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