brake sensor SUZUKI SWIFT 2000 1.G RG413 Service User Guide

3E-24 REAR SUSPENSION
2) Press in a new bearing (2) and retainer ring (3) in order by
using an hydraulic press (4).
3) Install wheel sensor ring (if equipped with ABS).
Refer to “REAR WHEEL SENSOR RING” of Section 5E.
4) Inspect axle shaft length.
Rear axle shaft length “a”
Left side : 657.5 mm (25.9 in.)
Right side : 785.5 mm (30.9 in.)
5) Apply grease to axle shaft oil seal (1) lip as shown.
“A” : Grease 99000-25010
6) Apply sealant to mating surface of axle housing (2) with
brake back plate.
“B” : Sealant 99000-31090
7) Install rear axle shaft to rear axle housing and tighten brake
back plate bolts to specified torque.
Tightening torque
Brake back plate bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft) NOTE:
Install wheel bearing spacer (1) with the tapered side of
its inner diameter directed toward outside, or brake
drum side.
Install wheel bearing with its sealed side directed
toward brake drum side.
Use care not to cause any damage to outside of
retainer ring.
A : Tapered side
B : Sealed side
C : Differential side
D : Without ABS
E : With ABS
NOTE:
Make sure to remove old sealant before applying it anew.
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.

REAR SUSPENSION 3E-25
8) Connect brake pipe to wheel cylinder and tighten brake pipe
flare nut to specified torque.
Tightening torque
Brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
9) Refill rear axle (differential) housing with new specified gear
oil. Refer to Section 7F for refill.
10) Install brake drum. For details, refer to “BRAKE DRUM” of
Section 5.
11) Connect parking brake cable (1) to parking brake shoe lever.
Secure parking brake cable to brake back plate with clip (2).
Install wheel speed sensor (if equipped with ABS).
12) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “BLEEDING BRAKES” in Sec-
tion 5.)
13) Install wheel and tighten wheel nuts to specified torque.
14) Upon completion of all jobs, pull parking brake lever with
about 20 kg, (44 lbs) load three to five times so as to obtain
proper drum-to-shoe clearance.
Adjust parking brake cable (for adjustment, refer to “PARK-
ING BRAKE INSPECTION AND ADJUSTMENT” in Section
5).
15) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
16) Perform brake test (foot brake and parking brake).
(For brake test, see Section 5.)
17) Check each installed part for oil leakage.
REAR AXLE SHAFT OIL SEAL (4WD VEHI-
CLE)
REMOVAL
1) Remove rear axle shaft. For details, refer to steps 1) to 8) of
“REAR AXLE SHAFT AND WHEEL BEARING” in this sec-
tion.
CAUTION:
Check to ensure that clip is in good condition before
installing it. If deformed or broken, replace.
1. Plug cap
2. Vinyl tube (See-through tube)
3. Container

3E-26 REAR SUSPENSION
2) Remove rear axle shaft oil seal (1) by using special tool.
Special tool
(A) : 09913-50121
INSTALLATION
1) Using special tools, drive in oil seal (1) or (2) until it contacts
oil seal protector (3) in axle housing.
Special tools
(A) : 09924-74510
(B) : 09944-67010
“A” : Grease 99000-25010
2) For procedure hereafter, refer to steps 5) to 7) of “REAR
AXLE SHAFT AND WHEEL BEARING” in this section.
REAR AXLE HOUSING (4WD VEHICLE)
REMOVAL
1) Hoist vehicle.
2) Remove rear axle shaft referring to item 2) to 8) of “REAR
AXLE SHAFT AND WHEEL BEARING” in this section.
3) Disconnect brake pipe from flexible hose and remove E-ring.
4) Remove brake pipe clamps and pipes from axle housing.
5) Remove parking brake cable clamps and disconnect parking
brake cable from axle housing.
6) Remove wheel speed sensor and release clamps from axle
housing (if equipped with ABS).
7) Remove LSPV adjust nut and detach spring end from rear
axle housing (if equipped with LSPV).
2. Axle housing
NOTE:
There are 2 types of oil seal ((1) & (2)). Their shapes are dif-
ferent as shown in the figure but they are both usable.
Special Tool (B) can be used for both oil seals (1) and (2).
Make sure that oil seal is free from inclination as it is
installed.
Refer to the figure to check that oil seal is installed in
proper direction.
CAUTION:
When installing oil seal (2), never hit any part other than
the position indicated as (6) in the figure. Make sure to
use special tools indicated below. Failure to observe this
caution will cause oil seal to be deformed and oil leakage
to occur.
4. Differential side
5. Apply grease here
6. Press-fitting point

REAR SUSPENSION 3E-29
4) Install lateral rod (1) and install bolt (3) in proper direction as
shown. At this time, mount bolt and nut (4) but don’t tighten
them.
5) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 99000-31110
6) Install differential carrier assembly to axle housing and
tighten carrier nuts to specified torque.
Tightening torque
Rear differential carrier nuts : 23 N·m (2.3 kg-m, 17.0 lb-ft)
7) Install propeller shaft to joint flange aligning match marks (1)
and tighten flange bolts to specified torque.
Tightening torque
Companion flange bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Install LSPV spring to rear axle.
Tighten LSPV adjust nut temporarily at this step. (if equipped
with LSPV).
9) Install wheel speed sensor and clamp wire securely (right &
left) (if equipped with ABS).
10) Remove floor jack from axle housing.
11) Connect brake pipes and parking brake cable and clamp
them securely.
For clamping positions, refer to Section 5.
12) Connect brake flexible hose to bracket and secure it with E-
ring.
2. Vehicle body
A : Forward

BRAKES 5-5
DIAGNOSIS TABLE
Condition Possible Cause Correction
Not enough braking
forceBrake oil leakage from brake lines Locate leaking point and repair.
Brake disc or pads stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Poor contact of shoes on brake drum Repair for proper contact.
Brake shoes linings stained with oil or wet with
waterReplace.
Badly worn brake pad linings Replace.
Defective wheel cylinders Repair or replace.
Malfunctioning caliper assembly Repair or replace.
Air in system Bleed system.
Maladjusted sensor spring length of LSPV, if
equippedCheck or adjust.
Broken sensor spring of LSPV, if equipped Replace.
Defective LSPV, if equipped Replace.
Malfunctioning ABS (Antilock brake system), if
equippedCheck system and replace as nec-
essary.
Brake pull
(Brakes not working in
unison)Pad linings and/or shoe linings are wet with
water or stained with oil in some brakesReplace.
Drum-to-shoe clearance out of adjustment in
some brakes
(Malfunctioning auto adjusting mechanism)Check for inoperative auto adjust-
ing mechanism.
Disc and/or drum is out of round in some
brakesReplace.
Wheel tires are inflated unequally Inflate equally.
Malfunction in wheel cylinders Repair or replace.
Disturbed front end alignment Adjust as prescribed.
Unmatched tires on same axle Tires with approximately the same
amount of tread should be used on
the same axle.
Restricted brake pipes or hoses Check for soft hoses and damaged
lines. Replace with new hoses and
new double-walled steel brake tub-
ing.
Malfunctioning caliper assembly Check for stuck or sluggish pistons
and proper lubrication of caliper
slide bush.
Caliper should slide.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifica-
tions.
Noise (high pitched
squeak without brake
applied)Front lining worn out Replace linings.
Contact wear indicator to brake disc Replace pads.
Rear brake locked pre-
maturelyMaladjusted sensor spring length of LSPV, if
equippedCheck or adjust.
Malfunction LSPV assembly, if equipped Replace assembly.

5E-2 ANTILOCK BRAKE SYSTEM (ABS)
DTC C1015 (DTC 15) – G SENSOR
CIRCUIT .................................................... 5E-22
DTC C1021 (DTC 21), DTC C1022
(DTC 22) – RIGHT-FRONT WHEEL
SPEED SENSOR CIRCUIT OR SENSOR
RING .......................................................... 5E-24
DTC C1025 (DTC 25), DTC C1026
(DTC 26) – LEFT-FRONT WHEEL
SPEED SENSOR CIRCUIT OR SENSOR
RING .......................................................... 5E-24
DTC C1031 (DTC 31), DTC C1032
(DTC 32) – RIGHT-REAR WHEEL
SPEED SENSOR CIRCUIT OR SENSOR
RING .......................................................... 5E-24
DTC C1035 (DTC 35), DTC C1036
(DTC 36) – LEFT-REAR WHEEL SPEED
SENSOR CIRCUIT OR SENSOR RING.... 5E-24
DTC C1041 (DTC 41) – RIGHT-FRONT
INLET SOLENOID CIRCUIT...................... 5E-26
DTC C1045 (DTC 45) – LEFT-FRONT
INLET SOLENOID CIRCUIT...................... 5E-26
DTC C1051 (DTC 51) – RIGHT-REAR
INLET SOLENOID CIRCUIT...................... 5E-26
DTC C1055 (DTC 55) – LEFT-REAR
INLET SOLENOID CIRCUIT...................... 5E-26
DTC C1042 (DTC 42) – RIGHT-FRONT
OUTLET SOLENOID CIRCUIT.................. 5E-26
DTC C1046 (DTC 46) – LEFT-FRONT
OUTLET SOLENOID CIRCUIT.................. 5E-26
DTC C1052 (DTC 52) – RIGHT-REAR
OUTLET SOLENOID CIRCUIT.................. 5E-26DTC C1056 (DTC 56) – LEFT-REAR
OUTLET SOLENOID CIRCUIT ................. 5E-26
DTC C1057 (DTC 57) – POWER
SOURCE CIRCUIT .................................... 5E-27
DTC C1061 (DTC 61) – ABS PUMP
MOTOR CIRCUIT ...................................... 5E-28
DTC C1063 (DTC 63) – ABS FAIL-SAFE
RELAY CIRCUIT ....................................... 5E-29
DTC C1071 (DTC 71) – ABS CONTROL
MODULE ................................................... 5E-30
ON-VEHICLE SERVICE................................ 5E-31
PRECAUTIONS ......................................... 5E-31
ABS HYDRAULIC UNIT OPERATION
CHECK (USING SUZUKI SCAN TOOL) ... 5E-31
ABS HYDRAULIC UNIT OPERATION
CHECK (NOT USING SUZUKI SCAN
TOOL) ........................................................ 5E-31
ABS HYDRAULIC UNIT/CONTROL
MODULE ASSEMBLY ............................... 5E-33
FRONT WHEEL SPEED SENSOR ........... 5E-35
FRONT WHEEL SPEED SENSOR
RING .......................................................... 5E-37
REAR WHEEL SPEED SENSOR.............. 5E-38
REAR WHEEL SPEED SENSOR
RING (FOR 2WD VEHICLE) ..................... 5E-41
REAR WHEEL SPEED SENSOR
RING(FOR 4WD VEHICLE) ...................... 5E-42
G SENSOR (FOR 4WD VEHICLE
ONLY) ........................................................ 5E-43
SPECIAL TOOL ............................................ 5E-44

GENERAL DESCRIPTION
COMPONENTS/PARTS LOCATION AND BRAKE HOSE/PIPE ROUTING
The ABS (Antilock Brake System) controls the fluid pressure applied to the Wheel cylinder of each brake from
the master cylinder so that each wheel is not locked even when hard braking is applied.
This ABS has also the following function.
While braking is applied, but before ABS control becomes effective, braking force is distributed between the front
and rear so as to prevent the rear wheels from being locked too early for better stability of the vehicle.

ANTILOCK BRAKE SYSTEM (ABS) 5E-3
The main component parts of this ABS include the following parts in addition to those of the conventional brake
system.
Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.
ABS warning lamp which lights to inform abnormality when system fails to operate properly.
ABS hydraulic unit/control module assembly is incorporated ABS control module, ABS hydraulic unit (actua-
tor assembly), fail-safe relay and pump motor relay.
–ABS control module which 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 which operates according to signal from ABS control module to control fluid pressure
applied to wheel cylinder of each 4 wheels.
–Fail-safe relay (solenoid valve) relay which supplies power to solenoid valve in ABS hydraulic unit and
pump motor relay.
–Pump motor relay which supplies power to pump motor in ABS hydraulic unit.
G sensor which detects body deceleration speed. (For 4WD model only)]
This ABS is equipped with Electronic Brake force Distribution (EBD) system that controls a fluid pressure of rear
wheels to best condition, which is the same function as that of proportioning valve, by the signal from wheel sen-
sor independently of change of load due to load capacity and so on. And if the EBD system fails to operate prop-
erly, the brake warning lamp lights to inform abnormality.
[A] : RH steering vehicle shown 4. Stop lamp switch
1. ABS hydraulic unit/control module assembly 5. ABS warning lamp
2. G sensor (For 4WD vehicle only) 6. EBD warning lamp (Brake warning lamp)
3. Wheel speed sensors
156
2 4
33
[A]
NOTE:
As for the difference of RH steering vehicle and LH steering vehicle, the location of the combination
meter and the brake master cylinder assembly only changes.

5E-4 ANTILOCK BRAKE SYSTEM (ABS)
SYSTEM SCHEMATIC
1. ABS hydraulic unit/control module assembly 7.“ABS” warning lamp 13. Wheel speed sensor (Right-front)
2. ABS control module 8.“EBD” warning lamp (Brake warning lamp) 14. Wheel speed sensor (Left-front)
3. ABS hydraulic unit 9. Lamp driver module 15. Wheel speed sensor (Right-rear)
4. Fail safe relay 10. ECM 16. Wheel speed sensor (Left-rear)
5. Pump motor relay 11. Data link connector 17. G sensor (For 4WD vehicle only)
6. Stop lamp switch 12. Monitor coupler
INPUT OUTPUT
ABS control
module Wheel speed sensor (LF)
Wheel speed sensor (LR)
Wheel speed sensor (RF)
Wheel speed sensor (RR)
Stop lamp switch
Diag. switch terminal
Battery Voltage
G sensor (for 4WD vehicle only)
Pump motor
relay
Fail-safe
relay
Hydraulic unit
Pump motor
LF inlet solenoid
LF outlet solenoid
LR inlet solenoid
LR outlet solenoid
RF inlet solenoid
RF outlet solenoid
RR inlet solenoid
RR outlet solenoid
“ABS” warning lamp
ECM
EBD warning lamp
(Brake warning lamp)
Data link connector
ABS hydraulic unit/control
module assembly

ANTILOCK BRAKE SYSTEM (ABS) 5E-7
1. Battery 9. ABS hydraulic unit/control module assembly 17. Left-rear wheel speed sensor
2. Main fuses 10. Terminal arrangement of connector E19 for ABS
hydraulic unit/control module assembly18. Right-front wheel speed sensor
3. Ignition switch 11. ABS fail-safe relay (Solenoid valve relay) 19. Left-front wheel speed sensor
4. Circuit fuses 12. ABS pump motor relay 20. Data link connector
5. Combination meter 13. Pump motor 21. To ECM, SDM and EPS controller (if equipped)
6. ABS warning lamp 14. Solenoid valves 22. Stop lamp
7. Brake warning lamp (“EBD” warning lamp) 15. Diagnosis monitor coupler 23. Stop lamp switch
8. Warning lamp driver module (for ABS) 16. Right-rear wheel speed sensor 24. G sensor (For 4WD vehicle only)
Wire color
BLK : Black LT GRN/BLK : Light Green/Black RED/BLU : Red/Blue
BLK/ORN : Black/Orange LT GRN/RED : Light Green/Red WHT : White
BLK/YEL : Black/Yellow ORN : Orange WHT/BLK : White/Black
BLU : Blue PNK : Pink WHT/BLU : White/Blue
BRN : Brown PNK/BLU Pink/Blue WHT/RED : White/Red
GRN : Green RED : Red YEL : Yellow
GRN/ORN : Green/Orange RED/BLK : Red/Black
TERMINAL CIRCUIT
E191–
2 Stop lamp switch
3 Right-front wheel speed sensor (+)
4 Right-front wheel speed sensor (–)
5–
6 Right-rear wheel speed sensor (–)
7 Right-rear wheel speed sensor (+)
8–
9–
10 Brake warning lamp (EBD warning lamp)
11 G sensor (For 4WD vehicle only)
12 Diagnosis switch terminal
13 Ground (For G sensor) (For 4WD vehicle only)
14 ABS warning lamp
15 Left-front wheel speed sensor (+)
16 Left-front wheel speed sensor (–)
17–
18 Ignition switch
19 Left-rear wheel speed sensor (+)
20 Left-rear wheel speed sensor (–)
21 Data link connector
22 Ground (for ABS pump motor)
23 ABS pump motor relay
24 Ground (for ABS control module)
25 ABS fail-safe relay

ANTILOCK BRAKE SYSTEM (ABS) 5E-11
c) Diagnostic Trouble Code (DTC) Check, Record and Clearance
Perform “DIAGNOSTIC TROUBLE CODE CHECK” procedure in this section, record it and then clear it
referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section.
If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again
when the ignition switch is turned ON, attempt to diagnose the trouble based on the DTC recorded in this
step may mislead the diagnosis or make diagnosing difficult. Proceed to Step 2) to check control module
for proper self-diagnosis function.
If the malfunction DTC which was once displayed and then cleared can be detected (indicated) again when
ignition switch is turned ON, proceed to Step 3).
2) DRIVING TEST
Test drive the vehicle at 40 km/h for more than a minute and check if any trouble symptom (such as abnor-
mal lighting of ABS warning light) exists.
If the malfunction DTC is confirmed again at ignition switch ON, driving test as described in above is not nec-
essary. Proceed to Step 3).
3) DIAGNOSTIC TROUBLE CODE CHECK
Recheck diagnostic trouble code referring to “DTC CHECK” as shown in the following page.
4) DIAGNOSTIC TROUBLE CODE FLOW TABLE
According to Diagnostic flow table for the diagnostic trouble code confirmation in Step 3), locate the cause of
the trouble, namely in a sensor, switch, wire harness, connector, actuator assembly or other part and repair
or replace faulty parts.
5)“DIAGNOSIS” IN “BRAKES” SECTION
Check the parts or system suspected as a possible cause referring to “DIAGNOSIS” in “BRAKES” section
and based on symptoms appearing on the vehicle (symptom obtained through Steps 1)-a, 1)-b and 2) and
repair or replace faulty parts, if any).
6) CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“INTERMITTENT TROUBLE” in “GENERAL INFORMATION” section and related circuit of trouble code
recorded in Step 1)-c.
7) FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the ABS is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear the DTC once and perform test driving and confirm
that no DTC is indicated.