2008 SUZUKI SWIFT intake system

Downloaded from www.Manualslib.com manuals search engine 7B-34 Air Conditioning System: Automatic Type
Automatic Type
Precautions
A/C System CautionS7RS0B7220001
Refer to “A/C System Caution”.
Precautions in Diagnosing TroubleS7RS0B7220002
• 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 SU ZUKI 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 inform ation (diagnostic trouble code) has priority, and only
diagnostic information (diagnostic troub le 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 “Precautions for Electrical Circuit Service in Section 00” before inspection.
Precautions on Servicing A/C SystemS7RS0B7220003
Refer to “Precautions on Servicing A/C System”.
General Description
Auto A/C System DescriptionS7RS0B7221001
The automatic type air conditioning system (auto A/C) is pr ovided with the function to automatically control the inside
air temperature, fan speed, air flow outl et direction and air intake position by HVAC control module in addition to
functions of the manual type air conditioning system (manua l A/C). Once the inside air temperature is set using the
temperature selector, HVAC control module automatically controls the inside air temperature at the constant level at all
times based on the inside air temperature, outside ai r temperature, amount of sunlight and engine coolant
temperature detected respectively by the inside air te mperature sensor, outside air temperature sensor, sunload
sensor and ECT sensor. At this time, “FULL AUTO A/ C” appears on the display of HVAC control module.
With the air intake selector pushed in the above state, it is possible to select any position of the air intake actuator.
Then, “FULL AUTO A/C” on the display changes to “AUTO A/C”.

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-35
Electronic Control System Location
NOTE
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the opposite side.

1
2
3 * 4 *
5
6 *
7 *
8 *
9 *
10 *
21
11
12 13
14
15161718
19
20
I5RS0C722001-01
1. ECT sensor
7. Blower motor13. AUTO switch19. MODE (air flow) selector
2. Outside air temperature sensor 8. Blower motor controller 14. Temperature selector 20. Blower speed selector
3. Sunload sensor 9. Temperature control actuator15. OFF switch21. HVAC control module
4. Air flow control actuator 10. Inside air temperature sensor 16. Air intake selector
5. Evaporator temperature sensor 11. Defroster switch 17. A/C switch
6. Air intake actuator 12. Display 18. Rear defogger switch

Downloaded from www.Manualslib.com manuals search engine 7B-36 Air Conditioning System: Automatic Type
Auto A/C Electronic Control Input / Output Table
HVAC Control Module Operation DescriptionS7RS0B7221002
Temperature Control
HVAC control module calculates the target temperature
control door position based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor and
controls the temperature control actuator so that the
current position of the temperature control door matches
its target position.
Fan Speed Control
HVAC control module calculates the target blower fan
speed based on signals from the temperature selector,
inside air temperature sensor, outside air temperature
sensor and sunload sensor, compares it with the current
blower fan speed inputted from the blower motor
controller to control the current blower fan speed to the
target level.
Air Flow Outlet Control
HVAC control module calculates the target temperature
control door position based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor.
Using thus obtained target temperature control door
position, it further calculates the target air flow control
door position and controls the ai r flow control actuator so
that the current air flow c ontrol door position becomes
the target position. Air Intake Position Control
HVAC control module determines the position of the air
intake control door based on signals from the
temperature selector, inside air temperature sensor,
outside air temperature sensor and sunload sensor and
selects any of the following positions by controlling the
position of the air intake control door.
• FRESH position (FRE)
• RECIRCULATION position (REC)
• MIX position (MIX)
Refrigerant Type IdentificationS7RS0B7221003
Refer to “Refrigerant Type Identification”.
Sub-Cool A/C System DescriptionS7RS0B7221005
Refer to “Sub-Cool A/C System Description”.
A/C Operation DescriptionS7RS0B7221006
Refer to “A/C Operation Description”.
Sunload sensor
Outside air temperature sensor Evaporator temperature sensor
A/C refrigerant pressure sensor
Temperature selector
MODE (air flow) selector
Blower speed selector
Air intake selector
AUTO switch
A/C switch
Compressor
Blower motor controller
Temperature control actuator
Air flow control actuator
Air intake control actuator
BCM
ECM
Data link connector
HVAC control module
CPU
ECT sensor
Inside air temperature sensor
VSS
*
I5RS0C722002-02
*: CAN communication

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-39
Diagnostic Information and Procedures
A/C System Symptom DiagnosisS7RS0B7224001
4. Rear defogger relay 15. Evaporator temperature sensor 26. Radiator cooling fan relay No.1 37. Rear defogger switch
5. Rear defogger 16. Sunload sensor 27. Radiator cooling fan relay No.2 38. To BCM
6. Blower motor relay 17. Junction block assembly 28. Radiator cooling fan relay No.3 39. To ECM
7. Blower motor 18. ECM 29. Information display 40. To main relay
8. Blower motor controller 19. ECT sensor 30. Lighting switch 41. To main fuse
9. DLC 20. Radiator cooling fan motor 31. A/C switch 42. Back-light
10. Air intake actuator 21. Compressor relay 32. MODE (air flow) selector 43. Defroster indicator 11. Air flow control actuator 22. Compressor 33. Air intake selector 44. Rear defogger indicator
Condition Possible cause Correction / Reference Item
No cool air comes out (A/
C system does not
operate) No refrigerant
Perform recovery, evacuation and charge
referring to “Operation Procedure for
Refrigerant Charge”.
Fuse blown Check related fuses, and then check for short
circuit to ground.
A/C switch faulty Check A/C switch referring to “Inspection of
HVAC Control Module and Its Circuit”.
Evaporator temperature sensor faulty Check evaporator temperature sensor
referring to “Evaporator Thermistor
(Evaporator Temperature Sensor) Inspection”.
A/C refrigerant pressure sensor faulty Check A/C refrigerant pressure sensor
referring to “A/C Refrigerant Pressure Sensor
and Its Circuit Inspection”.
Wiring or grounding faulty Repair as necessary.
ECT sensor faulty Check ECT sensor referring to “ECT Sensor
Inspection in Section 1C”.
ECM faulty Check ECM referring to “A/C System
Inspection at ECM”.
HVAC control module faulty Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
Magnet clutch faulty Check magnet clutch. Referring to “Magnet
Clutch Inspection”.
Compressor drive belt loosened or
broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Compressor relay faulty Check compressor relay referring to
“Compressor Relay Inspection”.
Temperature selector, blower speed
selector, and/or air flow selector faulty Check HVAC control module referring to
“Inspection of HVAC Control Module and Its
Circuit”.
BCM faulty Check BCM referring to “Inspection of BCM
and its Circuits in Section 10B”.

Downloaded from www.Manualslib.com manuals search engine 7B-46 Air Conditioning System: Automatic Type
Scan Tool DataS7RS0B7224007
As the data values given in the following are standard values estimated on the basis of values obtained from the
normally operation vehicles by using a scan tool, use them as reference values. Even when the vehicles are in good
condition, there may be cases where the checked values do not fall within each specifies data range. Therefore,
judgement as abnormal should not be ma de by checking with these data alone.
Scan Tool Data Condition Normal Condition / Reference
Va l u e
) TEMP CONT
SWITCH Each reference value is relative to the position of
temperature selector of HVAC control module. Max Cool, 18.5
°C (65 ° F), 19 °C (66
° C) – 31 °C (88 °F), 31.5 °C (89 °F),
Max Hot
) CABIN
TEMPERATURE Reference value is relative to in-car temperature. –6.5
°C – 57.25 ° C
(20.3 °F – 135.05 °F)
) OUTSIDE AIR TEMP Reference value is relative to outside air
temperature. –23.3
°C – 65.95 °C
(–9.94 °F – 150.71 °F)
) EVAPORATOR
TEMP Reference value is relative to temperature of
evaporator. –29.7
°C – 59.55 °C
(–21.46 °F – 139.19 °F)
) COOLANT TEMP At specified id le speed after warming up. 80 °C – 100 °C (176 ° F – 212 ° F)
) SUN LOAD Reference value depends on the situation. 0 W/m
2 – 4447.8 W/m2
)MODE CONT
SWITCH Each reference value is relative to the position of air
flow selector of HVAC control module.
AUTO, FACE, B/L, FOOT, D/F, DER
) FAN CONT SWITCH Each reference value is relative to the position of
blower speed selector of HVAC control module. AUTO, OFF, 1st, 2nd – 7th, 8th
) FAN DESIRED VOLT Reference value is relative to the position of blower
speed selector of HVAC control module. 0 – 16.0 V
) AIR MIX POS SEN Reference value is relative to the position of
temperature selector of HVAC control module. about 2.0 V (Max Hot)
about 4.0 V (Max Cool)
) MODE POS SENSOR Reference value is relative to the position of air flow
selector of HVAC control module. about 1.6 V (DEF)
about 4.0 V (VENT)
) A/C CONT SIG A/C system is ON. ON
A/C system is OFF. OFF
) BLOWER LOAD SIG Position of blower speed selector is 1st position or
more.
ON
Position of blower speed selector is OFF position. OFF
) AIR INTAKE MODE Fresh air (FRE) mode is activated. FRE
Recirculation air (REC) mode is activated. REC
AUTO mode is activated. AUTO
) REFRIGERANT
PRESSURE Engine running. A/C ON (A/C is operating)
at ambient temperature:
30
°C (86 °F) 1470 – 1770 kPa For more details,
refer to pressure of high pressure
gauge under “A/C System Performance Inspection”
A/C OFF (A/C is not
operating) at ambient
temperature: 30 °C (86
° F) and engine coolant
temperature: 90 ° – 100
° C 600 – 1000 kPa After longer than 10
min from A/C switch turned off
) A/C COMP CLUTCH Engine running. A/C switch and blower
motor switch turned ON
ON
A/C switch and/or blower
motor switch turned OFF OFF
) DFR INDICATOR Defroster indicator
lamp is lighted. ON
Defroster indicator la mp is not lighted. OFF
) VEHICLE SPEED At stop. OFF
0 km/h (0 mph)

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-47
Scan Tool Data Definitions
TEMP CONT SWITCH (TEMPERATURE SELECTOR): Position of temperature control
selector of HVAC control module
CABIN TEMPERATURE: In-car temperature detected
by inside air temperature sensor installed in HVAC
control module
OUTSIDE AIR TEMP (OUTSIDE AIR TEMPERATURE): Outside air temperature
detected by outside air temperature sensor installed
in front bumper member
EVAPORATOR TEMP (EVAPORATOR TEMPERATURE): Temperature of air passed
through evaporator
COOLANT TEMP (ENGINE COOLANT TEMPERATURE): Engine coolant temperature
detected by engine coolant temperature sensor
SUN LOAD: Amount of sunlight detected by sunload
sensor installed on the driver side on the dashboard
MODE CONT SWITCH (MODE (AIR FLOW) SELECTOR): Position of air flow selector of HVAC
control module
FAN CONT SWITCH (BLOWER SPEED SELECTOR): Position of blower speed selector of HVAC control
module
FAN DESIRED VOLT: Voltage for blower motor AIR MIX POS SEN (TEMPERATURE CONTROL
ACTUATOR POSITI ON SENSOR): Input signal
from position sensor in temperature control actuator
MODE POS SENSOR (AIR FLOW CONTROL ACTUATOR POSITI ON SENSOR): Input signal
from position sensor in air flow control actuator
A/C CONT SIG (A/C SWITCH SIGNAL, ON or OFF): State of A/C switch
BLOWER LOAD SIG (BLO WER FAN LOAD SIGNAL,
ON or OFF): ON: Position of blower speed selector
is 1st position or more / OFF: Position of blower
speed selector is OFF position.
AIR INTAKE MODE (AUTO, FRE or REC): State of air
intake mode
REFRIGERANT PRESSURE (A/C REFRIGERANT ABSOLUTE PRESSURE): This parameter
indicates A/C refrigerant absolute pressure
calculated by ECM
A/C COMP CLUTCH (A/C COMPRESSOR MAGNET CLUTCH, ON or OFF): This parameter indicates
the state of the A/C switch
DFR INDICATOR (DEFROSTER INDICATOR LAMP, ON or OFF): State of defroster indicator lamp
VEHICLE SPEED: It is computed based on pulse
signals from vehicle speed sensor
Air Conditioning System CheckS7RS0B7224008
Step Action YesNo
1 Customer complaint analysis
1) Perform )”Customer complaint analysis”.
Was customer complaint analysis performed? Go to Step 2.
Perform customer
complaint analysis.
2 Visual inspection
1) Perform )“Visual inspection”.
Is there any faulty condition? Repair or replace
malfunction part.
Go to Step 3.
3 DTC check
1) Perform )“DTC check”.
Is there any DTC code? Go to Step 4.
Go to Step 5.
4 Troubleshooting malfunction
1) Perform ) “Troubleshooting malfunction”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 7.
Go to Step 5.
5 Perform A/C system symptom diagnosis
1) Inspect and repair referri ng to “A/C System Symptom
Diagnosis”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 7.
Go to Step 6.
6 Check for intermittent problem
1) Check for intermittent troubles referring to “Intermittent
and Poor Connection Inspection in Section 00”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 7.
Go to Step 7.
7 Final confirmation test
1) Perform ) “Final confirmation test”.
Is there any malfunction code? Go to Step 4.
End.

Downloaded from www.Manualslib.com manuals search engine 7B-68 Air Conditioning System: Automatic Type
G51-8 BLU/REDBlower motor control
voltage feedback 10 – 14 V Ignition switch turned ON, blower speed selector OFF
About 8.5 V Ignition switch turned ON, blower speed selector 1st
position
About 6.5 V Ignition switch turned ON, blower speed selector 2nd
position
About 5.5 V Ignition switch turned ON, blower speed selector 3rd
position
About 4.0 V Ignition switch turned ON, blower speed selector 4th
position
About 3.0 V Ignition switch turned ON, blower speed selector 5th
position
About 2.0 V Ignition switch turned ON, blower speed selector 6th
position
About 1.0 V Ignition switch turned ON, blower speed selector 7th
position
Below 1.0 V Ignition switch turned ON, blower speed selector HIGH
position
G51-9 GRY Blower motor controller 0 – 1 V
Ignition switch turned ON, blower speed selector OFF
position
2 – 3 V Ignition switch turned ON, blower speed selector
between 1st and HIGH position
G51-10 BLK/RED Rear defogger indicator 0 – 1 V Ignition switch turned ON, rear defogger switch OFF
10 – 14 V Ignition switch turned ON, rear defogger switch ON
G51-11 RED/YEL Illumination switch 0 – 1 V Ignition switch turned ON, lighting switch OFF position
10 – 14 V Ignition switch turned ON, lighting switch ON position
G51-12 BLK/YEL Illumination ground 0 – 1 V Full-time
G51-13 — — — —
G51-14 — — — —
G51-15 RED Air intake actuator
(RECIRCULATION AIR) 0 – 1 VIgnition switch turned ON, air intake selector is
recirculation air mode or air intake actuator is working
in operation to recirculation air position or fresh air
position.
10 – 14 V Ignition switch turned ON, ai
r intake selector is fresh
air mode (air intake actuator fresh air position).
G51-16 GRN/RED Air intake actuator
(MIX AIR) 10 – 14 V
Ignition switch turned ON, air intake actuator is
recirculation air or fresh air position.
0 – 1 V Ignition switch turned ON, air intake actuator is mix air
position or air intake actuator is working in operation to
recirculation air position or fresh air position.
G51-17 GRN Air intake actuator
(FRESH AIR) 0 – 1 V
Ignition switch turned ON, ai
r intake selector is fresh
air mode or air intake actuator is working in operation
to recirculation air position or fresh air position.
10 – 14 V Ignition switch turned ON, air intake selector is
recirculation air mode (air intake actuator recirculation
air position).
G51-18 GRN/WHT A/C switch signal Refer to “Inspe ction of BCM and its Circuits in Section 10B”
G51-19 BLU/WHT Electric load signal for
blower motor 10 – 14 V
Ignition switch turned ON, blower speed selector OFF
or between 1st and 5th position
0 – 2 V Ignition switch turned ON, blower speed selector
between 6th and HIGH position
G51-20 BRN Rear defogger switch 0 – 1 V
Ignition switch turned ON, rear defogger switch ON
(rear defogger switch is kept in push) position
4 – 6 V Ignition switch turned ON, rear defogger switch OFF
position
Terminal Wire Color Circuit
Normal
Vo l ta g e Condition

Downloaded from www.Manualslib.com manuals search engine Air Conditioning System: Automatic Type 7B-73
HVAC Unit Removal and InstallationS7RS0B7226003
Refer to “HVAC Unit Removal and Installation”.
Temperature Control Actuator Removal and
Installation
S7RS0B7226004
Removal1) Disconnect negative (–) cable at battery.
2) Remove steering column hol e cover from instrument
panel.
3) Remove foot duct from HVAC unit.
4) Disconnect temperature control actuator connector (1).
5) Detach temperature control actuator rods (2) from linkage (3).
6) Remove temperature control actuator (4) from HVAC unit.
Installation
Reverse removal procedure.
Temperature Control Actuator InspectionS7RS0B7226005
1) Remove temperature control actuator from HVAC unit referring to “Temperature Control Actuator
Removal and Installation”.
2) Connect connector to temperature control actuator.
3) Set temperature selector of HVAC control module to MAX HOT position with ignition switch ON, and
make sure if the position of actuator lever is MAX
HOT position (A).
4) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
5) Measure resistance between terminal “3” and “5”.
Temperature control actuator resistance between
terminal “3” and “5” (MAX HOT position)
Approximately 2.5 k Ω at 25 °C (77 °F) 6) Connect connector to tem
perature control actuator.
7) Set temperature selector of HVAC control module to MAX COOL position with ignition switch ON, and
make sure if the position of actuator lever is MAX
COOL position (B).
8) Turn ignition switch OFF, and then disconnect connector from temperature control actuator.
9) Measure resistance between terminal “3” and “5”
Temperature control actuator resistance between
terminal “3” and “5” (MAX COOL position)
Approximately 4.8 k Ω at 25 °C (77 °F)
If check result is not satisfactory, replace the actuator
with new one.
2. Blower upper case 9. Blower motor controller 16. Evaporator 23. Temperature control actuator
3. Air intake control actuator 10. Blower lower case 17. O-ring24. Air flow control actuator
4. Air filter (if equipped) 11. Blower motor 18. Expansion valve25. Inside air temperature sensor
5. Heater unit upper case 12. Heater unit lower case 19. Evaporator temperature sensor 26. Aspirator hose
6. Foot duct 13. Heater core 20. Packing : Do not reuse.
7. Air flow control door assembly 14. Temperature control links 21. Filter cover
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I5RS0A722020-02
I5RS0A722021-03
I5RS0A722022-03