2006 SUZUKI SX4 section 1a

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-31
Terminal Wire color Circuit Normal voltage Condition
E11-1 LT GRN/BLKIgnition switch signal for P/S
control module10 – 14 V Ignition switch ON
E11-2 — — — —
E11-3 — — — —
E11-4 PPL Vehicle speed signal*0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.7”
under “Inspection
of BCM and Its
Circuits in
Section 10B”)• Ignition switch ON
• Front left tire turned quickly with right
tire locked
E11-5 GRY “EPS” warning light0 V Ignition switch ON
0 – 14 V Engine running
E11-6 — — — —
E11-7 — — — —
E11-8 GRN9 V power supply for torque
sensorAbout 9 V• Ignition switch ON
• Voltage between “E11-8” and “E11-9”
terminals
E11-9 BLK Ground for torque sensors — —
E11-10 WHT Torque sensor signal (Sub)About 2.5 – 4.0 V• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 1.0 – 2.5 V• Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E11-11 BLUSerial communication circuit for
data link connector——
E11-12 BRN Engine speed signal*0 – 1 V
↑↓
8 – 14 V
(“Reference
waveform No.24
and No.25” under
“Inspection of
ECM and Its
Circuits in
Section 1A”)Engine idling
E11-13 — — — —
E11-14 RED/BLU P/S active signal (idle up signal)About 12 V Ignition switch ON
0 – 1 VEngine idling and turned steering wheel
to the right or left until it stops
E11-15 — — — —
E11-16 — — — —
E11-17 — — — —
E11-18 YEL Torque sensor signal (Main)About 1.0 – 2.5 V• Steering wheel with left turn
• Out put voltage varies linearly
depending on steering force
About 2.5 V Steering wheel at free
About 2.5 – 4.0 V• Steering wheel with right turn
• Out put voltage varies linearly
depending on steering force
E11-19 GRY Ground for shield wire — —

Downloaded from www.Manualslib.com manuals search engine 6C-34 Power Assisted Steering System:
Steering Wheel Play CheckS6RW0D6304021
• Check steering wheel for looseness or rattle by
moving it in its shaft direction and lateral direction.
If found defective, repair or replace.
• Check steering wheel for play, holding vehicle in
straight forward condition on the ground with engine
stopped.
If steering wheel play is not within specification,
inspect as follows and replace if found defective.
– Tie-rod end ball stud for wear (Ball stud should
move when more than 0.2 N⋅m (2 kg-cm, 0.44 lb-ft)
torque is applied.)
– Lower ball joint for wear
– Steering shaft joint for wear
– Steering pinion or rack gear for wear or breakage
– Each part for looseness
Steering wheel play
“a”
: 0 – 30 mm (0 – 1.18 in.)
Steering Force CheckS6RW0D6304022
1) Place vehicle on level road and set steering wheel at
straight-ahead position.
2) Check if tire inflation pressure is as specified
referring to the tire placard.
3) Remove driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
4) Start engine.
5) With engine idling, measure steering force by turning
torque wrench.
Steering force
: Less than 6.4 N⋅m (0.64 kgf-m, 4.6 lb-ft)
6) Install driver air bag (inflator) module referring to
“Driver Air Bag (Inflator) Module Removal and
Installation in Section 8B”.
I3RM0A630021-01
I3RM0A630022-01

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-37
3) Inspect for proper toe referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
4) After confirming proper toe, tighten tie-rod end lock
nut to specified torque.
Tightening torque
Tie-rod end lock nut (a): 45 N·m (4.5 kgf-m, 32.5
lb-ft)
5) Tighten wheel bolts to specified torque and lower
hoist.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
Tie-Rod End InspectionS6RW0D6306004
• Inspect for play in ball joint.
• Inspect for play in rack end ball joint.
In either case, if found defective, replace.
Steering Shaft Joint On-Vehicle InspectionS6RW0D6306005
Check shaft joint for wear, breakage and any other
damage and replace if any defect exists.
Steering Gear Case Assembly Removal and
Installation
S6RW0D6306006
Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps, otherwise, contact coil of air bag
system may get damaged.

1) Remove steering joint cover.
2) Make alignment marks (1) on pinion shaft (2) and
joint of steering lower shaft (3) for a guide during
reinstallation.
3) Loosen joint bolt (steering column side) (4) and
remove joint bolt (pinion shaft side) (5) and
disconnect steering lower shaft (3) from pinion shaft
(2).
4) Disconnect torque sensor connector and P/S motor
connector from steering gear case.
5) Remove front suspension frame referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B”, and then
remove steering gear case.
Installation
1) Install grommet (1) as shown in figure.
I3RM0A630030-01
I4RS0A630043-01
I4RS0B630012-01
2. Protrusion
5
2
1
5
34
3
I4RS0B630013-01
1
2
1
2
I5RW0A630018-02

Downloaded from www.Manualslib.com manuals search engine 6C-38 Power Assisted Steering System:
2) Install steering gear case to vehicle, and then install
front suspension frame referring to “Front
Suspension Frame, Stabilizer Bar and/or Bushing
Removal and Installation in Section 2B”.
3) Install steering gear case to suspension frame (3) as
follows.
a) Set member bracket (2) to steering gear case
(1).
b) Install all steering gear case mounting bolts by
hand.
c) Tighten steering mounting bolts in numerical
order and specified torque.
Tightening torque
Steering gear case mounting bolt (a): 70 N·m (
7.0 kgf-m, 51.0 lb-ft)
4) Connect torque sensor connector and P/S motor
connector to steering gear case.
5) Be sure that steering wheel and brake discs (right &
left) are all straight-ahead position and then insert
steering lower shaft (5) into steering pinion shaft (3)
with matching marks (4).
6) Tighten steering shaft joint lower bolt (1) and upper
bolt (2) to specified torque (tighten lower side first
and then tighten upper side).
Tightening torque
Steering lower shaft assembly upper joint bolt
(a): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
Steering lower shaft assembly lower joint bolt
(b): 25 N·m (2.5 kgf-m, 18.5 lb-ft)
7) Install steering joint cover.Steering Rack Boot InspectionS6RW0D6306007
Hoist vehicle.
Inspect each boot for tear. A torn boot allows entry of
dust and water which can cause wear to steering rack
and pinion to produce noise as well as rust to result in
malfunction of steering system.
Even if boot tear is small, replace with new one.
Also, check each boot for dent. If there is a dent, keep
boot in most compressed state for some seconds to
correct dent.
Boots should be visually inspected for any damage, dent
and tear during every periodical inspection at specified
intervals and whenever vehicle is hoisted for any other
purpose.
Tie-Rod / Rack Boot Removal and InstallationS6RW0D6306008
Removal
1) Remove steering gear case assembly referring to
“Steering Gear Case Assembly Removal and
Installation”.
2) Remove member bracket from steering gear case
assembly.
3) For ease of adjustment after installation, make
marking (1) of tie-rod end lock nut position of tie-rod
thread.
4) Loosen tie-rod end lock nut and remove tie-rod end.
5) Remove boot band (2) and clip (1).
6) Remove boot from tie-rod.I7RW01632009-01
5
4 1, (b)
3
2, (a)
1, (b)5
I5RW0A630020-01
I2RH01630012-01
I4RS0A630044-01
IYSQ01630034-01

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 7-1 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 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