Unnecessary Compressor Replacement Due To Noise Service Manual Update (TS 06 10224)

Publication date: 2004-10-21
Reference number: TS 06 10224

UNNECESSARY COMPRESSOR REPLACEMENT DUE TO NOISE SERVICE MANUAL UPDATE

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 06 10224, Date of Issue: October 22, 2004

SUZUKI:	2003-2005, XL-7
SECTION:	HVAC

CONDITION

A noise that can be described as a hum, whine or groan can be heard whenever the A/C is on and compressor is operating which goes away when the A/C is turned off.

CAUSE

To satisfy the A/C requirements of the large passenger area in the XL-7 the A/C compressor displacement was increased. This increase in displacement has resulted in a normal increase in operating noise which may be noticeable inside the vehicle.

CORRECTION

Do not replace the compressor without a complete diagnosis. Most noises heard inside the vehicle are not caused by compressor failure. Follow the "Abnormal Noise Diagnosis" chart in the appropriate Service Manual and Section in conjunction with the attached Service Manual Update.

AFFECTED SERVICE MANUAL(S)

Manual Name	Part Number	Corresponding Page
2005 Grand Vitara / XL-7 Service Manual	99500S52D40-33E	Page 7B-16
2004 Grand Vitara / XL-7 Service Manual	99500-52D30-33E	Page 7B-16
2003 Grand Vitara / XL-7 Service Manual	99500-52D20-33E	Page 7B-19

NOTE: Replace the "Abnormal Noise Diagnosis" section with one shown below.

ABNORMAL NOISE DIAGNOSIS

There are various types of noise, ranging from those produced in the engine compartment to those from the passenger compartment, also from rumbling noises to whistling noises.

ABNORMAL NOISE FROM COMPRESSOR

Problem	Possible Causes	Correction
During compressor operation, a rumbling noise is heard proportional to engine revolutions	Inadequate clearance in piston area (piston or swash-plate)	Repair or replace compressor as necessary.
A loud noise is heard at a certain rpm, disproportionately to engine revolution	Loose or faulty V-belt	Adjust V-belt tension, or replace belt.
A loud noise is heard at a certain rpm, disproportionately to engine revolution	Loose mounting bolts	Retighten mounting bolts.
A loud rattle is heard at low engine rpm	Loose compressor center bolt	Retighten center bolt. Replace compressor if it was operated in this condition for a long time.
A hum can be heard whenever the A/C is ON and compressor is operating which goes away when the A/C is turned OFF.	Inadequate charge of refrigerant	Check for low side and high side pressure to inspect A/C system performance, referring to "Performance Diagnosis of A/C System: Manual Type"