Brake SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

ANTILOCK BRAKE SYSTEM (ABS) 5E-31
ON-VEHICLE SERVICE
PRECAUTIONS
When connector is connected to ABS hydraulic unit/control mod-
ule assembly, do not disconnect connectors of sensors with igni-
tion switch ON. Then DTC will be set in ABS control module.
ABS HYDRAULIC UNIT OPERATION CHECK
(USING SUZUKI SCAN TOOL)
1) Connect SUZUKI scan tool to data link connector (DLC) (1)
with ignition switch OFF.
Special tool
(A) : 09931-76011 (SUZUKI scan tool)
(B) : Mass storage cartridge
(C) : 09931-76030 (16/14 pin DLC cable)
2) Turn ignition switch to ON position and check actuator oper-
ation using “HYDRAULIC CONTROL TEST” under “miscel-
laneous test” (“MISC. TEST”) mode of SUZUKI scan tool.
ABS HYDRAULIC UNIT OPERATION CHECK
(NOT USING SUZUKI SCAN TOOL)
1) Check that basic brake system other than ABS is in good
condition.
2) Check that battery voltage is 11 V or higher.
3) With ABS warning lamp, check that no abnormality is
detected in ABS. Refer to “DIAGNOSTIC TROUBLE CODE
(DTC) CHECK” in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake drag-
ging occurs. If it does, correct.
(A)
(B) (C) 1

5E-32 ANTILOCK BRAKE SYSTEM (ABS)
7) With diagnosis switch terminal (1) of monitor coupler (2) con-
nected to ground terminal (3) using service wire (4), turn
ignition switch ON and check if ABS warning lamp indicates
DTC 12.
If malfunction DTC is indicated, repair it first.
8) Turn ignition switch OFF.
9) Perform the following checks with help of another person.
Brake pedal (1) should be depressed and then ignition
switch (2) turned ON by one person and wheel (3) should be
turned by another person’s hand. At this time, check that :
Operation sound of solenoid is heard and wheel turns only
about 0.5 sec. (Brake force is depressurized).
Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF → ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace
hydraulic unit/control module assembly.
11) Turn ignition switch OFF and remove service wire from mon-
itor coupler.
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1
4

ANTILOCK BRAKE SYSTEM (ABS) 5E-33
ABS HYDRAULIC UNIT/CONTROL MODULE ASSEMBLY
HYDRAULIC UNIT INSPECTION
Check hydraulic unit for fluid leakage.
If any, repair or replace.
REMOVAL
1) Disconnect negative cable from battery.
2) Disconnect ABS hydraulic unit/control module assembly
connector (1) by pulling up lock (2). CAUTION:
Never disassemble ABS hydraulic unit/control module assembly, loosen blind plug or remove motor.
Performing any of these prohibited services will affect original performance of ABS hydraulic unit/
control module assembly.
1. Brake pipe 3. Bracket
2. ABS hydraulic unit/control module assembly 4. Connector
9 N·m (0.9 kg-m)
9 N·m (0.9 kg-m)
26 N·m (2.6 kg-m)
16 N·m (1.6 kg-m)
16 N·m (1.6 kg-m)
4 2
3
11
1

5E-34 ANTILOCK BRAKE SYSTEM (ABS)
3) Using special tool, loosen flare nuts (1) and disconnect
brake pipes (2) from ABS hydraulic unit/control module
assembly (3).
Special tool
09950-78220
4) Remove two nuts and disconnect take out ABS hydraulic
unit/control module assembly (1) from bracket using flat end
rod or the like (2).
INSTALLATION
1) Install hydraulic unit/control module assembly by reversing
removal procedure.
Tightening torque
Brake pipe flare nut (a) :
16 N·m (1.6 kg-m, 11.5 lb-ft)
ABS hydraulic unit/control module assembly bolt (b) :
9 N·m (0.9 kg-m, 6.5 lb-ft)
ABS hydraulic unit/control module assembly bracket bolt
(c) : 26 N·m (2.6 kg-m, 18.0 lb-ft)
2) Bleed air from brake system referring to “BRAKES” section.
3) Check each installed part for fluid leakage and perform “ABS
HYDRAULIC UNIT OPERATION CHECK” in this section. NOTE:
Put bleeder plug cap onto pipe to prevent fluid from spill-
ing. Do not allow brake fluid to get on painted surfaces.
312
CAUTION:
Do not give an impact to hydraulic unit.
Use care not to allow dust to enter hydraulic unit.
Do not place hydraulic unit on its side or upside down.
Handling it in inappropriate way will affect its original
performance.
NOTE:
For new ABS hydraulic unit/control module assembly, if
“ABS HYDRAULIC UNIT OPERATION CHECK” procedure
has not been performed, “ABS” warning lamp may flash
when ignition switch is turned ON position.
Accordingly preform “ABS HYDRAULIC UNIT OPERA-
TION CHECK” to stop flashing of ABS warning lamp.
(b)
(c) (b)(a)

ANTILOCK BRAKE SYSTEM (ABS) 5E-35
FRONT WHEEL SPEED SENSOR
OUTPUT VOLTAGE INSPECTION
1) Turn ignition switch OFF.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Disconnect wheel speed sensor grommet from vehicle body.
5) Connect voltmeter between connector (1) terminals.
6) While turning wheel by hand at a speed of approximately 1/2
rotation to 1 rotation per second, check AC voltage of sen-
sor.
Output AC voltage at 1/2 to 1 rotation per second
: 106 mV or more
7) If measured voltage is not as specified, check sensor, rotor
and their installation conditions.
1. Left front wheel speed sensor 3. Grommet 5. Sensor ring
2. Clamp bolt 4. Connector

5E-36 ANTILOCK BRAKE SYSTEM (ABS)
Reference
When using oscilloscope for this check, check if peak-to-peak
voltage (1) meets specification and waveform is complete.
Peak-to-peak voltage at 1/2 to 1 rotation per second
: 150 mV or more at 20 Hz
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect front wheel speed sensor coupler (1).
3) Hoist vehicle and remove wheel.
4) Remove harness clamp bolts (2) and grommet (3).
5) Remove front wheel speed sensor (4) from knuckle.
SENSOR INSPECTION
Check sensor for damage.
Check sensor for resistance and continuity.
Between both terminals (1) sensor
: 1.2 – 1.6 k
Ω
ΩΩ Ω at 20°C (68°F)
Between sensor terminal and sensor body (2)
: No continuity
If the check result is not as specified and any malcondition is
found, replace.
CAUTION:
Do not pull wire harness when removing front wheel
speed sensor.
Do not cause damage to surface of front wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.

ANTILOCK BRAKE SYSTEM (ABS) 5E-37
SENSOR ROTER INSPECTION
Check rotor for being missing, damaged or deformed.
Turn drive shaft and check if rotor rotation is free from
eccentricity and looseness.
Check that no foreign material is attached.
If any faulty is found, repair or replace. Refer to “WHEEL
HUB” in Section 3D.
INSTALLATION
1) Check that no foreign material is attached to sensor (1) and
sensor ring (2).
2) Install it by reversing removal procedure.
Tightening torque
Front wheel speed sensor bolt (a) :
10 N·m (1.0 kg-m, 7.5 lb-ft)
3) Check that there is no clearance between sensor and
knuckle.
FRONT WHEEL SPEED SENSOR RING
For removal and installation of wheel side joint assembly of drive
shaft, refer to “FRONT DRIVE SHAFT” section.
CAUTION:
Do not pull or twist wire harness more than necessary
when installing front wheel speed sensor.
NOTE:
The front wheel sensor ring can not be removed or
replaced alone. If front wheel sensor ring needs to be
replaced, replace it as a wheel side joint assembly of
drive shaft.

5E-38 ANTILOCK BRAKE SYSTEM (ABS)
REAR WHEEL SPEED SENSOR
OUTPUT VOLTAGE INSPECTION
1) Turn ignition switch OFF.
2) Remove rear seat referring to Section 9.
3) Turn over floor carpet.
4) Hoist vehicle.
5) Disconnect connector of wheel speed sensor.
6) Connect voltmeter between connector (1) terminals.
7) While turning wheel at a speed of approximately 1/2 rotation
to 1 rotation per second, check AC voltage of sensor.
Output AC voltage at 1/2 to 1 rotation per second
2WD vehicle : 85 mV or more
4WD vehicle : 106 mV or more
8) If measured voltage is not as specified, check sensor, rotor
and their installation conditions.
1. Left rear wheel speed sensor 3. Trailing arm
2. Right rear wheel speed sensor 4. Sensor ring
3 1
4
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3

ANTILOCK BRAKE SYSTEM (ABS) 5E-39
Reference
When using oscilloscope for this check, check if peak-to-peak
voltage (1) meets specification and waveform is complete.
Peak-to-peak voltage at 1/2 to 1 rotation per second
2WD vehicle : 120 mV or more at 20 Hz
4WD vehicle : 150 mV or more at 20 Hz
REMOVAL
1) Disconnect negative cable at battery.
2) Remove rear seat referring to Section 9.
3) Turn over floor carpet.
4) Hoist vehicle.
5) Disconnect rear wheel speed sensor coupler (1).
6) Detach ABS wheel sensor wire harness (2) from suspension
frame (3).
7) Remove rear wheel speed sensor (4) from rear axle housing.
SENSOR INSPECTION
Check sensor for damage.
Check sensor for resistance and continuity.
Between both terminals of sensor
2WD vehicle : 0.9 – 1.3 k
Ω
ΩΩ Ω at 20°C (68°F)
4WD vehicle : 1.2 – 1.6 k
Ω
ΩΩ Ω at 20°C (68°F)
Between sensor terminal and sensor body
: No continuity
If the check result is not as specified and any malcondition is
found, replace.
NOTE:
Do not detach crip of rear wheel speed sensor connector
from vehicle body unless replacement is necessary.
CAUTION:
Do not pull wire harness when removing rear wheel
speed sensor.
Do not cause damage to surface of rear wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.
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231

5E-40 ANTILOCK BRAKE SYSTEM (ABS)
SENSOR ROTOR INSPECTION
Check rotor serration (teeth) for being missing, damaged or
deformed.
Turn wheel and check if rotor rotation is free from eccentric-
ity and looseness.
Check that no foreign material is attached.
If any faulty is found, repair or replace.
INSTALLATION
Reverse removal procedure for installation noting the following.
Check that no foreign material is attached to sensor (1) and
ring.
Be sure to install wheel speed sensor and its bolt at the cor-
rect (upper) position as shown in figure.
Tighten sensor bolt to specified torque.
Tightening torque
Sensor bolt (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Check that there is no clearance between sensor and rear
axle shaft.
[A] : For 2WD
[B] : For 4WD
[B] [A]
1
CAUTION:
Do not pull or twist wire harness more than necessary
when installing rear wheel speed sensor.