is in between “BENT” position and
“DEF” position.
• Be sure to insert pin (1) of air flow control actuator into
the groove (2) of link.
Air Flow Control Actuator and Its Circuit
Inspection
S6RW0D7226007
1) Remove air flow control actuator from HVAC unit
referring to “Air Flow Control Actuator Removal and
Installation”.
2) Connect connector to air flow control actuator.
3) Set air flow selector to “BENT” position with ignition
switch turned ON.
4) Connect voltage meter between terminal “2” and
body ground.
5) Turn air flow selector to “DEF” position.
6) Measure output voltage variation while air flow
control actuator is operated from “BENT” position (A)
to “DEF” position (B) as following specification.
If measure voltage is out of specification or does not
vary linearly as the shown in graph, check related
wire circuit and HVAC control module. If wire circuits
and HVAC control module are OK, go to next step.
Air flow control actuator output voltage
0.48 – 4.53 V (linear variation as following graph)
13
2
I7RW01722022-01
1
2
I7RW01722023-02
[A]: BENT [D]: FOOT
[B]: DEF [E]: DEF / FOOT
[C]: BI-LEVEL [F]: Actuator lever position
123456
6
M5
3
2
1 A
B
(V)
4.53
3.35
2.60
1.78
0.48
[A][B]
[C] [D] [E][F]5.00
I7RW01722024-02

Downloaded from www.Manualslib.com manuals search engine 7B-84 Air Conditioning System: Automatic Type
7) Set air flow selector of HVAC control module to
“DEF” position with ignition switch turned ON, and
make sure if the position of actuator lever is “DEF”
position (A).
8) Turn ignition switch to OFF position, and then
disconnect connector from air flow control actuator.
9) Measure resistance between terminal “1” and “2”.
Air flow control actuator resistance between
terminal “1” and “2” (DEF position) (Reference
value)
Approx. 0.45 kΩ at 25 °C (77 °F)
10) Connect connector to air flow control actuator.
11) Set air flow selector of HVAC control module to
“VENT” position with ignition switch turned ON, and
make sure if the position of actuator lever is “VENT”
position (B).
12) Turn ignition switch to OFF position, and then
disconnect connector from air flow control actuator.13) Measure resistance between terminal “1” and “2”.
Air flow control actuator resistance between
terminal “1” and “2” (VENT position) (Reference
value)
Approx. 4.3 kΩ at 25 °C (77 °F)
If measure resistance is out of specification, replace the
actuator with new one.
Air Intake Actuator Removal and InstallationS6RW0D7226008
Remove and install air intake actuator referring to “Air
Intake Control Actuator Removal and Installation in
Section 7A”.
Air Intake Actuator InspectionS6RW0D7226009
For inspection, refer to “Air Intake Control Actuator
Inspection in Section 7A”.
Actuator Linkage InspectionS6RW0D7226010
• Check if each actuator linkage operates smoothly.
• Check actuator rod for bend.
• Check each actuator linkage for breakage.
• Make sure if there is not any obstruction in operating
range of actuator linkage.
If any malfunction is found, repair or replace faulty
part(s).
Blower Motor Controller Removal and
Installation
S6RW0D7226011
Refer to “Blower Motor Resistor Removal and
Installation in Section 7A”.
123456
6
M5
3
2
1 A
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M5
3
2
1 B
I7RW01722026-01