2006 SUZUKI SX4 air conditioning

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Diagnostic Information and Procedures
A/C System Performance InspectionS6RW0D7214001
1) Confirm that vehicle and environmental conditions
are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 35 °C (77 – 95
°F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal.
• Blower motor is normal.
• There is no air leakage from air ducts.
• Condenser fins are clean.
• HVAC air filter is not clogged with dirt and dust (if
equipped).
• Battery voltage is about 12 V.
• Radiator cooling fan operates normally.
2) Make sure that high pressure valve (1) and low
pressure valve (2) of manifold gauge are firmly
closed.
3) Connect high pressure charging hose (3) to high
pressure service valve (5) on vehicle and low
pressure charging hose (4) to low pressure service
valve (6).
4) Bleed the air in charging hoses (3) and (4) by
loosening their nuts respectively utilizing the
refrigerant pressure. When a hissing sound is heard,
immediately tighten nut.
CAUTION!
Do not connect high and low pressure
charging hoses in reverse.

5) Warm up engine to the normal operating
temperature and keep it at the specified idle speed.
6) Turn A/C switch ON, set blower speed selector at
maximum speed position, temperature selector at
maximum cold position, air flow selector at face
position, and air intake selector at recirculation
position. (Confirm that A/C compressor, A/C
condenser cooling fan and radiator cooling fan are
working.)
7) Wait for ten minutes to stabilize the A/C operation.
8) Open all door windows, front doors and engine hood.
9) With about 20 mm (0.8 in.) of dry bulb thermometer
(1) put right in front of center ventilation louver and a
wet and dry bulb thermometer (2) near air inlet of
HVAC unit.
321
4
6
5
I7RW01721006-01
2
1
I5RW0A721008-01

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10) Check for each pressure of low side and high side if it is within shaded range of graph. If each gauge reading is out
of specified pressure, correct defective part referring to the following table.
When diagnosing troubles of abnormal pressure on the low side and high side for each pressure more specifically,
refer to “Trouble Diagnosis for Abnormal Pressure”.
NOTE
Pressure registered on gauge varies with ambient temperature. Therefore, use the graphs when
determining if pressures are normal or not.

Low side and high side pressure example, Gauges should read as follows when ambient temperature is 30
°C (86 °F)
Pressure on high pressure gauge (HI): 1130 – 1560 kPa (11.4 – 15.6 kgf/cm2)
Pressure on low pressure gauge (LO): 270 – 390 kPa (2.7 – 3.9 kgf/cm2)
High pressure gauge
[A]: Pressure of high pressure gauge [C]: Ambient temperature [E]: Acceptable range
[B]: Pressure of low pressure gauge [D]: Humidity
Condition Possible cause Correction
Pressure is higher than
acceptable range
(“A” area)Refrigerant overcharged Recharge.
Expansion valve frozen or clogged Check expansion valve.
Clogged refrigerant passage of high pressure side Clean or replace.
Condenser cooling fan malfunction (Insufficient
cooling of condenser)Check condenser cooling fan.
Dirty or bent condenser fins (Insufficient cooling of
condenser)Clean or repair.
Compressor malfunction (Insufficient oil etc.) Check compressor.
Engine overheat Check engine cooling system
referring to “Engine Cooling Symptom
Diagnosis in Section 1F”.
22 312.9 2200
0 1 2 3
30 70 30 70%
4 5 6 7 8 9 10
11 12 13
14
15
16
17
18
19 21 298.7 2100
20
14.2 28.4 42.7 56.9 71.1 85.3 99.5 113.8 128.0
142.2
151.4 170.6 184.9
199.1
213.3
227.5
241.7
256.0
270.2
284.4
100 200 300 400 500 600 700 800 900 1000
1100 1200 1300
1400
1500
1600
1700
1800
1900
2000
25 30 35
77 86 95 psi kPa kgf/cm
2
[C] [B] [A]
C
F
“A”
“B”
“C”
[E]
[E]
“D”[D]
I6RW0D721001-01

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Low pressure gauge
11) Check inlet port temperature-to-outlet port temperature relationship using the graph. For example, if temperature
near air inlet of HVAC unit is 30 °C (86 °F) and the one at air outlet of center ventilation louver is 17 °C (62.6 °F),
their crossing point is within acceptable range as shown in the graph. In this case, cooling performance is
satisfactory and proper.
12) If crossing point is out of acceptable range, diagnose trouble referring to the following table. Pressure is lower than
acceptable range
(“B” area)Insufficient refrigerant (Insufficient charge or
leakage)Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too
wide)Check expansion valve.
Compressor malfunction (Insufficient
compression)Check compressor.
Condition Possible cause Correction
Pressure is higher than
acceptable range
(“C” area)Expansion valve malfunction (valve opens too
wide)Check expansion valve.
Compressor malfunction (Insufficient
compression)Check compressor.
Pressure is lower than
acceptable range
(“D” area)Insufficient refrigerant (Insufficient charge or
leakage)Check for leakage, repair if necessary
and recharge.
Expansion valve malfunction (valve opens too
narrow)Check expansion valve.
Clogged refrigerant passage (crashed pipe) Repair or replace.
[A]: Temp at air outlet of center ventilation louver [C]: Humidity
[B]: Temp near air inlet of HVAC unit [D]: Acceptable range
Condition Possible cause Correction
8 9 10 11 12 13
14 15 16
17 18 19
20 21
22 23
24
25
26
27
28
46.4 48.2 50.0 51.8 53.6 55.4
57.2 59.0 60.8
62.6 64.4 66.2
68.0 69.8
71.6 73.4
75.2
77.0
78.8
80.6
82.4
25 30 35
77 86 95 F C
C
F
“E”
“F”
[D]
[B]
30 70 %
[C] [A]
I6RW0D721002-01

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Thermometer at center ventilation louver
Trouble Diagnosis for Abnormal PressureS6RW0D7214002
NOTE
Normal pressure values on high side and low side in following table are measured when the ambient
temperature is 30 °C. As normal pressure values on high side and low side vary depending on the
ambient temperature, be sure to perform following steps first when diagnosing troubles.
1. Measure the ambient temperature and using that value, read the normal value from the graph given
in Step 10 of “A/C System Performance Inspection”.
2. Put that value in place of the normal pressure in following table.

Condition Possible cause Correction
Crossing point is higher
than acceptable range
(“E” area)Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in
cooling (heater) unitRepair or replace.
Compressor malfunction Check compressor.
Crossing point is lower
than acceptable range
(“F” area)Insufficient air volume from center duct (Heater
blower malfunction)Check blower motor and fan.
Compressor malfunction Check compressor.
Condition
Possible cause Correction Manifold gauge MPa (kgf/cm2) (psi)
Detail
Lo Hi
0.27 – 0.39
(2.7 – 3.9)
(38.8 – 56.0)1.13 – 1.56
(11.4 – 15.6)
(162.3 – 221.8)Normal condition
——
Negative pressure 0.5 – 0.6
(5 – 6)
(71.2 – 85.3)The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.
Presence of frost around
tubing to and from
receiver/dryer and
expansion valve.Dust particles or water
droplets are either
stuck or frozen inside
expansion valve,
preventing the
refrigerant from
flowing.Replace expansion
valve.
Replace desiccant and
cap with filter.
Evacuate the A/C
system and recharge
with fresh refrigerant.
Normal:
0.27 – 0.39
(2.7 – 3.9)
(38.8 – 56.0)
↑ ↓
Abnormal:
Negative pressureNormal:
1.13 – 1.56
(11.4 – 15.6)
(162.3 – 221.8)
↑ ↓
Abnormal:
0.7 – 1.0
(7 – 10)
(100 – 142)During A/C operation, the
low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.Expansion valve is
frozen due to moisture
in the system, and
temporarily shuts off
the refrigeration cycle.Replace expansion
valve.
Replace desiccant and
cap with filter.
Evacuate A/C system
and recharge with
fresh refrigerant.

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A/C System Inspection at ECMS6RW0D7214003
When checking voltage at ECM terminals related to A/C system, refer to “Inspection of ECM and Its Circuits in Section
1A”.0.05 – 0.15
(0.5 – 1.5)
(4.2 – 21.3)0.7 – 1.0
(7 – 10)
(100 – 142)Both low and high
pressure sides indicate
low readings.
Output air is slightly cold.Insufficient refrigerant
in system
(Refrigerant leaking).Using leak detector,
check for leaks and
repair as necessary.
Recharge refrigerant to
a specified amount.
If the pressure reading
is almost 0 when the
manifold gauges are
attached, check for any
leaks, repair them, and
evacuate the system.
0.4 – 0.6
(4 – 6)
(56.9 – 85.3)Pressure on low pressure
side is high.
Pressure on high pressure
side is low.
Both pressure becoming
equal right after A/C is
turned OFF.Internal leak in
compressor.Inspect compressor
and repair or replace
as necessary.
0.40 – 0.45
(4.0 – 4.5)
(57 – 64)2.0 – 2.5
(20 – 25)
(285 – 355)High pressure reading on
both low and high
pressure sides.Overcharged A/C
system.Adjust refrigerant to
specified amount.
Faulty condenser
cooling operation.Clean condenser.
Faulty condenser
cooling fan operation.Inspect and repair
condenser cooling fan.
High pressure reading on
both low and high
pressure sides.
Low pressure side tubing
is not cold when touched.Presence of air in A/C
system
(Improperly
evacuated).Replace desiccant and
cap with filter.
Inspect quantity of
compressor oil and
presence of
contaminants in oil.
Evacuate system and
recharge with fresh
refrigerant.
0.45 – 0.55
(4.5 – 5.5)
(64 – 78)High pressure reading on
both low and high
pressure sides.
Large amount of frost or
dew on the low pressure
side tubing.Faulty expansion
valve.
Refrigerant flow is not
regulated properly.Replace expansion
valve. Condition
Possible cause Correction Manifold gauge MPa (kgf/cm
2) (psi)
Detail
Lo Hi

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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”.

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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

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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.