2006 SUZUKI SX4 Precautions

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-3
EPS Diagnosis General DescriptionS6RW0D6301002
The P/S system in this vehicle is controlled by the P/S control module. The P/S control module has an on-board
diagnostic system which detects a malfunction in this system. When diagnosing troubles, be sure to have full
understanding of the outline of “On-Board Diagnostic System Description” and each item in “Precautions in
Diagnosing Troubles”, and then execute diagnosis according to “EPS System Check”.
On-Board Diagnostic System DescriptionS6RW0D6301003
The P/S control module performs the on-board diagnosis (self-diagnosis) on the system and operates the “EPS”
warning light (1) as follows.
• The “EPS” warning light lights when the ignition switch is turned to ON position (but the engine at stop) regardless
of the condition of the P/S control system. This is only to check if the “EPS” warning light is operated properly.
• If the areas monitored by the P/S control module is free from any trouble after the engine start (while engine is
running), the “EPS” warning light turns OFF.
• When the P/S control module detects a trouble which has occurred in the monitored areas the “EPS” warning light
comes ON while the engine is running to warn the driver of such occurrence of the trouble and at the same time it
stores the exact trouble area in memory inside of the P/S control module.
Driving Cycle
A “Driving Cycle” consists of engine startup and engine shutoff.
3 Driving Cycles Detection Logic
The malfunction detected in the first and second driving cycle is stored in P/S control module memory (in the form of
pending DTC) but the “EPS” warning light does not light at these time. It lights up at the third detection of same
malfunction also in the next driving cycle.
1
I7RW01632002-01

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 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”.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-1
HVAC
Air Conditioning System
Manual Type
Precautions
A/C System CautionS6RW0D7210001
CAUTION!
The A/C system of this vehicle uses HFC-134a (R-134a) refrigerant, specified compressor oil and
specified parts.
Do not use CFC-12 (R-12) refrigerant, R-12 exclusive use compressor oil and R-12 exclusive parts in
this A/C system, do not attempt to use R-12 servicing equipment. Otherwise, use of it will result in
leakage of refrigerant, damage or other faulty condition of A/C system and damage or other faulty
condition of servicing equipment.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.

Precautions on Servicing A/C SystemS6RW0D7210002
WARNING!
Should refrigerant HFC-134a (R-134a) is exposed to your eye(s), consult a doctor immediately.
• Do not reuse your hand to rub affected eye(s). Instead, use fresh cold water to splash it over
affected area to thus gradually raise its temperature above the freezing point.
• Obtain proper treatment as soon as possible from a doctor or eye specialist. Should liquid
refrigerant HFC-134a (R-134a) is exposed to your skin, such affected part should be treated in the
same manner as when skin is frostbitten or frozen.

Handling Refrigerant HFC-134a (R-134a)
• Always wear goggles to protect your eyes.
• Avoid direct contact to liquid refrigerant.
• Do not heat refrigerant container higher than 40 °C (104 °F).
• Do not discharge refrigerant into atmosphere.
• Do not expose bright metals to liquid refrigerant. Refrigerant combined with moisture is corrosive and tarnishes
surfaces of bright metals including chrome.
• Never use heat for bending pipes. When bending a pipe, try to make its bending angle as smooth as possible.
• Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system, install
a blind plug or cap to the fitting immediately.
• When handling recovery and recycling equipment, be sure to follow the instruction manual for the equipment.
• Check local governmental regulations regarding working with refrigerator systems and its tooling.
• When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to O-ring.
• Replace O-ring with new one once hoses, pipes and parts disconnected.
• When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
• Route drain hose so that drained water does not make any contact to vehicle components.
• If pipes or hoses are replaced, replenish specified amount of compressor oil to compressor suction side referring to
“Replenishing Compressor Oil” in “Operation Procedure for Refrigerant Charge”.

Downloaded from www.Manualslib.com manuals search engine 7B-38 Air Conditioning System: Automatic Type
Automatic Type
Precautions
A/C System CautionS6RW0D7220001
Refer to “A/C System Caution”.
Precautions in Diagnosing TroubleS6RW0D7220002
• Do not disconnect couplers from HVAC control module, battery cable from battery, HVAC control module ground
wire harness from body or main fuse before confirming diagnostic information (diagnostic trouble code) stored in
HVAC control module memory.
• Diagnostic information (diagnostic trouble code) stored in HVAC control module can be checked by display of HVAC
control module. Also, it can be checked by using SUZUKI scan tool. Before checking diagnostic information
(diagnostic trouble code), read this manual and operator's manual for SUZUKI scan tool to know how to read
diagnostic information (diagnostic trouble code).
• When trouble is diagnosed using diagnostic information (diagnostic trouble code) on display of HVAC control
module, keep in your mind that each diagnostic information (diagnostic trouble code) has priority, and only
diagnostic information (diagnostic trouble code) which has the highest priority is indicated. Therefore, after
troubleshooting the malfunction, make sure if there exists any other diagnostic information (diagnostic trouble
code).
• Be sure to read “Air Bag Warning in Section 00” before inspection.
Precautions on Servicing A/C SystemS6RW0D7220003
Refer to “Precautions on Servicing A/C System”.

Downloaded from www.Manualslib.com manuals search engine Table of Contents 8- i
8
Section 8
CONTENTS
Restraint
Precautions ................................................. 8-1
Precautions............................................................. 8-1
Precautions on Restraint ....................................... 8-1
Seat Belts ................................................. 8A-1
Precautions........................................................... 8A-1
Precautions on Service and Diagnosis of Seat
Belt .................................................................... 8A-1
General Description ............................................. 8A-2
Seat Belt Construction ........................................ 8A-2
Diagnostic Information and Procedures ............ 8A-3
Repair and Inspection Required after
Accident ............................................................ 8A-3
Repair Instructions .............................................. 8A-4
Front Seat Belt Components ............................... 8A-4
Front Seat Belt Removal and Installation ............ 8A-5
Front Seat Belt Inspection................................... 8A-6
Rear Seat Belt Components ............................... 8A-7
Rear Seat Belt Removal and Installation ............ 8A-8
Rear Seat Belt Inspection ................................... 8A-8
Specifications....................................................... 8A-8
Tightening Torque Specifications ........................ 8A-8
Air Bag System ........................................ 8B-1
Precautions........................................................... 8B-1
Precautions on Service and Diagnosis of Air
Bag System....................................................... 8B-1
Precautions on Handling and Storage of Air
Bag System Components ................................. 8B-1
Precautions on Disposal of Air Bag and Seat
Belt Pretensioner .............................................. 8B-5
General Description ............................................. 8B-5
Air Bag System Construction .............................. 8B-5
Air Bag System Block Diagram ........................... 8B-6
Air Bag System Input / Output Table .................. 8B-7
Schematic and Routing Diagram ........................ 8B-8
Air Bag System Wiring Circuit Diagram .............. 8B-8
Component Location ......................................... 8B-11
Air Bag System Components, Wiring and
Connectors Location ....................................... 8B-11
Diagnostic Information and Procedures .......... 8B-12
Air Bag Diagnostic System Check .................... 8B-12
Air Bag Diagnostic System Check Flow ............ 8B-13
DTC Table ......................................................... 8B-14DTC Check........................................................ 8B-18
DTC Clearance ................................................. 8B-18
Scan Tool Data ................................................. 8B-18
“AIR BAG” Warning Light Comes ON Steady ... 8B-19
“AIR BAG” Warning Light Does Not Come ON .. 8B-22
Serial Data Link Circuit Check .......................... 8B-23
DTC B1013: SDM Internal Failure .................... 8B-25
DTC B1014: “AIR BAG” Warning Light Circuit .. 8B-26
DTC B1016: Power Supply Voltage too High.... 8B-26
DTC B1017: Power Supply Voltage too Low .... 8B-27
DTC B1021: Front Air Bag Deployment
Record............................................................. 8B-28
DTC B1024 / B1025: Side Air-Bag
Deployment Record ........................................ 8B-29
DTC B1026: Seat Belt Pretensioner
Activation Record ............................................ 8B-29
DTC B1027: Number of Deployment Times
Exceeded Limit................................................ 8B-30
DTC B1031: Driver Air Bag Circuit High
Resistance ...................................................... 8B-31
DTC B1032: Driver Air Bag Circuit Low
Resistance ...................................................... 8B-33
DTC B1033: Driver Air Bag Circuit Shorted to
Ground ............................................................ 8B-35
DTC B1034: Driver Air Bag Circuit Shorted to
Power Supply .................................................. 8B-37
DTC B1041: Passenger Air Bag Circuit High
Resistance ...................................................... 8B-40
DTC B1042: Passenger Air Bag Circuit Low
Resistance ...................................................... 8B-43
DTC B1043: Passenger Air Bag Circuit
Shorted to Ground........................................... 8B-45
DTC B1044: Passenger Air Bag Circuit
Shorted to Power Supply ................................ 8B-46
DTC B1051 / B1055: Seat Belt Pretensioner
Circuit High Resistance ................................... 8B-48
DTC B1052 / B1056: Seat Belt Pretensioner
Circuit Low Resistance.................................... 8B-51
DTC B1053 / B1057: Seat Belt Pretensioner
Shorted to Ground........................................... 8B-52
DTC B1054 / B1058: Seat Belt Pretensioner
Circuit Shorted to Power Supply ..................... 8B-54
DTC B1061 / B1065: Side-Air Bag Circuit
High Resistance .............................................. 8B-55

Downloaded from www.Manualslib.com manuals search engine Precautions: 8-1
Restraint
Precautions
Precautions
Precautions on RestraintS6RW0D8000001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Fastener Caution
Refer to “Fastener Caution in Section 00”.
Precautions on Service and Diagnosis of Seat Belt
Refer to “Precautions on Service and Diagnosis of Seat Belt in Section 8A”.
Precautions on Service and Diagnosis of Air Bag System
Refer to “Precautions on Service and Diagnosis of Air Bag System in Section 8B”.
Precautions on Handling and Storage of Air Bag Components
Refer to “Precautions on Handling and Storage of Air Bag System Components in Section 8B”.
Precautions on Disposal of Air Bag and Seat Belt Pretensioner
Refer to “Precautions on Disposal of Air Bag and Seat Belt Pretensioner in Section 8B”.