2006 SUZUKI SX4 Motor

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 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 Heater and Ventilation: 7A-1
HVAC
Heater and Ventilation
General Description
Heater and Ventilation ConstructionS6RW0D7101001
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

I6RW0C710001-02
A: Air flow 7. Defroster air 15. Rear duct (if equipped)
B: Water flow 8. Demister air 16. Foot duct
1. HVAC unit 9. Fresh air 17. Engine
2. Ventilator duct 10. Recirculation air 18. Radiator
3. Defroster duct and demister duct 11. Center ventilation air 19. Reservoir
4. Heater core 12. Air intake door 20. Temperature control door
5. Side ventilation air 13. Blower motor 21. Air flow control door
6. Foot air 14. Resistance board (non-A/C) or evaporator (A/C)

Downloaded from www.Manualslib.com manuals search engine 7A-2 Heater and Ventilation:
Schematic and Routing Diagram
Heater and Ventilation Wiring Circuit DiagramS6RW0D7102001
Non–A/C
Manual A/C
Refer to “A/C System Wiring Diagram in Section 7B”.
Auto A/C
Refer to “A/C System Wiring Diagram in Section 7B”.
Component Location
Electronic Control System Components LocationS6RW0D7103001
Refer to “Electronic Control System Components Location in Section 7B” (non-A/C and manual A/C) or “Electronic
Control System Components Location in Section 7B” (auto A/C).
5V
BLK
RED/BLK3
5 72
G154-3
G154-4
G154-7
G154-8
G154-10
G154-13
G155-2
G155-3
G155-7
G155-6
G155-1
G154-9
G154-14
BLK/WHT
YEL
BLU/WHT
RED
RED/BLKRED
GRN
GRN/YEL
RED/YEL
RED/BLU
BLK/ORN
46
8
BLU
YELGRN
WHT
13
1514
[A]21
BLK/RED
12V
BLK/YELBLK/WHTM
BLK
1IG1
IG2
12
BLK/RED
M 10
11
11
BLU/WHT 19
16
17
18 9 20
I6RW0C710003-01
[A]: Illumination control model 6. Blower motor resistor 12. Main fuse box 18. Illumination light
1. Ignition switch 7. Junction block assembly 13. Blower speed selector 19. Rear defogger relay
2. Blower motor 8. BCM 14. Air intake selector 20. Rear defogger
3. HVAC control unit 9. ECM 15. Rear defogger switch 21. Tail light
4. Lighting switch 10. Air intake control actuator 16. “REC” indicator light
5. Blower motor relay 11. To BCM 17. Rear defogger indicator

Downloaded from www.Manualslib.com manuals search engine Heater and Ventilation: 7A-3
Diagnostic Information and Procedures
Heater and Ventilation Symptom DiagnosisS6RW0D7104001
Condition Possible cause Correction / Reference Item
Blower motor does not
operate with blower
speed selector ONFuse blownCheck related fuses, and then check for short
circuit to ground.
Blower motor relay faultyCheck blower motor relay referring to “Blower
Motor Relay Inspection”.
Blower motor resistor faultyCheck blower motor resistor referring to
“Blower Motor Resistor Inspection”.
Blower speed selector faultyCheck blower speed selector referring to
“Blower Speed Selector Inspection”.
Blower motor faultyCheck blower motor referring to “Blower Motor
Inspection”.
Wiring or grounding faultyRepair as necessary.
Incorrect temperature
outputTemperature control cable broken or
bent (non-A/C and manual A/C)Check temperature control cable.
Temperature selector faulty (non-A/C
and manual A/C)Check temperature selector.
Incorrect installation of temperature
control cable (non-A/C and manual A/C)Check position and adjust it as necessary.
Temperature control door assembly
brokenRepair temperature control door assembly.
Air ducts cloggedRepair air ducts.
Heater core leaked or cloggedReplace heater core.
Heater hoses leaked or cloggedReplace heater hoses.
Thermostat faultyCheck thermostat referring to “Thermostat
Inspection in Section 1F”.
Temperature control actuator faulty
(auto A/C)Check temperature control actuator referring to
“Temperature Control Actuator and Its Circuit
Inspection in Section 7B”.
HVAC control module faulty (auto A/C)Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (auto 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 changedAir flow control cable broken or bent
(non-A/C and manual A/C)Check air flow control cable.
Air flow selector faulty (non-A/C and
manual A/C)Check air flow selector.
Incorrect installation of air flow control
cable (non-A/C and manual A/C)Check position and adjust it as necessary.
Air flow control door assembly brokenRepair air flow control door assembly.
Air ducts leaked or cloggedRepair air ducts.
Air flow control actuator faulty (auto A/C)Check air flow control actuator referring to “Air
Flow Control Actuator and Its Circuit Inspection
in Section 7B”.
HVAC control module faulty (auto A/C)Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit in Section 7B”.
Wiring or grounding faulty (auto A/C)Repair as necessary.
Air intake door does not
change even if air intake
mode is changedAir intake door brokenRepair air intake door.
Air intake control actuator faultyCheck air intake control actuator referring to
“Air Intake Control Actuator Inspection”.
Air intake selector faultyCheck air intake selector referring to “Air Intake
Selector Inspection”.
Wiring or grounding faultyRepair as necessary.

Downloaded from www.Manualslib.com manuals search engine 7A-4 Heater and Ventilation:
Repair Instructions
HVAC Unit ComponentsS6RW0D7106001
For non-A/C and manual A/C, refer to “HVAC Unit
Components in Section 7B”.
For auto A/C, refer to “HVAC Unit Components in
Section 7B”.
HVAC Unit Removal and Installation (Non-A/C)S6RW0D7106002
For manual A/C and auto A/C, refer to “HVAC Unit
Removal and Installation in Section 7B”.
Removal
1) Drain engine coolant referring to “Cooling System
Draining in Section 1F”, and then disconnect heater
hoses from HVAC unit.
2) Remove cowl top cover from vehicle body referring
to “Cowl Top and Front Lower Crossmember
Components in Section 9K”.
3) Remove instrument panel from vehicle body
referring to “Instrument Panel Removal and
Installation in Section 9C”.
4) Remove HVAC unit (1) from vehicle body by
removing nuts (2).Installation
Reverse removal procedure noting the following
instructions.
• Be careful not to catch any cable and wiring harness
in inappropriate position.
• Adjust control cables of HVAC control unit referring to
“HVAC Control Unit Removal and Installation”.
• Refill cooling system with coolant referring to “Cooling
System Flush and Refill in Section 1F”.
Blower Motor Removal and InstallationS6RW0D7106003
Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect connector (1) from blower motor (2).
3) Remove blower motor (2) from HVAC unit as follows.
a) Remove screws (4).
b) Release tub (3) to arrow direction.
c) Hold Step b) and turn blower motor (2) to arrow
direction.
Installation
Reverse removal procedure.
Blower Motor InspectionS6RW0D7106004
• Check blower motor for resistance between two
terminals as shown.
If there is no continuity, replace blower motor.
2
2
2
1
I7RW01710003-01
3
2
b)
c)
1
4
4I7RW01710004-02
I7RW01710005-01