2006 SUZUKI SX4 Water

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-11
Thermometer at center ventilation louver
Trouble Diagnosis for Abnormal PressureS6RW0D7214002
NOTE
Normal pressure values on high side and low side in following table are measured when the ambient
temperature is 30 °C. As normal pressure values on high side and low side vary depending on the
ambient temperature, be sure to perform following steps first when diagnosing troubles.
1. Measure the ambient temperature and using that value, read the normal value from the graph given
in Step 10 of “A/C System Performance Inspection”.
2. Put that value in place of the normal pressure in following table.

Condition Possible cause Correction
Crossing point is higher
than acceptable range
(“E” area)Insufficient or excessive charge of refrigerant Check refrigerant pressure.
Dirty or bent A/C evaporator fins Clean or repair.
Air leakage from cooling (heater) unit or air duct Repair or replace.
Malfunctioning, switch over function of door in
cooling (heater) unitRepair or replace.
Compressor malfunction Check compressor.
Crossing point is lower
than acceptable range
(“F” area)Insufficient air volume from center duct (Heater
blower malfunction)Check blower motor and fan.
Compressor malfunction Check compressor.
Condition
Possible cause Correction Manifold gauge MPa (kgf/cm2) (psi)
Detail
Lo Hi
0.27 – 0.39
(2.7 – 3.9)
(38.8 – 56.0)1.13 – 1.56
(11.4 – 15.6)
(162.3 – 221.8)Normal condition
——
Negative pressure 0.5 – 0.6
(5 – 6)
(71.2 – 85.3)The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.
Presence of frost around
tubing to and from
receiver/dryer and
expansion valve.Dust particles or water
droplets are either
stuck or frozen inside
expansion valve,
preventing the
refrigerant from
flowing.Replace expansion
valve.
Replace desiccant and
cap with filter.
Evacuate the A/C
system and recharge
with fresh refrigerant.
Normal:
0.27 – 0.39
(2.7 – 3.9)
(38.8 – 56.0)
↑ ↓
Abnormal:
Negative pressureNormal:
1.13 – 1.56
(11.4 – 15.6)
(162.3 – 221.8)
↑ ↓
Abnormal:
0.7 – 1.0
(7 – 10)
(100 – 142)During A/C operation, the
low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.Expansion valve is
frozen due to moisture
in the system, and
temporarily shuts off
the refrigeration cycle.Replace expansion
valve.
Replace desiccant and
cap with filter.
Evacuate A/C system
and recharge with
fresh refrigerant.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-17
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.
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Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Manual Type 7B-23
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
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b
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2
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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
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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
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4
6 1
2
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1
5
642
3
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Downloaded from www.Manualslib.com manuals search engine 8A-1 Seat Belts:
Restraint
Seat Belts
Precautions
Precautions on Service and Diagnosis of Seat BeltS6RW0D8100001
WARNING!
If replacing seat belt is necessary, replace buckle and seat belt together as a set. This is for the reason
of ensuring locking of tongue plate with buckle. If these parts are replaced individually, such a locking
condition may become unreliable. For this reason, SUZUKI will supply only the spare buckle and seat
belt assembly in a set part.

Before servicing or replacing seat belts, refer to the following precautionary items.
• Seat belts should be normal relative to strap retractor and buckle portions.
• Keep sharp edges and damaging objects away from belts.
• Avoid bending or damaging any portion of belt buckle or latch plate.
• Do not bleach or dye belt webbing. (Use only mild soap and lukewarm water to clean it.)
• When installing a seat belt anchor bolt, it should be tightened by hand at first to prevent cross-threading and then to
specified torque.
• Do not attempt any repairs on retractor mechanisms or retractor covers. Replace defective assemblies with new
replacement parts.
• Keep belts dry and clean at all times.
• If there exist any parts in question, replace such parts.
• Replace belts whose webbing is cut or otherwise damaged.
• Do not put anything into trim panel opening which seat belt webbing passes through.

Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-2
• Never attempt disassembly of SDM.
• When storing SDM, select a place where neither high
temperature nor high humidity is anticipated and oil,
water and dust are kept off.
• If SDM has been dropped, replace it with a new one.
• If SDM installation part of floor was damaged, repair
that part completely before reinstallation.
• All SDM and mounting bracket fasteners must be
carefully torqued and the arrow must be pointed
toward the front of the vehicle to ensure proper
operation of the air bag system.
Live (Undeployed) Air Bag (Inflator) Modules
Special care is necessary when handling and storing a
live (undeployed) air bag (inflator) modules.
The rapid gas generation produced during deployment
of the air bag could cause the air bag (inflator) module,
or an object in front of the air bag (inflator) module, to be
thrown through the air in the unlikely event of an
accidental deployment.
WARNING!
Never attempt to measure the resistance of
the air bag (inflator) modules (driver module,
passenger module and side modules and
curtain modules). It is very dangerous as the
electric current from the tester may deploy
the air bag.

• Never attempt disassembly of the air bag (inflator)
modules.
• If any abnormality is found, be sure to replace it with
new one as an assembly.
• When an abnormality is noted as existing in the live
(undeployed) air bag (inflator) module, be sure to
deploy it before discarding it.
• When grease, cleaning agent, oil, water, etc., got on
the air bag (inflator) modules (driver and passenger),
wipe it off immediately with a dry cloth.
• If air bag (inflator) module was dropped from a height
of 90 cm (3 ft) or more, it should be replaced with a
new one as an assembly.
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Downloaded from www.Manualslib.com manuals search engine Air Bag System: 8B-4
• Never attempt to disassemble the seat belt
pretensioners (retractor assembly).
• If any abnormality is found, be sure to replace it with
new one as an assembly.
• When an abnormality is noted as existing in the live
(inactivated) seat belt pretensioner, be sure to activate
it before discarding it.
• When grease, cleaning agent oil, water, etc., got on
the seat belt pretensioners (retractor assembly), wipe
it off immediately with a dry cloth.
• If seat belt pretensioner was dropped from a height of
30 cm (1 ft) or more, it should be replaced with a new
one as an assembly.
WARNING!
• For handling and storage of a live seat belt
pretensioner, select a place where the
ambient temperature below 65 °C (150 °F),
without high humidity and away from
electric noise.
• Never carry the seat belt pretensioner by
webbing.
• When placing a live seat belt pretensioner
on the workbench or other surface, be sure
not to lay it with its exhaust hole (1)
provided side facing down. It is also
prohibited to put something on its face
with an exhaust hole (1) or to put a seat
belt pretensioner on top of another.
Otherwise, personal injury may result.

Deployed Air Bag (Inflator) Module and Activated
Seat Belt Pretensioner
WARNING!
• The air bag (inflator) module and seat belt
pretensioner immediately after
deployment/activation is very hot. Wait for
at least 30 minutes to cool it off before
proceeding the work.
• Do not apply water, oil, etc. to deployed air
bag (inflator) module and to activate seat
belt pretensioner.
• After an air bag (inflator) module has been
deployed, the surface of the air bag may
contain a powdery residue. This powder
consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by-
products of the chemical reaction. As with
many service procedures, gloves and
safety glasses should be worn.
• Wash your hands with mild soap and water
after completing the work.

Refer to the procedure described under “Deployed Air
Bag (Inflator) Module and Activated Seat Belt
Pretensioner Disposal” for disposal.
Air Bag Wire Harness and Connector
Air bag wire harness is included in main harness (1),
instrument panel harness (4), floor harness (3), seat
harness (5) and curtain air bag harness (6). Air bag wire
harness can be identified easily as the part of connector
side wire harness is covered with a yellow protection
tube. Be very careful when handling it.
• When an open in air bag wire harness, damaged wire
harness, connector or terminal is found, replace wire
harness, connectors and terminals as an assembly.
• When installing it, be careful so that the air bag wire
harness is not caught or does not interfere with other
parts.
• Make sure air bag system grounding point (2) is clean
and ground is securely fastened for optimum metal-to-
metal contact. Poor grounding can cause intermittent
problems that are difficult to diagnose.
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Downloaded from www.Manualslib.com manuals search engine 8B-109 Air Bag System:
WARNING!
• For handling and storage of seat belt
pretensioner, select place where ambient
temperature is below 65 °C (150 °F),
without high humidity and away from
electric noise.
• Never carry seat belt pretensioner by
webbing.
• When placing seat belt pretensioner on
workbench or other surface, be sure to lay
it with its exhaust hole (1) side facing up. It
is also prohibited to put something on seat
belt pretensioner.
Otherwise, personal injury may result.

6) Set air bag (inflator) module or seat belt pretensioner
as follows.
• For driver air bag (inflator) module
a. Clear space (3) on ground about 185 cm (6 ft)
in diameter where driver air bag (inflator)
module (1) is set for deployment. Paved,
outdoor location where there is no activity is
preferred. If outdoor location is not available,
use space on shop floor where there is no
activity and sufficient ventilation is provided.
Ensure no loose or flammable object exists
within deployment area.
b. Place driver air bag (inflator) module (1) with
its vinyl trim cover facing up (2) on ground in
St ep a .• For passenger air bag (inflator) module
a. Clear space (3) on ground about 185 cm (6 ft)
in diameter where passenger air bag (inflator)
module (1) is set for deployment. Paved,
outdoor location where there is no activity is
preferred. If outdoor location is not available,
use space on shop floor where there is no
activity and sufficient ventilation is provided.
Ensure no loose or flammable object exists
within deployment area.
b. Place deployment fixture (A) on ground in
Step a.
Special tool
(A): 09932–75041
c. Fill plastic reservoir in deployment fixture (A)
with water or sand. This is necessary to
provide sufficient stabilization of fixture during
deployment.
d. Attach passenger air bag (inflator) module (1)
in deployment fixture (A) securely using M8
bolt (2).
CAUTION!
Be sure to use M8 size and 7T strength bolt
for fixing passenger air bag (inflator) module
(1) to deployment fixture (A).

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2
(A)
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