ect SUZUKI JIMNY 2005 3.G Service Workshop Manual

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

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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-5
ABS Control Module
Self-diagnosis function
ABS control module diagnoses conditions of the system compo-
nent parts (whether or not there is any abnormality) all the time
and indicates the results (warning of abnormality occurrence and
DTC) through the “ABS” warning lamp as described below.
1) When ignition switch is turned ON, “ABS” warning lights for 2
seconds to check its bulb and circuit.
2) When no abnormality has been detected (the system is in
good condition), “ABS” warning lamp turns OFF after 2 sec-
onds.
3) When an abnormality in the system is detected, “ABS” warn-
ing lamp lights and the area where that abnormality lies is
stored in the memory in ABS control module.
4) When Diag. switch terminal of monitor connector is
grounded, the abnormal area is output as DTC.
For procedure to clear all DTC’s, refer to the item “Diagnostic
Trouble Code (DTC) Clearance” in this section.
Fail-safe function
When an abnormality occurs (an abnormal DTC is detected),
ABS control module turns OFF the fail-safe transistor which sup-
plies power to ABS hydraulic unit. Thus, with ABS not operating,
brakes function just like the brake system of the vehicle without
ABS.SYSTEM CONDITIONDIAGNOSIS
SWITCH
TERMINAL“ABS”
WARNING
LAMP
In good
condition
at presentNo trouble in the past Open OFF
Grounded DTC 12
Trouble occurred in
the pastOpen OFF
Grounded History DTC
Abnormal-
ity exists
at presentNo trouble in the past Open ON
Grounded Current DTC
Trouble occurred in
the pastOpen ON
GroundedCurrent and
history DTC
NOTE:
The current code and the history code are displayed
without any classification.
1. Ignition switch 4. ABS control module
2.“ABS” warning lamp 5. Sensed information
3. Monitor connector 6. Output
3-1. Diag. switch terminal 7. Lamp driver module
3-2. Ground terminal

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Diagnosis
To ensure that the trouble diagnosis is done accurately and smoothly, observe “Precautions in Diagnosing Trou-
bles” and follow “ABS Diagnostic Flow Table”.
Precaution in Diagnosing Troubles
If the vehicles was operated in any of the following ways, “ABS” warning lamp may light momentarily but this
does not indicate anything abnormal in ABS.
–The vehicle was driven with parking brake pulled.
–The vehicle was driven with brake dragging.
–The vehicle was stuck in mud, sand, etc.
–Wheel spin occurred while driving.
–Wheel(s) was rotated while the vehicle was jacked up.
Be sure to read “Precautions for Electronic Circuit Service” in Section 0A before inspection and observe
what is written there.
Be sure to use the trouble diagnosis procedure as described in the flow table. Failure to follow the flow table
may result in incorrect diagnosis. Some other diag. trouble code may be stored by mistake in the memory of
ABS control module during inspection.
ABS Diagnostic Flow Table
Refer to the following for the details of each step.
Step Action Yes No
1 Perform customer complaint analysis, problem symptom confir-
mation and diagnostic trouble code check record and clear-
ance.
Is there any trouble code?Go to Step 2. Go to Step 5.
2 Perform driving test.
Is trouble symptom identified?Go to Step 3. Go to Step 6.
3 Check diagnostic trouble code.
Is it malfunction code?Go to Step 4. Go to Step 5.
4 Inspect and repair referring to applicable diagnostic trouble
code table in this section. Then perform final confirmation test
after clearing diagnostic trouble code.
Is trouble recur?Go to Step 7. End.
5 Inspect and repair referring to “Diagnosis Table” in Section 5.
Then perform final confirmation test after clearing diagnostic
trouble code.
Is trouble recur?Go to Step 7. End.
6 Check for intermittent problems referring to “Intermittent and
Poor Connection” in Section 0A and related circuit of trouble
code recorded in Step 3. Then perform final confirmation test
after clearing diagnostic trouble code.
Is trouble recur?Go to Step 7. End.
7 Perform diagnostic trouble code check record and clearance.
Is there any trouble code?Go to Step 4. Go to Step 5.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-7
1) MALFUNCTION ANALYSIS
a) Customer Complaint Analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to
the point required for proper analysis and diagnosis.
CUSTOMER QUESTIONNAIRE (EXAMPLE)
b) Problem Symptom Confirmation
Check if what the customer claimed in “Customer Questionnaire” is actually found in the vehicle and if the
symptom is found, determine whether it is identified as a failure. (This step should be shared with the cus-
tomer if possible.) When “ABS” warning lamp is not operating correctly, proceed to “Diagnostic Flow Table-
A, B or C” in this section.
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 ABS control mod-
ule 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.

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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 lamp) 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” in this section.
4) DIAGNOSTIC TROUBLE CODE FLOW TABLE
According to Diagnostic Flow Table for the diagnostic trouble code confirmed in Step 3, locate the cause of
the trouble, namely in a sensor, switch, wire harness, connector, actuator, ABS control module or other part
and repair or replace faulty parts.
5)“DIAGNOSIS TABLE” IN SECTION 5
Check the parts or system suspected as a possible cause referring to “Diagnosis Table” in Section 5 and
based on symptoms appearing on the vehicle (symptoms obtained through Step 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 Section 0A 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 a normal code is indicated.

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 5E-10 ANTILOCK BRAKE SYSTEM (ABS)
DTC Check (Using SUZUKI Scan Tool)
1) Connect SUZUKI scan tool to data link connector after set-
ting cartridge for ABS to it.
Special tool
(A) : SUZUKI scan tool
2) Turn ignition switch ON.
3) Read DTC according to instructions displayed on SUZUKI
scan tool and print it or write it down. Refer to SUZUKI scan
tool operator's manual for further details.
4) After completing the check, turn ignition switch off and dis-
connect SUZUKI scan tool from DLC.
Diagnostic Trouble Code (DTC) Clearance
After repair or replace malfunction part(s), clear all DTC’s by pre-
forming the following procedure.
1) Turn ignition switch OFF.
2) Using service wire (4), connect diag. switch terminal (3) of
monitor connector (1) to ground terminal (2).
3) With connection described in above step 2) maintained, turn
ignition switch ON.
4) Repeat ON/OFF operation of service wire (4) at ground ter-
minal (2) at least 5 times within 10 seconds.
5) Turn ignition switch OFF and disconnect service wire (4)
from monitor connector (1).
6) Perform “DRIVING TEST” (Step 2 of “ABS Diagnostic Flow
Table”) and “DTC CHECK” and confirm that normal DTC
(DTC 12) is displayed.
WARNING:
When preforming a driving test, select a safe place where
there is neither any traffic nor any traffic accident possi-
bility and be very careful during testing to avoid occur-
rence of an accident.
NOTE:
Service wire ON time must be for 0.1 second and more.
NOTE:
It is also possible to clear DTC by using SUZUKI scan
tool. Refer to Cartridge Manual for procedure to clear
DTC.

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