2006 SUZUKI SX4 Engine Cooling System

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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”.

Downloaded from www.Manualslib.com manuals search engine 7B-14 Air Conditioning System: Manual Type
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

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
I7RW01721025-04

Downloaded from www.Manualslib.com manuals search engine 7B-26 Air Conditioning System: Manual Type
HVAC Unit Removal and InstallationS6RW0D7216008
Removal
1) Recover refrigerant from A/C system with recovery
and recycling equipment referring to “Recovery” in
“Operation Procedure for Refrigerant Charge”.
2) Drain engine coolant referring to “Cooling System
Draining in Section 1F”, and then disconnect heater
hoses from HVAC unit.
3) Remove cowl top cover from vehicle body referring
to “Cowl Top and Front Lower Crossmember
Components in Section 9K”
4) Remove instrument panel from vehicle body
referring to “Instrument Panel Removal and
Installation in Section 9C”.
5) Loosen a bolt (1) and remove pipes from expansion
valve (2).6) Remove HVAC unit (1) from vehicle body by
removing nuts (2).
7. Cover (without HVAC air
filter)14. Heater core 21. Temperature control lever : Do not reuse.
1
2
I7RW01721016-01
2
2
2
1
I7RW01710003-01

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-30 Air Conditioning System: Manual Type
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 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