speed sensor SUZUKI JIMNY 2005 3.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8E
5E
9
10
10A
10B
10
10A
10B
SECTION 5E
ANTILOCK BRAKE SYSTEM (ABS)
CONTENTS
General Description ....................................... 5E-2
System Schematic ....................................... 5E-3
ABS Component Parts Location .................. 5E-4
ABS Control Module ..................................... 5E-5
Self-diagnosis function ............................. 5E-5
Fail-safe function ...................................... 5E-5
Diagnosis ........................................................ 5E-6
Precaution in Diagnosing Troubles .............. 5E-6
ABS Diagnostic Flow Table .......................... 5E-6
“ABS” Warning Lamp Check ........................ 5E-9
Diagnostic Trouble Code (DTC) Check ........ 5E-9
DTC Check (Using SUZUKI Scan Tool) ..... 5E-10
Diagnostic Trouble Code (DTC)
Clearance ................................................... 5E-10
Diagnostic Trouble Code (DTC) Table ....... 5E-11
System Circuit ............................................ 5E-12
Table – A “ABS” Warning Lamp Circuit
Check – Lamp Does Not Come “ON”
at Ignition Switch ON .................................. 5E-14
Table – B “ABS” Warning Lamp Circuit
Check – Lamp Comes “ON” Steady ........... 5E-15
Table – C “ABS” Warning Lamp Circuit
Check – Lamp Flashes Continuously
While Ignition Switch is ON ........................ 5E-16
Table – D Code (DTC) is Not Outputted
Even With Diag. Switch Terminal
Connected to Ground. ................................ 5E-17
DTC C1015 (DTC 15) – G Sensor
Circuit ......................................................... 5E-18
DTC C1016 (DTC 16) – Stop Lamp
Circuit ......................................................... 5E-20
DTC C1021 (DTC 21), DTC C1022
(DTC 22) – Right Front Wheel Speed
Sensor Circuit ............................................. 5E-21
DTC C1025 (DTC 25), DTC C1026
(DTC 26) – Left Front Wheel Speed
Sensor Circuit ............................................. 5E-21DTC C1031 (DTC 31), DTC C1032
(DTC 32) – Right Rear Wheel Speed
Sensor Circuit ............................................ 5E-21
DTC C1035 (DTC 35), DTC C1036
(DTC 36) – Left Rear Wheel Speed
Sensor Circuit ............................................ 5E-21
DTC C1041 (DTC 41), DTC C1042
(DTC 42) – Right Front Solenoid Circuit .... 5E-24
DTC C1045 (DTC 45), DTC C1046
(DTC 46) – Left Front Solenoid Circuit....... 5E-24
DTC C1055 (DTC 55), DTC C1056
(DTC 56) – Rear Solenoid Circuit .............. 5E-24
DTC C1057 (DTC 57) – Power Source
Circuit ......................................................... 5E-25
DTC C1061 (DTC 61) – ABS Pump
Motor Circuit............................................... 5E-26
DTC C1063 (DTC 63) – ABS Fail Safe
Circuit ......................................................... 5E-27
DTC C1071 (DTC 71) – ABS Control
Module ....................................................... 5E-28
On-Vehicle Service ...................................... 5E-29
Precaution .................................................. 5E-29
ABS Hydraulic Unit Operation Check ........ 5E-29
ABS Hydraulic Unit / Control Module
Assembly ................................................... 5E-30
Front Wheel Speed Sensor........................ 5E-32
Front Wheel Sensor Ring........................... 5E-35
Rear Wheel Speed Sensor ........................ 5E-36
Rear Wheel Sensor Ring ........................... 5E-38
G Sensor .................................................... 5E-39
Tightening Torque Specification ................ 5E-40
Special Tool .................................................. 5E-40 NOTE:
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
same part number or with an equivalent part if replacement part of lesser quality or substitute design.
Torque values must be used as specified during reassembly to assure proper retention of all parts.
There is to be no welding as it may result in extensive damage and weakening of the metal.

Downloaded from www.Manualslib.com manuals search engine 5E-2 ANTILOCK BRAKE SYSTEM (ABS)
General Description
The ABS (Antilock Brake System) is a system to prevent each wheel to lock during hard braking or braking on a
slippery road by controlling the fluid pressure from master cylinder to each brake (either brake caliper or wheel
cylinder).
The ABS of this vehicle monitors all four wheels (four sensors) and controls all four wheels when the system is
active.
The component parts of this ABS includes following parts in addition to those of the conventional brake system.
Wheel speed sensor senses revolution speed of each wheel and sends outputs to ABS control module.
In this ABS, ABS hydraulic unit (actuator assembly), ABS control module, pump motor transistor and fail-
safe transistor are combined as one component.
ABS control module sends operation signal to ABS hydraulic unit to control fluid pressure applied to each
wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking.
ABS hydraulic unit operates according to signal from ABS control module and controls fluid pressure applied
to wheel cylinder of each of 4 wheels.
Fail-safe transistor which supplies power to solenoid valve in ABS hydraulic unit.
Pump motor transistor supplies power to pump motor in ABS hydraulic unit.
“ABS” warning lamp lights to inform abnormality when system fails to operate properly.
G sensor which detects body deceleration speed.
1. Front disc brake 5. Brake master cylinder / booster
2. Proportioning valve [A] : For LH steering vehicle
3. Rear drum brake [B] : For RH steering vehicle
4. ABS hydraulic unit / control module assembly

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-3
System Schematic
1. Wheel speed sensor (Right front) 7. Wheel speed sensor (Left rear) 13. ABS hydraulic unit
2. Stop lamp switch 8.“ABS” warning lamp 14. G sensor
3. ABS control module 9. ABS pump motor transistor 15. Data link connector
4. Wheel speed sensor (Right rear) 10. ABS solenoid valve transistor 16. ABS hydraulic unit / control module assembly
5. Monitor connector 11. Proportioning valve 17. 4WD switch (for 4WD model only)
6. ABS lamp driver module 12. Wheel speed sensor (Left front)
INPUTOUTPUT
ABS control
module Wheel speed sensor (RF)
Wheel speed sensor (RR)
Wheel speed sensor (LR)
Wheel speed sensor (LF)
Stop lamp switch
Diag. switch terminal
Battery voltage
4WD switch (for 4WD model only) G sensor
Pump motor
transistor
Fail-safe
transistor
Pump motor
LF hold solenoid
LF release solenoid
RF hold solenoid
RF release solenoid
Rear hold solenoid
Rear release solenoid
“ABS” warning lamp
Idle-up
ECM
Data link connector
ABS hydraulic unit/control
module assembly

Downloaded from www.Manualslib.com manuals search engine 5E-4 ANTILOCK BRAKE SYSTEM (ABS)
ABS Component Parts Location
1. Wheel speed sensor (Right front) 6. ABS hydraulic unit / control module assembly 11. Proportioning valve
2. Stop lamp switch 7. Monitor connector [A] : For LH steering vehicle
3.“ABS” warning lamp 8. Wheel speed sensor (Left front) [B] : For RH steering vehicle
4. Wheel speed sensor (Right rear) 9. Wheel speed sensor ring
5. Wheel speed sensor (Left rear) 10. G sensor

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-9
“ABS” Warning Lamp Check
Turn ignition switch ON and check that “ABS” warning lamp
comes ON for about 2 seconds and then goes OFF. If any faulty
condition is found, advance to Diagnostic Flow Table-A, B or C.
Diagnostic Trouble Code (DTC) Check
1) Test drive vehicle at 40 km/h for more than a minute.
2) Stop vehicle and while IG switch OFF, connect diagnosis
switch terminal (3) and ground terminal (2) of monitor con-
nector (1) with service wire (4).
3) Turn IG switch ON, read the flashing “ABS” warning lamp
which represents DTC as shown in example below and write
it down. When more than 2 DTC’s are stored in memory,
flashing for each DTC is repeated three times starting with
the smallest DTC number in increasing order.
For details of DTC, refer to “DTC Table”.
Example : When right front wheel speed sensor circuit opens (DTC 21)
4) After completing the check, turn ignition switch off, discon-
nect service wire from monitor connector.
NOTE:
“ABS” warning lamp indicates only following DTCs, DTC
12 which means that no malfunction DTC is stored and
history DTC which indicates history trouble area. When
there is current trouble, “ABS” warning lamp remains ON
and therefore DTC is not indicated.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-11
Diagnostic Trouble Code (DTC) Table
DTC
(displayed on
SUZUKI scan
tool)DTC
(indicated by
ABS warn-
ing lamp)ABS warning light flashing
patternDIAGNOSTIC ITEMS
–12 Normal
C1015 15 G sensor circuit (for 4WD model only)
C1016 16 Stop lamp switch circuit
C1021 21 RF
Wheel speed sensor circuit and/or sen-
sor ring C1025 25 LF
C1031 31 RR
C1035 35 LR
C1022 22 RF
C1026 26 LF
C1032 32 RR
C1036 36 LR
C1041 41
RFHold solenoid valve circuit
C1042 42 Release solenoid valve circuit
C1045 45
LFHold solenoid valve circuit
C1046 46 Release solenoid valve circuit
C1055 55
RearHold solenoid valve circuit
C1056 56 Release solenoid valve circuit

Downloaded from www.Manualslib.com manuals search engine 5E-12 ANTILOCK BRAKE SYSTEM (ABS)
System Circuit
C1057 57 Power source
C1061 61 ABS pump motor circuit
C1063 63 ABS solenoid valve circuit
C1071 71 ABS control module
1. Battery 5-5. Solenoid valves 14. Stop lamp switch
2. Main fuses 6. Combination meter 15. ECM
3. Ignition switch 7. Right rear wheel speed sensor 16. G sensor
4. Circuit fuses 8. Left rear wheel speed sensor 17. 4WD switch (for 4WD model only)
5. ABS hydraulic unit / control module assem-
bly9. Right front wheel speed sensor 18. 4WD indicator lamp (for 4WD model only)
5-1. Terminal arrangement for ABS hydraulic unit
/ control module assembly10. Left front wheel speed sensor 19. 4WD controller (for 4WD model only)
5-2. ABS fail-safe transistor 11. Data link connector 20.“ABS” warning lamp
5-3. ABS pump motor transistor 12. Monitor connector 21. ABS lamp driver module
5-4. Pump motor 13. Stop lamp
DTC
(displayed on
SUZUKI scan
tool)DTC
(indicated by
ABS warn-
ing lamp)ABS warning light flashing
patternDIAGNOSTIC ITEMS

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-13
TERMINAL CIRCUIT
A1 Idle up signal
A2 Stop lamp switch
A3 Right front wheel speed sensor (+)
A4 Right front wheel speed sensor (–)
A5–
A6 Right rear wheel speed sensor (–)
A7 Right rear wheel speed sensor (+)
A8–
A9–
A10–
A11 G sensor signal
A12 Diagnosis switch terminal
A13 G sensor ground
A14“ABS” warning lamp
A15 Left front wheel speed sensor (+)
A16 Left front wheel speed sensor (–)
A17 4WD switch (for 4WD model only)
A18 Ignition switch
A19 Left rear wheel speed sensor (+)
A20 Left rear wheel speed sensor (–)
A21 Data link connector
A22 Ground (for ABS pump motor)
A23 ABS pump motor power supply
A24 Ground (for ABS control module)
A25 Solenoid valve power supply
Wire color
B : Black G/W : Green / White R/W : Red / White
B/BI : Black / Blue Lg/B : Light green / Black W/Bl : White / Blue
B/W : Black / White Lg/R : Light green / Red W/G : White / Green
B/Or : Black / Orange Or : Orange W/R : White / Red
Bl : Blue Or/B : Orange / Black Y : Yellow
Bl/W : Blue / White P/B : Pink / Black Y/B : Yellow / Black
G : Green P/G : Pink / Green
G/B : Green / Black R/Bl : Red / Blue

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-21
DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right Front Wheel Speed Sensor
Circuit
DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left Front Wheel Speed Sensor
Circuit
DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right Rear Wheel Speed Sensor
Circuit
DTC C1035 (DTC 35), DTC C1036 (DTC 36) – Left Rear Wheel Speed Sensor
Circuit
DESCRIPTION
The ABS control module monitors the voltage at the positive (+) terminal of each sensor while the ignition switch
is ON. When the voltage is not within the specified range, an applicable DTC will be set. Also, when no sensor
signal is inputted at starting or while running, an applicable DTC will be set.
1. Ignition switch 4. Right front wheel speed sensor 7. ABS hydraulic unit / control module connector of harness
2. ABS hydraulic unit / control module assembly 5. Left rear wheel speed sensor
3. Left front wheel speed sensor 6. Right rear wheel speed sensor
NOTE:
When the vehicle was operated in any of the following ways, one of these DTC’s may be set even when
the sensor is in good condition. If such possibility is suspected, repair the trouble (dragging of brake,
etc.) of the vehicle, clear DTC once and then after performing the driving test as described in Step 2 of
“ABS DIAG. FLOW TABLE” in this section, check whether or not any abnormality exists.
The vehicle was driven with parking brake pulled.
The vehicle was driven with brake dragging.
Wheel spin occurred while driving.
Wheel(s) was turned while the vehicle was jacked up.
The vehicle was stuck.

Downloaded from www.Manualslib.com manuals search engine 5E-22 ANTILOCK BRAKE SYSTEM (ABS)
INSPECTION
Step Action Yes No
1 1) Disconnect the applicable sensor connector with ignition
switch OFF.
2) Measure resistance between sensor terminals.
Resistance of wheel speed sensor: 1.4 – 1.8 kΩ (at
20°C, 68°F)
3) Measure resistance between each terminal and body
ground.
Insulation resistance: 1MΩ or higher
Were measured resistance values in step 2) and 3) as spec-
ified? (See [A])Go to step 2. Replace sensor.
2 1) Ignition switch OFF.
2) Disconnect connector from ABS hydraulic unit / control
module assembly. (See [B])
3) Check for proper connection to ABS hydraulic unit / con-
trol module assembly at each sensor terminal.
4) If OK, then turn ignition switch ON and measure voltage
between sensor positive terminal of module connector
and body ground.
Is it 0V?Go to step 3. Sensor positive cir-
cuit shorted to
power.
3 1) Ignition switch OFF.
2) Connect connector to sensor.
3) Measure resistance between sensor terminals at mod-
ule connector.
4) Measure resistance between sensor positive terminal
and negative terminal of module connector, between
positive terminal and body ground.
Are measured resistance values within each specified range
described in above step 1?Go to step 4. Circuit open or
shorted to ground.
4 1) Remove wheel speed sensor.
2) Check sensor for damage or foreign material being
attached.
Is it in good condition? (See [C])Go to step 5. Clean or replace
sensor.
5 Check visually through wheel speed sensor installation hole
for following.
Ring serration (teeth) neither missing or damaged.
No foreign material being attached.
Ring not being eccentric.
Wheel bearing free from excessive play.
Are they in good condition? (See [D])Go to step 6. Clean, repair or
replace.
6 1) Install sensor to knuckle or axle housing.
2) Tighten sensor bolt to specified torque and check that
there is not any clearance between sensor and knuckle
or axle housing. (See [E])
Replace sensor if any.
Referring to “Front Wheel Speed Sensor” in this section,
check output voltage or waveform of sensor. Is proper out-
put voltage or waveform obtained?Substitute a known-
good ABS hydraulic
unit / control module
assembly and
recheck.Replace sensor and
recheck.