2006 SUZUKI SX4 clutch

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-13
A/C System Symptom DiagnosisS6RW0D7214004
Condition Possible cause Correction / Reference Item
No cool air comes out (A/
C compressor does not
operate)No refrigerantPerform recovery, evacuation and charge
referring to “Operation Procedure for
Refrigerant Charge”.
Fuse blownCheck related fuses, and then check for short
circuit to ground.
A/C switch faultyCheck A/C switch referring to “A/C Switch
Inspection”.
Blower speed selector faultyCheck blower speed selector referring to
“Blower Speed Selector Inspection in Section
7A”.
Evaporator temperature sensor faultyCheck evaporator temperature sensor
referring to “Evaporator Temperature Sensor
Inspection”.
A/C refrigerant pressure sensor faultyCheck A/C refrigerant pressure sensor
referring to “A/C Refrigerant Pressure Sensor
and Its Circuit Inspection”.
Wiring or grounding faultyRepair as necessary.
ECM faultyCheck ECM referring to “A/C System
Inspection at ECM”.
Magnet clutch faultyCheck magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor drive belt loosened or
brokenAdjust or replace drive belt.
Compressor faultyCheck compressor.
Compressor relay faultyCheck compressor relay referring to “A/C
System Relay Inspection”.
BCM faultyCheck BCM referring to “Inspection of BCM
and Its Circuits in Section 10B”.
No cool air comes out
(radiator cooling fan
motor does not operate)Fuse blownCheck related fuses, and then check for short
circuit to ground.
Wiring or grounding faultyRepair as necessary.
Condenser cooling fan relay faultyCheck condenser cooling fan motor relay
referring to “A/C System Relay Inspection”.
Condenser cooling fan motor faultyCheck condenser cooling fan motor referring to
“Condenser Cooling Fan Inspection”.
ECM faultyCheck ECM referring to “A/C System
Inspection at ECM”.
No cool air comes out
(blower motor does not
operate)Fuse blownCheck related fuses, and then check for short
circuit to ground.
Blower motor relay faultyCheck blower motor relay referring to “Blower
Motor Relay Inspection in Section 7A”.
Blower motor resistor faultyCheck blower motor resistor referring to
“Blower Motor Resistor Inspection in Section
7A”.
Blower speed selector faultyCheck blower speed selector referring to
“Blower Speed Selector Inspection in Section
7A”.
Wiring or grounding faultyRepair as necessary.
Blower motor faultyCheck blower motor referring to “Blower Motor
Inspection in Section 7A”.

Downloaded from www.Manualslib.com manuals search engine 7B-14 Air Conditioning System: Manual Type
Cool air does not come
out or insufficient cooling
(A/C compressor normal
operation)Insufficient or excessive charge of
refrigerantCheck the amount of refrigerant and system
for leaks.
Condenser cloggedCheck condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
A/C evaporator clogged or frostedCheck A/C evaporator and evaporator
temperature sensor referring to “Evaporator
Inspection” and “Evaporator Temperature
Sensor Inspection”.
Evaporator temperature sensor faultyCheck evaporator temperature sensor
referring to “Evaporator Temperature Sensor
Inspection”.
Expansion valve faultyCheck expansion valve referring to “Expansion
Valve Inspection”.
Desiccant cloggedCheck desiccant and cap with filter.
Compressor drive belt loosened or
brokenAdjust or replace drive belt.
Magnet clutch faultyCheck magnet clutch referring to “Magnet
Clutch Inspection”.
Compressor faultyCheck compressor.
Air in A/C systemReplace condenser, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Air leaking from HVAC unit or air ductRepair as necessary.
Heater and ventilation system faultyCheck HVAC unit.
Blower motor faultyCheck blower motor referring to “Blower Motor
Inspection in Section 7A”.
Excessive compressor oil in A/C systemDrain excessive compressor oil from A/C
system circuit and compressor.
Cool air does not come
out only intermittentlyWiring connection faultyRepair as necessary.
Evaporator temperature sensor faultyCheck evaporator temperature sensor
referring to “Evaporator Temperature Sensor
Inspection”.
Expansion valve faultyCheck expansion valve referring to “Expansion
Valve Inspection”.
Excessive moisture in A/C systemReplace condenser, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Magnet clutch faultyCheck magnet clutch referring to “Magnet
Clutch Inspection”.
Excessive amount of refrigerantCheck the amount of refrigerant.
Cool air comes out only at
high speedCondenser cloggedCheck condenser referring to “Condenser
Assembly On-Vehicle Inspection”.
Insufficient charge of refrigerantCheck the amount of refrigerant and system
for leaks.
Air in A/C systemReplace condenser, and then perform
evacuation and charge referring to “Operation
Procedure for Refrigerant Charge”.
Compressor drive belt loosened or
brokenAdjust or replace drive belt.
Compressor faultyCheck compressor.
Cool air does not come
out only at high speedExcessive amount of refrigerantCheck the amount of refrigerant.
A/C evaporator frostedCheck A/C evaporator and evaporator
temperature sensor referring to “Evaporator
Inspection” and “Evaporator Temperature
Sensor Inspection”. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-15
Abnormal Noise Symptom Diagnosis of A/C SystemS6RW0D7214005
Abnormal Noise from Compressor
Abnormal Noise from Magnetic ClutchInsufficient air flow of
cooled airA/C evaporator clogged or frostedCheck A/C evaporator and evaporator
temperature sensor referring to “Evaporator
Inspection” and “Evaporator Temperature
Sensor Inspection”.
Air leaking from HVAC unit or air ductRepair as necessary.
Blower motor faultyCheck blower motor referring to “Blower Motor
Inspection in Section 7A”.
Wiring or grounding faultyRepair 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
revolutionsInadequate clearance in scroll areaReplace compressor.
A loud noise is heard at a
certain rpm,
disproportionately to
engine revolutionLoose or faulty compressor drive beltAdjust drive belt tension or replace drive belt.
Loose compressor mounting boltsRetighten mounting bolts.
A loud rattle is heard at
low engine rpmLoose compressor clutch plate boltRetighten 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 operationWorn or damaged bearingsReplace magnet clutch assembly.
A chattering noise is
heard when compressor
is in operationFaulty magnet clutch clearance
(excessive clearance)Adjust magnet clutch clearance.
Worn magnet clutch friction surfaceReplace magnet clutch assembly.
Compressor oil leaked from shaft seal,
contaminating the friction surfaceReplace compressor body assembly.

Downloaded from www.Manualslib.com manuals search engine 7B-30 Air Conditioning System: Manual Type
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

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-31
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

Downloaded from www.Manualslib.com manuals search engine 7B-32 Air Conditioning System: Manual Type
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

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-33
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

Downloaded from www.Manualslib.com manuals search engine 7B-34 Air Conditioning System: Manual Type
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