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Code 4 - Air Mix Door Error

WARNING: This page is about a different car, the 2006 Suzuki Verona. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Code 4 - Air Mix Door Error Circuit Diagram
G04720096Courtesy of SUZUKI OF AMERICA CORP.

This code will set if the output of the mix door indicator indicates that the door opening angle is out of range or does not change value when the door should be moving. This would indicate a short circuit or an open in the sensor or the associated wiring harness, a door motor that is not operating, or a malfunction of the ATC controller.

DIAGNOSTIC PROCEDURE

Step Action Value(s) Yes No
1
  1. Disconnect the I/P wiring harness connector from the air mix door (AMD) motor.
  2. Use an ohmmeter to measure the resistance between terminals 5 and 7 on the AMD motor.

Does the measured resistance indicate an open or a shorted condition?		 Open = ≈ Ω, Short = ≈ 0 Ω Go to Step 4 Go to Step 2
2 Measure the resistance between terminals 2 and 3 on the AMD motor.
Is the resistance equal to the value specified?		 ≈ 3,000 Ω Go to Step 3 Go to Step 4
3 Measure the resistance between terminals 6 and 2, and between terminals 6 and 3 on the AMD motor.
Do these resistances add to approximately the value measured between terminals 2 and 3?		 ≈ 3,000 Ω Go to Step 5 Go to Step 4
4 Replace the AMD motor.
Is the repair complete?		 - System OK -
5 Check the connector terminals at the AMD motor and the wiring in the ATC harness.
Is there a problem with any terminal on either the harness connector or the motor connector, or the wiring?		 - Go to Step 6 Go to Step 7
6 Repair the problem found with a connector terminal or the wiring, or replace the motor as required.
Is the repair complete?		 - System OK -
7
  1. Remove the ATC controller from the instrument panel.
  2. Disconnect the harness connectors from the ATC controller.
  3. Examine the connector terminals on the harness connectors and the controller connectors and the harness wiring.

Is there a problem with any of these connectors or the wiring?		 - Go to Step 8 Go to Step 9
8 Repair the problem found with a connector terminal or wiring.
Is the repair complete?		 - System OK -
9 Check continuity in the harness between the controller connectors and the AMD motor connector.
  • Controller terminal A2 to motor terminal 7.
  • Controller terminal A8 to motor terminal 5.
  • Controller terminal B6 to motor terminal 2.
  • Controller terminal B5 to motor terminal 6.
  • Controller terminal B4 to motor terminal 3.

Does the continuity equal the specified value?		 ≈ 0 Ω Go to Step 10 Go to Step 11
10 Repair the continuity problem.
Is the repair complete?		 - System OK -
11
  1. Reconnect the AMD motor to the ATC harness.
  2. Reconnect the ATC harness connectors to the controller.
  3. Turn the ignition to ON.
  4. Use backprobing for voltage measurements.
  5. Measure the voltage between ground and terminal B5 at the controller.

Is the voltage equal to the specified value?		 < 4 V Go to Step 12 Go to Step 14
12
  1. Set the temperature controller to 18 °C (64 °F).
  2. Connect a voltmeter between ground and terminal A8 at the controller. It should display about 12 V.
  3. Raise the temperature setting on the controller to 32 °C (90 °F).

Does the voltage equal the specified value?		 Drops from 12 - 0 V Go to Step 13 Go to Step 15
13
  1. Connect a voltmeter between ground and terminal A2 at the controller. It should display about 12 V.
  2. Change the temperature setting to 18 °C (64 °F).

Does the voltage equal the specified value?		 Drops from 12 - 0 V Go to Step 20 Go to Step 15
14
  1. Recheck the wiring harness and the connector terminals associated with controller terminals B4, B5, and B6, and AMD motor terminals 2, 6, and 3.
  2. Repair any problem found.

Is the repair complete?		 - System OK -
15 Recheck all wiring circuits between the controller and the AMD motor.
Is there a problem in the wiring or the connectors?		 - Go to Step 16 Go to Step 17
16 Repair the problem in the wiring between the ATC controller and the AMD motor.
Is the repair complete?		 - System OK -
17 Recheck the AMD motor.
Is there a problem in the AMD motor?		 - Go to Step 18 Go to Step 19
18 Replace the AMD motor.
Is the repair complete?		 - System OK -
19 Replace the controller.
Is the repair complete?		 - System OK -
20 Observe the operation of the air mix door when the temperature setting is changed.
Does the door move normally?		 - Go to Step 22 Go to Step 21
21 Repair or replace the air mix door.
Is the repair complete?		 - System OK -
22 Observe the operation of the AMD motor when the temperature setting is changed.
Does the motor operate normally?		 - Go to Step 24 Go to Step 23
23 Replace the AMD motor.
Is the repair complete?		 - System OK -
24 Reconnect everything and test the system.
Does code 4 reset?		 - Go to Step 25 System OK
25 Replace the controller.
Is the repair complete?		 - System OK -
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