Suzuki Grand Vitara JB627. Manual — part 266

6C-25 Power Assisted Steering System:

Special Tools and Equipment

Recommended Service Material

S6JB0B6308001

NOTE
Required service material is also described in the following.
“P/S Gear Case Assembly Components”

Special Tool

S6JB0B6308002

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Super Grease A

P/No.: 99000–25010

)

Thread lock cement

Thread Lock Cement 1305

P/No.: 99000–32100

)

09913–75821

09915–77412

Bearing installer attachment

Oil pressure gauge

)

)

09915–77420

09943–88211

Oil pressure gauge
attachment and hose set

Pinion bearing installer

)

)

09945–55410
Bushing installer
)

/ )

Table of Contents 7- i

7

Section 7

CONTENTS

HVAC

Precautions . . . . . . . . . . . . .7-1

Precautions. . . . . . . . . . . . . . . . 7-1

Precautions for HVAC. . . . . . . . . . ... 7-1

Heater and Ventilation. . . . . . . . 7A-1

General Description . . . . . . . . . . . .7A-1

Heater and Ventilation Construction . . . . ... 7A-1
Body Ventilation Construction. . . . . . . . 7A-2
On-Board Diagnostic System Description (for

Vehicle without A/C). . . . . . . . . . .. 7A-2

HVAC Control System Description (for

Vehicle without A/C). . . . . . . . . . .. 7A-2

Schematic and Routing Diagram. . . . . . 7A-3

Heater and Ventilation Wiring Circuit Diagram . 7A-3
Electronic Control Input / Output Diagram (for

Vehicle without A/C). . . . . . . . . . .. 7A-3

Component Location . . . . . . . . . . ...7A-4

Electronic Components Location for Heater

(for Vehicle without A/C) . . . . . . . . ... 7A-4

Diagnostic Information and Procedures. . . 7A-5

Heater and Ventilation System Check . . . . 7A-5
Visual Inspection. . . . . . . . . . . . . 7A-7
DTC Check . . . . . . . . . . . . . . . 7A-7
DTC Clearance . . . . . . . . . . . . ... 7A-7
DTC Table. . . . . . . . . . . . . . ... 7A-7
Fail-Safe Table. . . . . . . . . . . . . 7A-7
Scan Tool Data . . . . . . . . . . . . ... 7A-7
Heater and Ventilation Symptom Diagnosis. . 7A-8

Repair Instructions . . . . . . . . . . . ..7A-9

Blower Unit and Heater Unit Components . . .. 7A-9
HVAC Unit Removal and Installation (for

Vehicle without A/C). . . . . . . . . . .. 7A-9

HVAC Air Filter Removal and Installation (for

Vehicle without A/C). . . . . . . . . . .. 7A-9

HVAC Air Filter Inspection (for Vehicle without

A/C). . . . . . . . . . . . . . . . ... 7A-9

Blower Motor Removal and Installation. . . ... 7A-9
Blower Motor Inspection . . . . . . . . . . 7A-9
Blower Motor Controller Removal and

Installation. . . . . . . . . . . . . ...7A-10

Blower Motor Controller Inspection . . . . ...7A-10
Blower Motor Relay Inspection . . . . . . .7A-11
Heater Core Removal and Installation . . . .. 7A-11

HVAC Control Module Removal and

Installation . . . . . . . . . . . . . ...7A-12

HVAC Control Module and Its Circuits

Inspection (for Vehicle without A/C) . . . . 7A-12

Air Flow Control Actuator Removal and

Installation . . . . . . . . . . . . . ...7A-12

Air Flow Control Actuator Inspection. . . . .7A-12
Temperature Control Actuator Removal and

Installation . . . . . . . . . . . . . ...7A-13

Temperature Control Actuator Inspection . . .7A-13
Air Intake Control Actuator Removal and

Installation . . . . . . . . . . . . . ...7A-13

Air Intake Control Actuator Inspection. . . ...7A-14
Actuator Linkage Inspection. . . . . . . ..7A-14
Center Ventilation Louver Removal and

Installation . . . . . . . . . . . . . ...7A-14

Side Ventilation Louver Removal and

Installation . . . . . . . . . . . . . ...7A-15

Rear Duct Components. . . . . . . . . .7A-16
Rear Duct Removal and Installation. . . . ..7A-16

Air Conditioning System. . . . . . . 7B-1

Precautions. . . . . . . . . . . . . . ...7B-1

A/C System Caution. . . . . . . . . . . 7B-1
Precautions on Servicing A/C System . . . . 7B-1
Precautions in Diagnosing Trouble . . . . . .7B-1
Precautions on Handling Refrigerant HFC-

134a (R-134a) . . . . . . . . . . . . ...7B-1

Precautions on Servicing Refrigerant Line. . ..7B-2
Precautions on Refrigerant Recovery . . . . .7B-2
Precautions on Refrigerant Charge. . . . . .7B-2
Precautions on Replenishing Compressor Oil . 7B-2
Precautions on Servicing Compressor

Assembly. . . . . . . . . . . . . . ...7B-3

General Description . . . . . . . . . . . .7B-4

AUTO A/C System Description . . . . . . ...7B-4
HVAC Control System Description. . . . . ..7B-4
HVAC Control Module Operation Description . .7B-4
A/C Refrigerant Type Description . . . . . ...7B-4
Sub-Cool A/C System Description . . . . . ..7B-5
A/C Evaporator Temperature Sensor

Description . . . . . . . . . . . . . . 7B-6

On-Board Diagnostic System Description. . ...7B-6

Schematic and Routing Diagram. . . . . . 7B-7

Air Flow Diagram of A/C System. . . . . . .7B-7

7-ii Table of Contents

Auto A/C Electronic Control Input / Output

Diagram . . . . . . . . . . . . . . . 7B-7

A/C System Wiring Circuit Diagram . . . . . 7B-8

Component Location . . . . . . . . . . ...7B-9

A/C Control System Components Location. . .7B-9

Diagnostic Information and Procedures. . ..7B-11

Air Conditioning System Check. . . . . . .7B-11
DTC Check. . . . . . . . . . . . . . 7B-13
DTC Clearance . . . . . . . . . . . . .7B-14
DTC Table. . . . . . . . . . . . . . .7B-15
Fail-Safe Table. . . . . . . . . . . . ..7B-17
Scan Tool Data . . . . . . . . . . . . .7B-18
Visual Inspection . . . . . . . . . . . ...7B-20
A/C System Performance Inspection . . . . 7B-20
A/C System Symptom Diagnosis . . . . . ..7B-26
Abnormal Noise Diagnosis. . . . . . . . 7B-28
Abnormal Noise Symptom Diagnosis of A/C

System . . . . . . . . . . . . . . . 7B-28

DTC B1502: Inside Air Temperature Sensor

and/or Its Circuit Malfunction . . . . . . ..7B-30

DTC B1503: A/C Evaporator Air Temperature

Sensor and/or Its Circuit Malfunction . . . ..7B-31

DTC B1504: Sunload Sensor and/or Its

Circuit Malfunction . . . . . . . . . . ..7B-33

DTC B1511: Temperature Control Actuator

(Position Sensor) and/or Its Circuit
Malfunction. . . . . . . . . . . . . ..7B-34

DTC B1512: Air Flow Control Actuator

(Position Sensor) and/or Its Circuit
Malfunction. . . . . . . . . . . . . ..7B-37

DTC B1513: Temperature Control Actuator

and/or Its Circuit Malfunction . . . . . . ..7B-39

DTC B1514: Air Flow Control Actuator and/or

Its Circuit Malfunction. . . . . . . . . ..7B-42

DTC B1520: Temperature Selector and/or Its

Circuit Malfunction . . . . . . . . . . ..7B-44

DTC B1521: Blower Speed Selector and/or Its

Circuit Malfunction . . . . . . . . . . ..7B-45

DTC B1530: Air Intake Control Actuator

(Position Sensor) and/or Its Circuit
Malfunction. . . . . . . . . . . . . ..7B-46

DTC B1531: Air Intake Control Actuator and/

or Its Circuit Malfunction . . . . . . . . .7B-48

DTC B1546: A/C Refrigerant Pressure

Malfunction. . . . . . . . . . . . . ..7B-51

DTC B1551: Serial Communication Circuit

Malfunction. . . . . . . . . . . . . ..7B-52

DTC B1552: Serial Communication Circuit

Malfunction. . . . . . . . . . . . . ..7B-53

DTC B1553: CAN Communication Circuit

Malfunction. . . . . . . . . . . . . ..7B-54

DTC B1556: Camshaft Position (CMP)

Sensor and/or Its Circuit Malfunction . . . ..7B-54

DTC B1557: Wheel Speed Sensor and/or Its

Circuit Malfunction . . . . . . . . . . ..7B-54

DTC B1561: Engine Coolant Temperature

Sensor and/or Its Circuit Malfunction . . . ..7B-55

DTC B1562: Outside Air Temperature Sensor

and/or Its Circuit Malfunction . . . . . . ..7B-55

DTC B1563: A/C Refrigerant Pressure

Sensor and/or Its Circuit Malfunction . . . ..7B-55

HVAC Control Module and Its Circuits

Inspection. . . . . . . . . . . . . . 7B-56

A/C System Inspection at ECM. . . . . . .7B-58

Repair Instructions . . . . . . . . . . . 7B-59

Operation Procedure for Charging A/C with

Refrigerant . . . . . . . . . . . . . ..7B-59

A/C Condenser Assembly On-Vehicle

Inspection. . . . . . . . . . . . . . 7B-63

A/C Condenser Assembly Removal and

Installation . . . . . . . . . . . . . ...7B-63

Desiccant Removal and Installation . . . . ..7B-64
HVAC Air Filter Removal and Installation . . .7B-65
HVAC Air Filter Inspection . . . . . . . . 7B-65
HVAC Unit Components . . . . . . . . ...7B-66
HVAC Unit Removal and Installation . . . . 7B-68
A/C Evaporator Removal and Installation . . .7B-69
A/C Evaporator Inspection . . . . . . . . 7B-69
A/C Evaporator Temperature Sensor

Removal and Installation. . . . . . . . .7B-70

A/C Evaporator Temperature Sensor

Inspection. . . . . . . . . . . . . . 7B-71

Expansion Valve On-Vehicle Inspection . . ...7B-71
Expansion Valve Removal and Installation . ...7B-71
A/C Refrigerant Pressure Sensor and Its

Circuit Inspection. . . . . . . . . . . .7B-72

A/C Refrigerant Pressure Sensor Removal

and Installation . . . . . . . . . . . . 7B-72

Sunload Sensor Removal and Installation . . 7B-73
Sunload Sensor Inspection . . . . . . . ...7B-73
Inside Air Temperature Sensor Removal and

Installation . . . . . . . . . . . . . ...7B-73

Inside Air Temperature Sensor Inspection. . 7B-73
Outside Air Temperature Sensor Removal

and Installation . . . . . . . . . . . . 7B-74

Outside Air Temperature Sensor Inspection . .7B-74
Air Flow Control Actuator Removal and

Installation . . . . . . . . . . . . . ...7B-74

Air Flow Control Actuator Inspection. . . . .7B-74
Air Intake Control Actuator Removal and

Installation . . . . . . . . . . . . . ...7B-74

Air Intake Control Actuator Inspection. . . ...7B-74
Temperature Control Actuator Removal and

Installation . . . . . . . . . . . . . ...7B-74

Temperature Control Actuator Inspection . . .7B-74
HVAC Control Module Removal and

Installation . . . . . . . . . . . . . ...7B-74

A/C Compressor Drive Belt Inspection and

Adjustment . . . . . . . . . . . . . ..7B-74

A/C Compressor Drive Belt Removal and

Installation . . . . . . . . . . . . . ...7B-74

A/C Compressor Relay Inspection . . . . . 7B-74
Compressor Assembly On-Vehicle Inspection ..7B-75
Compressor Assembly Removal and

Installation . . . . . . . . . . . . . ...7B-75

Magnet Clutch Components. . . . . . . ..7B-76
Magnet Clutch Operating Check . . . . . ...7B-76
Magnet Clutch Removal and Installation. . ...7B-77
Relief Valve On-Vehicle Inspection. . . . ...7B-78

Table of Contents 7-iii

Specifications. . . . . . . . . . . . . .7B-79

Tightening Torque Specifications. . . . . ..7B-79

Special Tools and Equipment . . . . . . ...7B-79

Recommended Service Material . . . . . ...7B-79