2006 SUZUKI SX4 check engine

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

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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

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A/C System Relay InspectionS6RW0D7216017
NOTE
Do not use blue relay for the substitute of
white relay because internal durability of a
blue relay is different from the durability of a
white relay.

1) Disconnect negative (–) cable from battery.
2) Remove compressor relay (1) or condenser cooling
fan relay (2) from main fuse box (3).
3) Check that there is no continuity between terminal
“c” and “d”. If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “b”
of relay and battery negative (–) terminal to terminal
“a” of relay, and then check continuity between
terminal “c” and “d”. If there is no continuity, replace
relay.
Compressor Drive Belt Inspection and
Adjustment
S6RW0D7216018
Inspection
• Check compressor drive belt (1) for wear, crack,
deformation and cleanliness. If any defect is found,
replace the belt with new one referring to
“Compressor Drive Belt Removal and Installation”.
• Check compressor drive belt tension by measuring
how much it deflects when pushed intermediate point
between magnet clutch pulley (6) and crankshaft
pulley (3) with about 100 N (10 kg) force after rotating
crankshaft pulley 360°. If belt tension is out of
specification, adjust belt tension referring to
“Adjustment”.
Compressor drive belt tension
“a”
: 7 – 8 mm (0.28 – 0.31 in.)
NOTE
When replacing drive belt, adjust drive belt
tension to the following specifications.

New compressor drive belt tension “a”
: 6 – 7 mm (0.24 – 0.28 in.)
Adjustment
1) Loosen tension pulley nut (4).
2) Adjust belt tension by tighten or loosen tension
pulley adjusting bolt (5).
3) Tighten tension pulley nut.
4) Rotate the crankshaft pulley 360°, and then recheck
belt tension.
3
1
2
“a”
“b”“c”
“d”
I5RW0B721023-01
2. Tension pulley
I5RW0A721033-01

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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 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

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”.

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On-Board Diagnostic System DescriptionS6RW0D7221004
NOTE
The diagnostic information as diagnostic
trouble code (DTC) can be known by using
SUZUKI scan tool. For further details, refer to
“DTC Check”.

HVAC control module detects malfunctions, which may
occur in the following area.
• Inside air temperature sensor
• Evaporator temperature sensor
• Sunload sensor
• Temperature control actuator
• Air flow control actuator
• Temperature selector of HVAC control module
• Air flow selector of HVAC control module
• Blower speed selector of HVAC control module
• Back-up power supply circuit of HAVC control module
• Serial communication line between BCM and HVAC
control module• Received data from BCM as follows
– Outside air temperature sensor signal
– ECT sensor signal
– A/C refrigerant pressure sensor signal
– VSS signal
– Engine type signal
– Combination meter spec signal
– CAN communication circuit failure signal
When HVAC control module detects malfunction, the “A/
C” indicator light (1) flashes to warn and the diagnostic
trouble code (DTC) is stored in the memory of the
module. When diagnosing trouble, the DTC can be
checked according to “DTC Check”.
Schematic and Routing Diagram
A/C System Air Flow DiagramS6RW0D7222001
Refer to “A/C System Air Flow Diagram”.
1
I5RW0A722002-01