2006 SUZUKI SX4 Oil ring

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-27
Installation
Reverse removal procedure noting the following
instructions.
• Replenish specified amount of compressor oil to
compressor suction side referring to “Replenishing
Compressor Oil” in “Operation Procedure for
Refrigerant Charge”.
• Install the padding (1) to the installation hole
uniformly.
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
• Refill cooling system with coolant referring to “Cooling
System Flush and Refill in Section 1F”.
• Adjust control cables referring to “HVAC Control Unit
Removal and Installation in Section 7A”. (vehicle with
manual type A/C)
Evaporator InspectionS6RW0D7216009
Check the followings.
• Clog of A/C evaporator fins.
If any clogs are found, A/C evaporator fins should be
washed with water, and then should be dried with
compressed air.
• A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace A/C
evaporator.
• A/C evaporator fittings for leakage.
If any defects are found, repair or replace A/C
evaporator.
Evaporator Temperature Sensor Removal and
Installation
S6RW0D7216010
Removal
1) Remove HVAC unit from vehicle body referring to
“HVAC Unit Removal and Installation”.
2) Remove evaporator temperature sensor (1) from
evaporator by (2) disassembling HVAC unit.
Installation
Reverse the removal procedure noting the following
instruction.
• Install evaporator temperature sensor (1) onto
evaporator (2) as shown.
LH steering vehicle
RH steering vehicle
1
I5RW0A721025-02
3. 138 ± 5 mm (3.3 ± 0.2 in.)
4. Sensor part fixed to 12th fin from pipe fitting side
5. Holding part fixed to 13th fin from pipe fitting side
6. Pipe fitting
1
2
I7RW01721018-01
5
4
6 1
2
3I7RW01721026-01
1
5
642
3
I6RW0C721007-01

Downloaded from www.Manualslib.com manuals search engine 7B-28 Air Conditioning System: Manual Type
Evaporator Temperature Sensor InspectionS6RW0D7216011
Check resistance between terminals of evaporator
temperature sensor (1).
If check results are as not specified, replace evaporator
temperature sensor.
Evaporator temperature sensor resistance
0 °C (32 °F): 6.6 – 6.8 kΩ
25 °C (77 °F): 2.0 – 2.1 kΩ
Expansion Valve Removal and InstallationS6RW0D7216012
Removal
1) Recover refrigerant from the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Loosen a bolt (1) and remove pipes from expansion
valve (2).
3) Loosen bolts (3) and remove expansion valve.
Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of expansion valve and
pipes.
• Tighten expansion valve bolts to specified torque.
Tightening torque
Expansion valve bolt: 4.5 N·m (0.45 kgf-m, 3.5 lb-
ft)
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
Expansion Valve InspectionS6RW0D7216013
Refer to “A/C System Performance Inspection”.
[A]: Resistance
[B]: Temperature
(kΩ)
6.75
2.00
0
3225
77 [A]
[B]
(˚C)
(˚F)
1
I7RW01721020-01
1
22 3
I4RS0A720028-01

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-29
A/C Refrigerant Pressure Sensor and Its Circuit
Inspection
S6RW0D7216014
1) Disconnect A/C refrigerant pressure sensor
connector.
2) Turn ignition switch to ON position.
3) Check if voltage between “RED” wire terminal and
“ORN” wire terminal of A/C refrigerant pressure
sensor connector is 4.75 V to 5.25 V.
If not, check A/C refrigerant pressure sensor circuit.
4) Connect A/C refrigerant pressure sensor connector
with ignition switch turned OFF.
5) Connect manifold gauge set to the charging valves.
6) Check A/C refrigerant pressure sensor voltage of
ECM connector referring to “A/C System Inspection
at ECM”.
If voltage is not as specified below, replace A/C
refrigerant pressure sensor.
A/C refrigerant pressure sensor voltage
specifications (A/C refrigerant pressure measured
by manifold gauge)
0.8 MPa (8.0 kgf/cm2, 116 psi): 1.40 – 1.78 V
1.4 MPa (14 kgf/cm2, 203 psi): 2.18 – 2.64 V
1.6 MPa (16 kgf/cm2, 232 psi): 2.44 – 2.92 V
1.8 MPa (18 kgf/cm2, 261 psi): 2.70 – 3.21 V
A/C Refrigerant Pressure Sensor Removal and
Installation
S6RW0D7216015
Removal
1) Recover refrigerant from the A/C system with the
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Disconnect negative (–) cable from battery.
3) Disconnect A/C refrigerant pressure sensor
connector.
4) Remove A/C refrigerant pressure sensor (1) from
liquid pipe (2).Installation
Reverse removal procedure noting the following
instructions.
• Apply compressor oil to O-ring of A/C refrigerant
pressure sensor.
• Tighten A/C refrigerant pressure sensor to specified
torque.
Tightening torque
A/C refrigerant pressure sensor (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
A/C Switch InspectionS6RW0D7216016
• Check that there is continuity between terminal (1)
and terminal (2) when A/C switch is at ON position.
• Check that there is no continuity between terminal (1)
and terminal (2) when A/C switch is at OFF position.
If check result does not meet the above conditions,
replace HVAC control unit.
2
1
I5RW0A721029-01
(a)
I5RW0A721030-01
1
2
I5RW0A721031-01

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

Downloaded from www.Manualslib.com manuals search engine 7B-36 Air Conditioning System: Manual Type
Relief Valve InspectionS6RW0D7216026
By using special tool, check is there is refrigerant
leakage.
If there is refrigerant leakage, replace the relief valve.
Special tool
(A) : 09990–86012
Relief valve Removal and InstallationS6RW0D7216027
Removal
1) Recover refrigerant from the A/C system with
recovery and recycling equipment referring to
“Recovery” in “Operation Procedure for Refrigerant
Charge”.
2) Remove right side engine under cover.
3) Remove relief valve (1) from compressor (2).Installation
Reverse removal procedure noting the following
instructions.
• Use new O-ring
• Apply compressor oil to O-ring.
• Tighten relief valve to the specified torque.
Tightening torque
Relief valve (a): 8 N·m (0.8 kgf-m, 6.0 lb-ft)
• Evacuate and charge the A/C system referring to
“Evacuation” and “Charge” in “Operation Procedure
for Refrigerant Charge”.
(A)
I5RS0C721014-01
12I4RS0A720048-01
(a)I4RS0A720049-01