yaw SUZUKI SWIFT 2004 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-47
DTC Troubleshooting
DTC C1090: Invalid Communication with ECMS7RS0B4604040
DTC Detecting Condition and Trouble Area
DTC TroubleshootingStep Action Yes No
1 Was “Electronic Stability Pr ogram Check” performed? Go to Step 2. Go to “Electronic
Stability Program
System Check”.
2 DTC check for ESP®
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ignition switch ON and check DTC for ESP ®.
Is there any DTC(s) other than C1075, C1076 and C1078? Go to applicable DTC
diag. flow.
Go to Step 3.
3 Check sensor calibration
1) Calibrate all sens ors referring to “Sensor Calibration”.
2) Clear all DTC(s) and check DTC for ESP ®.
Is DTC C1075, C1076 and/ or C1078 still detected? DTC C1075: Substitute
a known-good steering
angle sensor and
recheck.
DTC C1076: Substitute
a known-good ESP
®
hydraulic unit / control
module assembly and
recheck.
DTC C1078: Substitute
a known-good yaw rate
/ G sensor assembly
and recheck. Calibration was
incompleted.
DTC Detecting Condition
Trouble Area
ESP ® control module rolling counte r failure is detected by
ECM. • CAN communication circuit
•ECM
• ESP
® control module
Step Action YesNo
1 Was “Electronic Stability Pr ogram Check” performed? Go to Step 2.Go to “Electronic
Stability Program
System Check”.
2 DTC check for ESP®
1) Connect scan tool to DLC with ignition switch turned
OFF.
2) Turn ignition switch ON and check DTC for ESP ®.
Is there any DTC(s) other than C1038 and C1090? Go to applicable DTC
diag. flow.
Go to Step 3.
3 DTC check for ECM
1) Check DTC for ECM.
Is DTC P1674 and/or DTC P1685 detected? Go to applicable DTC
diag. flow.
Substitute a known-
good ESP
® hydraulic
unit / control module
assembly and recheck.

Downloaded from www.Manualslib.com manuals search engine 4F-54 Electronic Stability Program:
Repair Instructions
ESP® Hydraulic Unit Operation CheckS7RS0B4606025
1) Check that basic brake system other than ESP ® is
in good condition.
2) Check that battery voltage is 11 V or higher.
3) Lift up vehicle.
4) Set transmission to neutral and release parking brake.
5) Turn each wheel gradually by hand to check if braked ragging occurs. If it does, correct.
6) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
7) Turn ignition switch to ON position and select menu press / depress in “HYDRAULIC CONTROL TEST”
under “miscellaneous test” (“MISC. TEST”) mode of
SUZUKI scan tool.
Refer to SUZUKI scan tool operator’s manual for
further details.
8) Perform the following checks with help of another person.
• Depressurization checkStep on brake pedal (1) and then select testing
wheel by SUZUKI scan tool and the wheel (2)
should be turned by another person’s hand. At this
time, check whether the wheel rotates freely due
to brake depressurization. • Pressurization check
Step off brake pedal (1) and then select testing
wheel by SUZUKI scan tool and the wheel (2)
should be turned by another person’s hand. At this
time, check whether the wheel locks due to brake
pressurization.
NOTE
Pressurization / Depressurization by SUZUKI
scan tool is available for 0.5 second.

9) Check for all 4-wheels condition respectively. If a faulty condition is found, replace hydraulic unit /
control module assembly.
10) After completing the check, turn ignition switch to OFF position and disconnect SUZUKI scan tool from
DLC.
Sensor CalibrationS7RS0B4606015
CAUTION!
If any DTC(s) other than C1075, C1076 or
C1078 are detected, sensor calibration can
not be completed. Repair the detected DTC
first.

NOTE
Steering angle sensor calibration is needed
when battery, “DOME” fuse or the steering
angle sensor is removed.
This sensor calibration can be done with/
without SUZUKI Scan Tool.
When ESP ® control module and/or yaw rate /
G sensor assembly is removed, sensor
calibration is needed with SUZUKI Scan Tool.

(A)
1
I4RS0B450003-01
I4RH01450021-01

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Front Wheel Encoder On-Vehicle InspectionS7RS0B4606033
Before inspect front wheel encoder, remove front drive
shaft or front wheel spindle referring to “Front Drive Shaft
Assembly Removal and Installation in Section 3A”.
• Check encoder (1) for being crack, damaged or deformed.
• Turn wheel and check if encoder rotation is free from eccentricity and looseness.
• Check that no foreign material is attached. If any faulty is found, cl ean encoder or replace wheel
bearing. Refer to “Front Wheel Hub, Steering Knuckle
and Wheel Bearing Removal and Installation in
Section 2B”.
Front Wheel Encoder Removal and InstallationS7RS0B4606034
CAUTION!
Front wheel encoder is included in front
wheel bearing. If front wheel encoder needs
to replaced, replace it as a front wheel
bearing.

For removal and installation of front wheel bearing,
referring to “Front Wheel Hub, Steering Knuckle and
Wheel Bearing Removal and Installation in Section 2B”.
Rear Wheel Encoder On-Vehicle InspectionS7RS0B4606035
Before inspect rear wheel encoder, hoist vehicle and
remove wheel.
• Check encoder (1) for being crack, damaged or deformed.
• Turn wheel and check if encoder rotation is free from eccentricity and looseness.
• Check that no foreign material is attached. If any faulty is found, cl ean encoder or replace rear
wheel hub assembly. Refer to “Rear Wheel Hub
Removal and Installati on in Section 2C”.
Rear Wheel Encoder Removal and InstallationS7RS0B4606036
CAUTION!
Rear wheel encoder is included in rear wheel
hub assembly. If rear wheel encoder needs to
replaced, replace it as a rear wheel hub
assembly.

For removal and installation of front wheel hub
assembly, referring to “Rear Wheel Hub Removal and
Installation in Section 2C”.
Master Cylinder Pressure Sensor On-Vehicle
Inspection
S7RS0B4606016
1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Check that basic brake system other than ESP ®
refer to “Brakes Diagnosi s Note in Section 4A”.
3) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
1
I5JB0A450034-01
1
I6RS0B460038-03
(A)
1
I4RS0B450003-01

Downloaded from www.Manualslib.com manuals search engine 4F-62 Electronic Stability Program:
4) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
5) When brake pedal is released, check “Master Cyl Press” under “DATA LIST” of SUZUKI scan tool.
If pressure is out of specification, replace ESP ®
hydraulic unit / cont rol module assembly.
Master cylinder pressure specification
Brake pedal released: 0 ± 0.8 MPa (0 ± 8 kg/cm2, 0
± 113 psi)
6) Hoist vehicle and remove right-side front wheel.
7) Connect special tool with rubber hose (1) to Front brake caliper bleeder plug (2).
Special tool
(A): 09956–02311
8) When bleeder plug loosen and depress brake pedal to make special tool gauge reading 10 MPa (100 kg/
cm
2, 1422 psi), check “Master Cyl Press” under
“DATA LIST” of SUZUKI scan tool.
If pressure displayed on SUZUKI scan tool is out of
specification, replace ESP ® hydraulic unit / control
module assembly.
Master cylinder pressure specification
Brake pedal depressed 10 MPa (100 kg/cm2, 1422
psi): 10 ± 1.2 MPa (100 ± 12 kg/cm2, 1422 ± 170
psi)
9) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
10) Tighten bleeder plug and bleed air from brake system, referring to “Air Bleeding of Brake System in
Section 4A”.
Yaw Rate / G Sensor Assembly On-Vehicle
Inspection
S7RS0B4606017
Lateral G Inspection
1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Park and level the vehicle with parking brake and fix wheels with chokes.
3) Check yaw rate / G sensor assembly installation
condition. 4) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
5) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
6) Check “G Sensor (lateral)” under “DATA LIST” of SUZUKI scan tool in the following vehicle conditions.
• Level condition
• Right-up condition
• Left-up condition
If Lateral G condition is ou t of specification, replace
yaw rate / G sensor assembly.
Lateral G sp ecification
2
(A)
1
I6JB01460025-01
Vehicle condition G Sensor (lateral)
Level condition 0 ± 0.1 G
Right-up condition 0.1 ± 0.1 G
Left-up condition –0.1 ± 0.1 G
[A]: Right-up condition “a”: Approx 350 mm (13.78 in.)
[B]: Left-up condition 1. Safety stand
(A)
1
I4RS0B450003-01
[A]
[B]“a”
1
“a”1
I6RS0B460039-02

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-63
Yaw Rate Inspection1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Check yaw rate / G sensor assembly installation
condition.
3) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
4) Turn ignition switch to ON position and select menu
“DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
5) Check “Yaw rate sensor” under “DATA LIST” of SUZUKI scan tool in the following vehicle conditions.
• Parking condition
• Drive vehicle in right turning condition with steering wheel fully turned
• Drive vehicle in left tu rning condition with steering
wheel fully turned
If yaw rate condition is ou t of specification, replace
yaw rate / G sensor assembly.
Yaw rate specification
NOTE
• Drive the vehicle on level ground and at 10 km/h (6.2 mph).
• Minimum turning radius is 5.2 m (17.1 ft).

Yaw Rate / G Sensor Assembly Removal and
Installation
S7RS0B4606018
CAUTION!
• When yaw rate / G sensor assembly is replaced, ESP ® control module needs zero
calibration. Perform zero calibration by
SUZUKI scan tool referring to “Sensor
Calibration”.
• Regarding yaw rate / G sensor assembly removal/installation, confirm specified
torque and never use impact wrench to
avoid damage.
• When handling the yaw rate / G sensor assembly, be careful not to drop it or apply
an impact to it.
If an excessive impact was applied, never
attempt disassembly or repair but replace
it with a new one.

Vehicle condition Yaw rate
Parking 0 ± 4 deg/s
Right turning 30 ± 4 deg/s
Left turning –30 ± 4 deg/s
(A)
1
I4RS0B450003-01
[A]: Right turning“a”: Approx 5.2 m (17.1 ft.)
[B]: Left turning
[A]
[B] “a”
“a”
I6RS0B460040-02

Downloaded from www.Manualslib.com manuals search engine 4F-64 Electronic Stability Program:
Removal1) Disconnect negative (–) cable at battery.
2) Remove front console box referring to “Console Box Components in Section 9H”.
3) Disconnect connector from yaw rate / G sensor
assembly.
4) Remove yaw rate / G sens or assembly from sensor
bracket.
Installation 1) Before installing yaw rate / G sensor assembly (1),
check installing condition as follows.
• Deformations around sensor installation area (2) (in sensor bracket).
• Foreign matters on mating surface between sensor and sensor bracket.
2) Install yaw rate / G sensor assembly (1) to floor panel.
Tightening torque
Yaw rate / G sensor assembly nut (a): 8 N·m (0.8
kgf-m, 6.0 lb-ft)
3) Connect connector to yaw rate / G sensor assembly.
4) Install console box referring to “Console Box Components in Section 9H”.
5) Connect negative (–) cable to battery.
6) After completing installation, calibrate yaw rate / G
sensor assembly referring to “Sensor Calibration”.Yaw Rate / G Sensor InspectionS7RS0B4606019
• Check sensor for dents, cracks or deformation.
• Check sensor connector (sensor side and harness
side) and sensor connector lock mechanism for
damage or crack.
• Check connector terminals for bend, corrosion or rust.
If it is found faulty, replace yaw rate / G sensor assembly.
Steering Angle Sensor On-Vehicle InspectionS7RS0B4606020
CAUTION!
Before each inspection, confirm steering
angle sensor calibration is completed.
If calibration is incompleted, calibrate sensor
referring to “Sensor Calibration”.

1) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
(a)
1
(a)
2I6RS0B460041-02
I6JB01460031-01
(A)
1
I4RS0B450003-01

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Specifications
Tightening Torque SpecificationsS7RS0B4607001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
NOTE
The specified tightening torque is also described in the following.
“ESP® Hydraulic Unit / Control Module Assembly Removal and Installation”

Special Tools and Equipment
Special ToolS7RS0B4608001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5 )
ESP ® hydraulic unit / control module assembly
bolt 90.9 6.5)
ESP ® hydraulic unit / control module assembly
bracket bolt 25 2.5 18.0)
Front wheel speed sensor bolt 11 1.1 8.0 )
Front wheel speed sensor harness clamp bolt 11 1.1 8.0 )
Rear wheel speed sensor bolt 11 1.1 8.0 )
Rear wheel speed sensor har ness clamp bolt 11 1.1 8.0 )
Yaw rate / G sensor assembly nut 8 0.8 6.0 )
09956–02311SUZUKI scan tool
Brake pressure gauge —
) This kit includes following
items. 1. Tech 2, 2. PCMCIA
card, 3. DLC cable, 4. SAE
16/19 adapter, 5. Cigarette
cable, 6. DLC loop back
adapter, 7. Battery power
cable, 8. RS232 cable, 9.
RS232 adapter, 10. RS232
loop back connector, 11.
Storage case, 12.) / ) / ) /
) / ) / ) / )

Downloaded from www.Manualslib.com manuals search engine 6C-46 Power Assisted Steering System:
P/S Control Module Removal and InstallationS7RS0B6306011
Removal1) Disconnect negative cable at battery.
2) Remove console box.
3) Disconnect connectors (1) from P/S control module (2).
4) Disconnect connector from yaw rate / G sensor
(ESP ® model).
5) Remove P/S control module (2) with bracket (3) from floor panel.
6) Separate P/S control module and bracket.
Installation
Reverse removal procedure for installation noting the
following.
• Tighten each screw to the specified torque. Tightening torque
P/S control module bracket screw (ABS model)
(a): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
P/S control module bracket screw (ESP ® model)
(a): 7 N·m (0.7 kgf-m, 5.0 lb-ft)
P/S control module mounting screw (b): 5 N·m (
0.5 kgf-m, 3.7 lb-ft)
Torque Sensor and Its Circuit InspectionS7RS0B6306012
1) Remove console box.
2) With ignition switch turned OFF, connect scan tool to DLC or connect voltage tester between “E52-18” –
“E52-9” (main sensor) or “E52-6” – “E52-9” (sub
sensor) with connected connector (1) to P/S control
module. 3) Set torque wrench to stee
ring wheel referring to
“Steering Force Check” for checking steering force.
4) Turn ON ignition switch without engine running and select scan tool “Data list” mode due to check of
“TQS Main Torque”, “TQS Sub Torque” and “Assist
Torque” display on scan tool when steering wheel
turned left and right (if used).
5) Check that characteristic of torque sensor (main and sub) output voltage or scan tool data and steering
force is as following graph when steering wheel is
turned left and right. If sensor voltage or scan tool
data is out of specified value or does not vary linearly
as the following graph, check P/S control module
and its circuit.
If they are OK, replace steering gear case assembly.
1
(a)
2
3
(b)
I7RS0A630020-01
[A]: Steering force at left turn
[B]: Steering force at right turn
[C]: Steering wheel at free
[D]: “TQS Main Torque”, “TQS Sub Torque” and “Assist Torque” in “Data List” displayed on scan tool
E52
18
9
6
9
6 18
1
I6RS0C630024-01
I3RM0A630022-01
0
[C] [N.m]
MAX MAX
[B]
[A]
2.33 - 2.68 [V]
[D]
0.65 - 0.72
(0 - 0.4)
4.21 - 4.41
(5.1 - 5.6)
6.86
-6.86
0
6.86
- 6.86
I6RS0C630021-04

Downloaded from www.Manualslib.com manuals search engine Wiring Systems: 9A-16
Instrument PanelS7RS0B910A003
E: Main harness and power steering wire (RHD)
E: Main harness
E: Power steering wire
J/B
E54
E53
E49
E51E52E84
E48
E50
Power steering wire
E47E74E42E61
E43
E45
(TO L02)
E44
(TO L03)E46
E40 E39
E41 E37
(TO G35)
E38
(TO G36)
8
E
I7RS0B910904-01
No./Color Connective position No./ColorConnective position
E37/GRY Instrument panel harness (To G35) E45/N Floor harness (To L02)
E38/N Instrument panel harness (To G36) E46/BLU BCM
E39/BRN J/B E47/N Brake light switch
E40/N J/B E48/BLU Power steering wire (To E50)
E41/N J/B E49/BLK P/S control module
E42/N J/C E61/N
(M16A
engine) APP (Acceleration pedal position) sensor
E43/N J/C E74/N (IF
EQPD) CPP (Clutch pedal position) switch
E44/YEL Floor harness (To L03) E84/BLK (IF
EQPD) YAW/G sensor
No./Color Connective position No./ColorConnective position
E50/BLU Main harness (To E48) E53/BLK P/S torque sensor
E51/BLU P/S control module E54/GRY P/S motor
E52/BLK P/S control module

Downloaded from www.Manualslib.com manuals search engine 9A-97 Wiring Systems:
F-3 Electronic Stability Program System Circuit DiagramS7RS0B910E039
1647
132 13
44E85
BLK
ABS
SOLABS
MOT
WHT/REDWHT/BLU
6
BLK
REDWHT
REDWHT
REDWHT
25
BLK/ORN
GRN/ORN
GRN/ORN
GRN/ORN
Individual circuit
fuse box (No.1) J/B
ABS
GRN/ORN
ECM
35
"A-5"
"C-3"
steering
angle sensor
RED
R
4246
WHT
W
RW
1
4G37
E46
2
2
BCM
A
A
A
BG59
B
B
RW
2
1
WHT/REDWHTRED
3910
(CAN) (CAN)
(CAN)
(CAN)
(CAN)
7
ESP
Cont.M
1E45 L02
LT GRN/RED
LT GRN/REDRED/YEL
RED/YEL
BLK/ORN
WHT/BLK
RY
J/C J/C
B
BLKBLK
BLK/ORN
BLK/ORN
16181410
BLK
ESP off
switch
L6956
42
G15
G541
29
RED/BLK
2
37
BLU/RED
3
31
GRN/BLK
5E84B
J/C
D
L74D
R
R
"D-3"J/B
YAW/G sensor
J/C
A
L24A
B
B
30A
16
40A
9
10A
31
15A
RADIO
40
E419G335
E37
G3514
I7RS0B910935-01