eps SUZUKI SWIFT 2000 1.G RG413 Service Owner's Manual

ELECTRICAL POWER STEERING (P/S) SYSTEM 3B1-27
TERMINAL
NO.CIRCUIT NORMAL VOLTAGE CONDITION
G24-2 Ground––
G24-1 P/S control module
power supply from battery10 – 14V–
G24-8 P/S control module
power supply from igni-
tion switch10 – 14V Ignition switch ON
G24-7 VSS✱ Indicator
deflection repeated
0 – 1V and 9 – 11VIgnition switch ON
Front left tire turned quickly with right
tire locked
G24-6 Engine speed signal✱ Indicator
deflection repeated
0 – 1V and 10 – 14VEngine idling
G24-5“EPS” light 0V“EPS” warning lamp ON
G24-4 Diagnosis switch terminal 0 – 14V Ignition switch ON
G24-3 Data link connector––
G24-2-2 Motor output 2 5 – 7V Engine idling and steering wheel
held at position for vehicle to run
straight
G24-2-1 Motor output 1 5 – 7V Engine idling and steering wheel
held at position for vehicle to run
straight
G24-2-4 Clutch output 2 0V–
G24-2-3 Clutch output 1 10 – 14V Engine idling
G24-1-5 Torque sensor (Main) About 2.5V Ignition switch ON and steering
wheel held at position for vehicle to
run straight
Check voltage between “G24-1-5”
and “G24-1-3” terminals
G24-1-4 Torque sensor (Sub) About 2.5V Ignition switch ON and steering
wheel held at position for vehicle to
run straight
Check voltage between “G24-1-4”
and “G24-1-3” terminals
G24-1-3 Torque sensor (GND) 0V–
G24-1-2 5V power supply
for torque sensorAbout 5V Ignition switch ON
Check voltage between “G24-1-2”
and “G24-1-3” terminals
G24-1-1 8V power supply
for torque sensorAbout 8V Ignition switch ON
Check voltage between “G24-1-1”
and “G24-1-3” terminals
NOTE:
✱
✱✱ ✱ : The voltage of this circuit may fail to check by voltmeter.
If so, use oscilloscope.

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

5-14 BRAKES
5) If rear brake pressure is not within specification, adjust it by
changing bolt (2) position as follows.
If rear brake pressure is higher than specification, move bolt
(2) center side and if it is lower, out side.
Repeat steps 3) and 4) until rear brake pressure is within
specification.
After adjustment, be sure to torque nut (1) to specification.
Tightening torque
LSPV nut (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
6) Upon completion of fluid pressure test, bleed brake system
and perform brake test.
MASTER CYLINDER AND BRAKE FLUID
LEVEL INSPECTION
1) Check master cylinder and reservoir tank for crack, damage
and brake fluid leakage. If any faulty condition exists, correct
or replace.
2) Check that brake fluid level is between MAX and MIN marks
on reservoir tank.
2
1, (a)
NOTE:
Be sure to use particular brake fluid either as indicated
on reservoir cap of that vehicle or recommended in
owner’s manual which comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked
on reservoir.
When brake warning lamp lights sometimes during driv-
ing, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake system for
leakage. Correct leaky points and then refill to specified
level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has
been used for mineral oil or a container which is wet from
water. Mineral oil will cause swelling and distortion of
rubber parts in hydraulic brake system and water mixed
into brake fluid will lower fluid boiling point. Keep all fluid
containers capped to prevent contamination.
MAX
MIN

5-38 BRAKES
3) Set master cylinder (1) on vise (3) and adjust “A” to be the
following.
Cap adjustment position
“A” : 50 mm (1.97 in.)
4) Apply air with radiator cap tester, and confirm that 50 kPa
pressure is applied.
5) Perform same steps 1)-4) for port (2).
INSTALLATION
1) Install new master cylinder gasket to booster.
2) Install master cylinder to booster and tighten master cylinder
fixing nuts (3) to specified torque.
Tightening torque
Master cylinder fixing nuts (a) : 13 N·m (1.3 kg-m, 9.5 Ib-ft)
3) Connect brake pipe to master cylinder and tighten flare nut
(2) to specified torque.
Tightening torque
Brake pipe flare nuts (b) : 16 N·m (1.6 kg-m, 11.5 Ib-ft)
4) Connect fluid level switch connector (1) of reservoir.
5) Fill reservoir with specified brake fluid up to its MAX mark.
6) After completing above work, bleed air and check brake
pedal for play.
BRAKE BOOSTER
REMOVAL
1) Remove master cylinder assembly from booster. Refer to
“MASTER CYLINDER”.
2) Disconnect vacuum hose from booster.
3, (a)
1
3, (a) 2, (b)
CAUTION:
Never disassemble brake booster. Disassembly will spoil
its original function. If faulty condition is found, replace it
with new one.

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.

ANTILOCK BRAKE SYSTEM (ABS) 5E-13
TABLE – A ABS WARNING LAMP CIRCUIT CHECK – LAMP DOES NOT COME
“ON” AT IGNITION SWITCH ON
CIRCUIT DESCRIPTION
Operation (ON/OFF) of ABS warning lamp is controlled by ABS control module through lamp driver module in
combination meter.
If the Antilock brake system is in good condition, ABS control module turns ABS warning lamp ON at the ignition
switch ON, keeps it ON for 2 seconds and then turns it OFF. If an abnormality in the system is detected, ABS
warning lamp is turned ON continuously by ABS control module. Also, it is turned ON continuously by lamp
driver module when the connector of ABS control module is disconnected.
INSPECTION
1. Main fuse 5. ABS warning lamp 9. Brake fluid level switch
2. Ignition switch 6. Brake warning lamp 10. ABS hydraulic unit/control module assembly
3. Circuit fuse 7. Lamp driver module 11. ABS hydraulic unit/control module connector
4. Combination meter 8. Parking brake switch
Step Action Yes No
1 1) Turn ignition switch ON.
Do other warning lamp come ON?Go to Step 2. Go to Step 4.
2 1) Disconnect ABS hydraulic unit/control mod-
ule connector.
Does ABS warning lamp light with ignition
switch ON?Substitute a known-good ABS
hydraulic unit/control module
assembly and recheck.Go to Step 3.
3 1) Remove combination meter.
Is bulb of ABS warning lamp in good condition?“RED/BLU” circuit shorted to
ground. If OK, replace combina-
tion meter (lamp driver module).Replace bulb.
4 Is IG fuse in good condition? Open in “BLK/WHT” wire to
combination meter or poor con-
nection.Repair and replace.

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.
3 22
1
4

ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-13
1. 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 an inspection form will facilitate collecting information to the point required for proper anal-
ysis and diagnosis.
2. DTC/FREEZE FRAME DATA CHECK, RECORD AND CLEARANCE
First, check DTC (including pending DTC), referring to “DTC check” section. If DTC is indicated, print it and
freeze frame data or write them down and then clear them by referring to “DTC clearance” section. DTC indi-
cates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the
past and the normal condition has been restored now. To check which case applies, check the symptom in
question according to Step 4 and recheck DTC according to Step 5.
Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.
3. and 4. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the engine
referring to “Visual Inspection” section.
5. TROUBLE SYMPTOM CONFIRMATION
Based on information obtained in Step 1 Customer complaint analysis and Step 2 DTC/freeze frame data check,
confirm trouble symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” described in each
DTC Diagnosis section.
6. and 7. RECHECKING AND RECORD OF DTC/FREEZE FRAME DATA
Refer to “DTC check” section for checking procedure.
8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE
Perform basic engine check according to the “Engine Basic Inspection Flow Table” first. When the end of the
flow table has been reached, check the parts of the system suspected as a possible cause referring to ENGINE
DIAGNOSIS TABLE and based on symptoms appearing on the vehicle (symptoms obtained through steps of
customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or replace
faulty parts, if any.
9. TROUBLESHOOTING FOR DTC (See each DTC Diag. Flow Table)
Based on the DTC indicated in Step 5 and referring to the applicable DTC diag. flow table in this section, locate
the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part and
repair or replace faulty parts.
10. CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“INTERMITTENT AND POOR CONNECTION” in Section 0A and related circuit of DTC recorded in Step 2.
11. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once, perform DTC confirmation procedure and confirm that
no DTC is indicated.NOTE:
If only Automatic transmission DTCs (P0702-P1709) or Immobilizer DTCs (P1620-P1623) are indicated
in this step, perform trouble diagnosis according to “Diagnosis” in Section 7B or Section 8G.