2006 SUZUKI SX4 AIR

Downloaded from www.Manualslib.com manuals search engine 7B-16 Air Conditioning System: Manual Type
Abnormal Noise from Tubing
Abnormal Noise from Condenser Assembly
Abnormal Noise from Crankshaft Pulley
Abnormal Noise from Tension Pulley
Abnormal Noise from A/C Evaporator
Abnormal Noise from Blower MotorCondition Possible cause Correction / Reference Item
A droning noise is heard
from inside of the vehicle,
but not particularly
noticeable in engine
compartmentFaulty tubing clampsReposition clamps or increase the number of
clamps.
Resonance caused by pulsation from
variations in refrigerant pressureAttach a silencer to tubing, or modify its
position and length.
Condition Possible cause Correction / Reference Item
Considerable vibration in
condenser assemblyResonance from condenser assembly
bracket and bodyFirmly insert a silencer between condenser
assembly bracket and body.
Condition Possible cause Correction / Reference Item
A large rattling noise is
heard at idle or sudden
accelerationLoosen crankshaft pulley boltRetighten bolt.
Condition Possible cause Correction / Reference Item
Clattering noise is heard
from pulleyWorn or damaged bearingReplace tension pulley.
Pulley cranks upon
contactCracked or loose bracketReplace or retighten bracket.
Condition Possible cause Correction / Reference Item
Whistling sound is heard
from A/C evaporatorDepending on the combination of the
interior / exterior temperatures, engine
rpm and refrigerant pressure, the
refrigerant flowing out of the expansion
valve may, under certain conditions,
make a whistling soundAt times, slightly decreasing refrigerant volume
may stop this noise.
Inspect expansion valve and replace if faulty.
Condition Possible cause Correction / Reference Item
Blower motor emits a
chirping sound in
proportion to its speed of
rotationWorn or damaged motor brushes or
commutatorReplace blower motor.
Fluttering noise or large
droning noise is heard
from blower motorLeaves or other debris introduced from
fresh air inlet to blower motorRemove debris and make sure that the screen
at fresh air inlet is intact.

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Repair Instructions
Operation Procedure for Refrigerant ChargeS6RW0D7216001
WARNING!
• Your eyes should not be exposed to refrigerant (liquid).
Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately –
6 °C (21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) is exposed to your eyes, it may
cause a serious injury. To protect your eyes from such accident, it is necessary to always wear
goggles. Should it occur that HFC-134a (R-134a) is exposed to your eyes, consult a doctor
immediately.
– Do not use your hand to rub the affected eye(s). Instead, use fresh cold water to splash it over the
affected area to gradually raise temperature of such area above freezing point.
– Obtain proper treatment as soon as possible from a doctor or eye specialist.
• Should the liquid refrigerant HFC-134a (R-134a) is exposed to your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.
• Do not handle refrigerant near any place where welding or steam cleaning is performed.
• Refrigerant should be kept in a cold and dark place. It should never be stored in any place where
temperature is high, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).
• Avoid breathing fume produced when HFC-134a (R-134a) is burned. Such fume may be hazardous to
your health.

Start evacuation.Start evacuation.
Stop evacuation.Stop evacuation.
15 minutes (above -100 kPa)15 minutes (above -100 kPa)
Wait 10 minutesWait 10 minutes
Check A/C system forCheck A/C system for
pressure tighteness.pressure tighteness.
Recharge A/C system withRecharge A/C system withrefrigerant.refrigerant.
Check A/C system for refrigerantCheck A/C system for refrigerantleaks and amount of refrigerantleaks and amount of refrigerantcharged.charged.
Performance testPerformance test
Inspect and repair connections.Inspect and repair connections.
If gauge showsIf gauge showsabnormal conditionsabnormal conditions
Recharge 430 20 g ofRecharge 430 20 g ofrefrigerant.refrigerant.
I5RW0A721011-01

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Recovery
When discharging refrigerant out of A/C system, always
recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a
(R-134a) into atmosphere would cause adverse effect to
environments.
NOTE
• After recovering refrigerant from system,
the amount of removed compressor oil
must be measured for replenishing
compressor oil.
• When handling recovery and recycling
equipment, be sure to follow the
instruction manual for the equipment.

Replenishing Compressor Oil
It is necessary to replenish specified amount of
compressor oil to compressor from compressor suction
side hole (1) before evacuating and charging refrigerant.When charging refrigerant only
When charging refrigerant without replacing any
component, replenish the same amount of measured oil
when recovering refrigerant (if not measure, replenish 10
cm
3 (10 ml, 0.34 US.oz, 0.35 Imp.oz) oil).
When replacing compressor
CAUTION!
Be sure to use specified compressor oil or an
equivalent compressor oil.

Compressor oil is sealed in each new compressor by the
amount required for A/C system. Therefore, when using
a new compressor, drain the calculated amount of oil
from it.
“C” = “A” – “B”
“C”: Amount of oil to be drained
“A”: Amount of oil in a new compressor
“B”: Amount of oil in removed compressor
NOTE
Compressor assembly supplied from factory
is filled up with the following amount of oil.

: Compressor oil 99000–99015–00A
(MATSUSHITADENKI GU10)
Oil amount in compressor
75 + 10, – 0 cm3 (75 + 10, – 0 ml, 2.54 + 0.34, – 0
US.oz, 2.64 + 0.35, – 0 lmp.oz)
When replacing other parts
Replenish the following amount of oil to compressor.
Amount of compressor oil to be replenished
Evaporator: 15 cm3 (15 ml, 0.51 US.oz, 0.53 Imp.oz)
Condenser: 10 cm3 (10 ml, 0.34 US.oz, 0.35 Imp.oz)
Dryer: 10 cm3 (10 ml, 0.34 US.oz, 0.35 Imp.oz)
Hoses: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
Pipes: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
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1
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1. New compressor
2. Removed compressor
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Evacuation
CAUTION!
Do not evacuate before recovering
refrigerant in A/C system.

NOTE
Once air conditioning system circuit is
opened (exposed) to atmospheric air, system
must be evacuated by using a vacuum pump.
The A/C system should be attached with a
manifold gauge set, and should be evacuated
for approximately 15 minutes.

1) Connect high charging hose (1) and low charging
hose (2) of manifold gauge set (3) (special tool)
respectively as follows:
High charging hose → High pressure charging valve
(4) on discharge hose
Low charging hose → Low pressure charging valve
(5) on suction pipe
Special tool
(A): 09990–06020
2) Attach center charging hose (6) of manifold gauge
set to vacuum pump (7).
3) Operate vacuum pump, and then open discharge
side valve (Hi) (8) of manifold gauge set.
If there is no blockage in the system, there will be an
indication on high pressure gauge (9).
When this occurs, open the other side valve (Lo)
(10) of the set.
4) Approximately 10 minutes later, low pressure gauge
(11) should show a vacuum lower than –100 kPa (–
1.0 kgf/cm
2, –760 mmHg, –14.7 psi) providing no
leakage exists.
NOTE
• If the system does not show a vacuum
below –100 kPa (–1.0 kgf/cm
2, –760 mmHg,
–14.7 psi), close both valves, stop vacuum
pump and watch movement of low
pressure gauge.
• Increase in the gauge reading suggests
existence of leakage. In this case, repair
the system before continuing its
evacuation.
• If the gauge shows a stable reading
(suggesting no leakage), continue
evacuation.

5) Evacuation should be carried out for a total of at
least 15 minutes.
6) Continue evacuation until low pressure gauge
indicates a vacuum less than –100 kPa (–1.0 kgf/
cm
2, –760 mmHg, –14.7 psi), and then close both
valves.
7) Stop vacuum pump. Disconnect center charging
hose from pump inlet. Now, the system is ready for
charging refrigerant.
Checking A/C System for Pressure Leaks
After completing the evacuation, close manifold gauge
high pressure valve and low pressure valve and wait 10
minutes. Verify that low pressure gauge reading has not
changed.
CAUTION!
If the gauge reading moves closer to “0”,
there is a leak somewhere. Inspect the tubing
connections and make necessary
corrections. And then, evacuate system once
again and make sure that there are no leaks.

7
89 3, (A)
11
10
1
2
5
4
6
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Charge
CAUTION!
• Because the sight glass is not used for this
A/C system, do not perform an additional
charge to the A/C system. To charge the
proper amount of refrigerant, recover and
evacuate the A/C system first. And then,
charge the proper amount of refrigerant
into the A/C system.
• Always charge refrigerant through low
pressure side of A/C system after the initial
charge is performed from the high
pressure side with the engine stopped.
• Never charge refrigerant through high
pressure side of A/C system with engine
running.
• Do not charge refrigerant while
compressor is hot.
• When installing tap valve to refrigerant
container to make a hole there through,
carefully follow directions given by
manufacturer.
• A pressure gauge should always be used
before and during refrigerant charge.
• The refrigerant container should be
emptied of refrigerant when discarding it.
• The refrigerant container should not be
heated up to 40 °C (104 °F) or over.
• Refrigerant container should not be
reversed in direction during refrigerant
charge. Reversing in direction causes
liquid refrigerant to enter compressor,
causing troubles, such as compression of
liquid refrigerant and the like.

NOTE
The air conditioning system contains HFC-
134a (R-134a).
Described here is a method to charge the air
conditioning system with refrigerant from the
refrigerant service container.
When charging refrigerant recovered by
using the refrigerant and recycling
equipment (when recycling refrigerant),
follow the procedure described in the
equipment manufacturer’s instruction
manual.

The initial charge of the A/C system is performed
through the high pressure side with the engine stopped.
And next, this method must be followed by charging from
the low pressure side with the engine running.
1) Check if hoses are routed properly after evacuating
the system.
2) Connect low charging hose (1) and high charging
hose (2) of the manifold gauge set (3) in position.
Then, open refrigerant container valve (4) to purge
the charging line.
3) Open the high pressure side valve (5) and charge
refrigerant to system.
4) After a while, open the low pressure side valve (6)
and close the high pressure side valve.
WARNING!
Make sure that high pressure side valve is
closed securely.

5) Start engine and keep engine speed at 1500 r/min,
and then operate A/C system.
6) Charge A/C system with refrigerant in vapor state. At
this time, refrigerant container should be held
upright.
4
3
6
2
1 5
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7) When refrigerant container (1) is emptied, use the
following procedure to replace it with a new
refrigerant container.
a) Close low pressure valve.
b) Replace empty container with a refrigerant
container which has been charged with
refrigerant. When using refrigerant container tap
valve (2), use the following procedure for
replacement.
i) Retract needle (3) and remove refrigerant
container tap valve by loosening its plate nut
(4).
ii) Install the refrigerant container tap valve to a
new refrigerant container.
c) Purge any air existing in center charging hose.
When using refrigerant container tap valve, use
the following procedure to purge air.
i) Once fully tighten refrigerant container tap
valve (1), and then loosen (open) plate nut
(2) slightly.
ii) Open low pressure side valve (3) of manifold
gauge set (4) a little.
iii) As soon as refrigerant comes out with a
“hiss” through a clearance between
refrigerant container and tap valve, tighten
plate nut as well as low pressure side valve.
iv) Turn handle of tap valve clockwise so that its
needle is screwed into the new container to
make a hole for refrigerant flow.8) After the system has been charged with specified
amount of refrigerant or when low pressure gauge
(1) and high pressure gauge (2) have indicated the
following specified value, close low pressure side
valve (3) on manifold gauge set (4).
Specified amount of refrigerant
430 ± 20 g (15.2 ± 0.7 oz))
Low side and high side pressure example
Removal of Manifold Gauge Set
WARNING!
High pressure side is under high pressure.
Therefore, be careful not to get injured
especially on your eyes and skin.

For the A/C system charged with the specified amount of
refrigerant, remove manifold gauge set as follows:
1) Close low pressure side valve of manifold gauge set.
(The high pressure side valve is closed continuously
during the process of charging.)
2) Close refrigerant container valve.
3) Stop engine.
4) Using shop rag, remove charging hoses from service
valves. This operation must be performed quickly.
5) Put caps on service valves.
I2RH01720018-01
I2RH01720019-01
Gauges should read as follows when ambient
temperature is 30 °C (86 °F).
Pressure
on high pressure gauge1130 – 1560 kPa
(11.4 – 15.6 kgf/cm
2)
(162.3 – 221.8 psi)
Pressure
on low pressure gauge270 – 390 kPa
(2.7 – 3.9 kgf/cm
2)
(38.8 – 56.0 psi)
4
2
1
3
I7RW01721013-02

Downloaded from www.Manualslib.com manuals search engine 7B-22 Air Conditioning System: Manual Type
Check A/C System for Refrigerant Leaks
Whenever a refrigerant leak is suspected in the system
or any service operation has been performed which may
result in malfunction of lines and connections, it is
advisable to check for leaks.
Common sense should be used during refrigerant leak
test, since the need and extent of any such test will, in
general, depend upon the nature of a complaint and the
type of a service performed on the system.
Liquid leak detector
WARNING!
• To prevent explosions and fires, make sure
that there are no flammables in the vicinity.
• When the refrigerant exposed to fire, it
turns into a poisonous gas (phosgene). Do
not inhale this gas.

There is a number of fittings and places throughout the
A/C system where a liquid leak detector solution may be
used to pinpoint refrigerant leaks.
By merely applying the solution to the area in question
with a swab, such as attached to the cap of a vial,
bubbles will form within seconds if there is a leak.
For confined areas, such as sections of the evaporator
and condenser, an electronic (refrigerant) leak detector
is more practical for determining leaks.
Special tool
(A): 09990–86012
Condenser Cooling Fan Removal and
Installation
S6RW0D7216002
CAUTION!
Be careful not to damage fins of radiator. If
radiator fin is bent, straighten it by using flat
head screwdriver or pair of pliers.

Removal
1) Disconnect negative (–) cable at battery.
2) Disconnect condenser cooling fan motor coupler.
3) Remove reservoir (1) from radiator.
4) Remove condenser cooling fan (2) from radiator (3).
Installation
Reverse removal procedure to install condenser cooling
fan.
(A)
I5RW0A721054-01
13
2
I5RW0A721017-01

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Condenser Cooling Fan InspectionS6RW0D7216003
1) Check condenser cooling fan motor for resistance
between terminal “a” and “b” as shown.
If there is no continuity, replace condenser cooling
fan motor.
2) Connect battery to condenser cooling fan motor
terminal “a” and “b” as shown in figure, and then
check if the condenser cooling fan motor operates
smoothly.
Reference
Condenser cooling fan specified current at 12 V:
7 A maximum
Condenser Assembly On-Vehicle InspectionS6RW0D7216004
Check the followings.
• Clog of condenser fins
If any clog is found, condenser fins should be washed
with water and should be dried with compressed air.
• Condenser fins for leakage and breakage
If any defects are found, repair or replace condenser.
• Condenser fittings for leakage.
If any defects are found, repair or replace condenser.
Condenser Assembly Removal and InstallationS6RW0D7216005
CAUTION!
Do not damage condenser fins. If condenser
fin is bent, straighten it by using flat head
screwdriver or pair of pliers.

Removal
1) Recover refrigerant from A/C system referring to
“Operation Procedure for Refrigerant Charge”.
NOTE
The amount of removed compressor oil must
be measured for replenishing compressor
oil.

2) Remove front bumper referring to “Front Bumper
and Rear Bumper Components in Section 9K”.
3) Disconnect discharge hose (1) and liquid pipe (2)
from condenser assembly (3).
4) Remove radiator assembly and condenser assembly
mounting bolts (4).
ab
I5RW0A721018-02
a
b
I5RW0A721019-02
1
2
3
4
4
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