low battery SUZUKI SWIFT 2004 2.G Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-12
DTC ClearanceS7RS0B4504006
WARNING!
When performing a driving test, select a safe
place where there is neither any traffic nor
any traffic accident possibility and be very
careful during testing to avoid occurrence of
an accident.

After repair or replace malfunction part(s), clear all DTCs
by performing the following procedure or using SUZUKI
scan tool.
1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection
for DTC check.
2) Turn ignition switch to ON position.
3) Erase DTC according to instructions displayed on scan tool. Refer to scan tool operator’s manual for
further derails.
NOTE
For DTC C 1021, C1022, C1025, C1026, C1031,
C1032, C1035, C1036 and C1061, confirm that
ABS warning light turns off after performing
Step 2 of “Test Driving” under “ABS Check”,
and then clear the DTCs.

4) After completing the clear ance, turn ignition switch
OFF and disconnect scan tool from data link
connector.
5) Perform “Driving Test” (S tep 2 of “ABS Check”) and
“DTC Check” and confirm that NO DTC is displayed
on scan tool.
Scan Tool DataS7RS0B4504007
The parameter data below are values measured with the
scan tool when the normally operating vehicle is under
the following conditions. When taking measurements for
comparison by using the scan tool, be sure to check that
the vehicle is under the following conditions.
• Apply parking brake and block wheels.
• Ignition switch ON.
• Turn OFF air conditioner (if equipped).
• Apply no load to power steering (if equipped). (Don’t turn it)
• Turn OFF all electric loads (except ignition).
• No DTC.
• ABS is not operated. (N ormal braking operation)
Scan Tool Data Definition
Battery Volt (V): Battery Voltage is an analog input
signal read by the ABS control module. Certain ABS
control module function s will be modified if the
battery voltage falls below or rises above
programmed thresholds.
Pump Motor Driver (V): This parameter indicates the
operational condition of the pump motor driver
(transistor).
RF Wheel Speed, LF Wheel Speed, RR Wheel Speed and LF Wheel Speed (km/h, MPH): Wheel speed
is an ABS control module inte rnal parameter. It is
computed by reference pulses from the wheel speed
sensor.
Brake Switch (ON, OFF): This switch signal informs
the ABS control modu le whether the brake is active
or not.
Scan Tool
Data Standards Condition
Battery
Voltage 10.0 – 18.0 V —
Pump Motor
Driver 0.0 V —
RF Wheel
Sp ee d 0 km/h, 0.0 MPH Vehicle stop
LF Wheel
Sp ee d 0 km/h, 0.0 MPH Vehicle stop
RR Wheel
Sp ee d 0 km/h, 0.0 MPH Vehicle stop
LR Wheel
Sp ee d 0 km/h, 0.0 MPH Vehicle stop
Brake Switch ONBrake pedal
depressed
OFF Brake pedal released

Downloaded from www.Manualslib.com manuals search engine 4E-21 ABS:
DTC C1057: Power Source CircuitS7RS0B4504014
Wiring Diagram
DTC Detecting Condition
The ABS control module monitors the power source voltage at terminal “E03-14”. When the power source voltage
becomes extremely high or low while vehicle is running at more than 20 km/h (13 MPH), this DTC will be set. As soon
as the power source volta ge becomes normal, the ABS warning light will be turned off and the ABS control module will
return to normal operation, bu t the set DTC will be remain.
DTC Troubleshooting
[A]: ABS hydraulic unit / control module connector (viewed from terminal side) 2. Main fuse box
1. Battery 3. ABS hydraulic unit / control module assembly
E03-14WHT/BLU
1 2
3
BLK
BLK
E03-13
E03-26
[A]
E03
15
16
17
18
19
20
21
22
23
24
25 2
3
4
5
6
7
8
9
10
11
12
1
13
14
26
12V
I6RS0C450011-01
Step
Action YesNo
1 Was “ABS Check” performed? Go to Step 2.Go to “ABS Check”.
2 1) Disconnect ABS hydraulic unit / control module connector with ignition switch turned OFF.
2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “E03-14” and
“E03-13”.
3) If OK, then turn ignition switch to ON position and measure voltage between terminals “E03-14” and “E03-
13”.
Is voltage 9.7
± 0.3 V or more? Go to Step 5. Go to Step 3.
3 1) Turn ignition switch to OFF. 2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “E03-13” and
“E03-26”.
3) If OK then turn ignition switch to ON and measure resistance between each terminal of “E03-13” and “E03-
26” and vehicle body ground.
Is resistance less than 2
Ω? Go to Step 4. “BLK” wire circuit in
open or high resistance.
4 1) Measure voltage between positive battery terminal and vehicle body ground with engine running.
Is voltage 9.7
± 0.3 V or more? Imperfect short between
“WHT/BLU” wire circuit
and body ground.
Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-22
DTC C1061: ABS Pump Motor and/or Motor Driver CircuitS7RS0B4504015
Wiring Diagram
DTC Detecting Condition
The ABS control module monitors the voltage at monitor terminal of pump motor circuit constantly with the ignition
switch turned ON. It sets this DTC when the voltage at the monitor terminal does not become high / low according to
ON/OFF commands to the motor driver (transistor) of the module (does not follow these commands).
DTC Troubleshooting 5 1) Measure voltage between terminals “E03-14” and “E03-
13” with engine running.
Is voltage 18
± 1.0 V or less? Poor connection of
“E03-14” and/or “E03-
13” terminals. If the
terminals are in good
condition, substitute a
known-good ABS
hydraulic unit / control
module and recheck.Check charging system
referring to “Generator
Test (Overcharged
Battery Check) in
Section 1J”.
Step Action Yes No
WHT/RED
1 2
5
BLK
BLK
E03-13
E03-26
[A]
E03
15
16
17
18
19
20
21
22
23
24
25 2
3
4
5
6
7
8
9
10
11
12
1
13
14
26
M
3
4E03-1
12V
12V
I6RS0C450012-01
[A]: ABS hydraulic unit / control module connector (viewed from terminal side) 2. Main fuse box 4. ABS pump motor
1. Battery 3. Pump motor driver (transistor) 5. ABS hydraulic unit / control module assembly
StepAction YesNo
1 Was “ABS Check” performed? Go to Step 2.Go to “ABS Check”.
2 1) Turn Ignition switch to OFF position.
2) Disconnect ABS hydraulic unit / control module connector.
3) Check for proper connection to ABS hydraulic unit / control module connector at terminal “E03-1”.
4) If OK, then measure voltage between terminal “E03-1” of module connector and body ground.
Is it 10 – 14 V? Go to Step 3.
“WHT/RED” circuit
open.
3 Measure resistance between terminal “E03-13” and “E03- 26” of ABS hydraulic unit / co ntrol module connector and
body ground.
Is resistance less than 1
Ω? Substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.
Ground circuit for ABS
hydraulic unit / control
module open or high
resistance.

Downloaded from www.Manualslib.com manuals search engine 4E-23 ABS:
DTC C1063: Solenoid Valve Power Supply Driver CircuitS7RS0B4504016
Wiring Diagram
DTC Detecting Condition
ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned ON.
Also, immediately after ignition switch is turned ON, perform initial check as follows.
Switch solenoid valve power supply driv er (transistor) in the order of OFF → ON and check if voltage changes to Low
→ High. If anything faulty is found in the initial check and when the voltage is low with ignition switch turned ON, this
DTC will be set.
DTC Troubleshooting
[A] E03
15
16
17
18
19
20
21
22
23
24
25 2
3
4
5
6
7
8
9
10
11
12
1
13
14
266
WHT/BLU
12V
5E03-14
5V
12V
8
GRN/ORNE03-7
WHT/BLU
GRN
1
2 3
4
7
I6RS0C450013-01
[A]: ABS hydraulic unit / control module connector
(viewed from terminal side) 5. Solenoid valve power supp
ly driver (transistor)
1. Battery 6. ABS hydraulic unit / control module assembly
2. Main fuse box 7. To solenoid valve
3. Ignition switch 8. ABS power control module
4. Circuit fuse box
Step Action YesNo
1 Was “ABS Check” performed? Go to Step 2.Go to “ABS Check”.
2 Check battery voltage.
Is it about 11 V or higher? Go to Step 3.
Check charging system
referring to “Battery
Inspection in Section
1J” and “Generator Test
(Undercharged Battery
Check) in Section 1J”.
3 Check main fuse for ABS solenoid and its terminal.
Is it in good condition? Go to Step 4.
Replace fuse and check
for short circuit to
ground.
4 1) Turn ignition switch to OFF position.
2) Disconnect ABS hydraulic unit / control module connector.
3) Check for proper connection to ABS hydraulic unit / control module at terminal “E03-14”.
4) If OK, then measure voltage between connector terminal “E03-14” and body ground.
Is it 10 – 14 V? Substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.
“WHT/BLU” circuit
imperfect short to
ground.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-24
DTC C1071: ABS Control ModuleS7RS0B4504017
Wiring Diagram
DTC Detecting Condition
This DTC will be set when an internal malfunction is detected in the ABS control module.
DTC Troubleshooting
1
2
WHT/RED
12VM
3
4
E03-1
E03-14
BLK
BLK
E03-13
E03-26
WHT/BLU [A]
E03
15
16
17
18
19
20
21
22
23
24
25 2
3
4
5
6
7
8
9
10
11
12
1
13
14
26
I6RS0C450014-01
[A]: ABS hydraulic unit / control module connector
(viewed from terminal side) 2. Main fuse box 4. ABS hydraulic unit / control module assembly
1. Battery 3. ABS power control module
Step Action YesNo
1 Was “ABS Check” performed? Go to Step 2.Go to “ABS Check”.
2 Clear all DTCs and check DTC.
Is it DTC C1071? Go to Step 3.
Could be a temporary
malfunction of the ABS
control module.
3 1) Check for proper connection of ABS hydraulic unit / control module connector.
2) If OK, disconnect ABS hydr aulic unit / control module
connector and check the following.
• Voltage “E03-1” terminal: 10 – 14 V
• Voltage “E03-14” terminal: 10 – 14 V
• Resistance between “E03-13” and body ground: Continuity
• Resistance between “E03-26” and body ground: Continuity
Are the check result as specified? Replace ABS hydraulic
unit / control module
assembly.
Repair “WHT/RED”,
“WHT/BLU” and/or
“BLK” circuit and
recheck.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-28
Repair Instructions
ABS Hydraulic Unit Operation CheckS7RS0B4506001
1) Check that basic brake system other than ABS 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 brake dragging 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
to “HYDRAULIC CONTROL TEST” under
“miscellaneous test” (“MISC. TEST”) mode of
SUZUKI scan tool.
8) Perform the following checks with help of another person.
Brake pedal (1) should be depressed 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 that:
• Operation sound of solenoid is heard and the 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.
9) Check for all 4-wheels co ndition 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.
8 1) Substitute a know-good BCM and recheck ABS control
module for DTC.
IS DTC U1100 detected? Substitute a know-good
ABS control module and
recheck.
End.
Step Action Yes No
1 (A)I4RS0A450020-01
I4RH01450021-01

Downloaded from www.Manualslib.com manuals search engine 4E-31 ABS:
2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage and perform “ABS Hydraulic Un it Operation Check”.
NOTE
For new ABS hydraulic unit / control module
assembly, if “ABS Hydraulic Unit Operation
Check” has not been performed, ABS
warning light may flash when ignition switch
is turned ON position.
Accordingly preform “ABS Hydraulic Unit
Operation Check” to stop flashing of ABS
warning light.

Front / Rear Wheel Speed Sensor On-Vehicle
Inspection
S7RS0B4506005
Output Voltage Inspection
1) Disconnect negative cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Disconnect wheel speed grommet from vehicle body.
5) Set up measuring devices as shown in figure, the resistance to 115 Ω and the power supply voltage to
12 V.
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

6) Measure voltage at resistance without wheel rotation.
If voltage is out of specification, check sensor,
mating encoder and their installation conditions.
Voltage at the resistance (115
Ω) without wheel
rotation
680 to 960 mV
7) Measure voltage at resistance with wheel rotation and confirm voltage alternately changes between
high and low voltages.
If voltage does not change with wheel rotation, check
sensor, mating encoder and their installation
conditions.
Voltage at the resistance (115
Ω) with wheel
rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
Reference
When using oscilloscope for this check, check if peak-to-
peak voltage and waveform meet specification.
Peak-to-peak Voltage at the resistance (115
Ω) with
wheel rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
[A]: Front wheel speed sensor 3. “WHT” wire terminal
[B]: Rear wheel speed sensor 4. “BLK” wire terminal
1. Wheel speed sensor connector 5. Power supply (12 V)
2. Resistance (115 Ω )
V
2
5
41
3
43
1
[A]
[B]
I6RS0B460031-02
[A]: Voltage [B]: Time
I5JB0A450027-01
I5JB0A450028-02

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-32
Front Wheel Speed Sensor Removal and
Installation
S7RS0B4506006
Removal1) Disconnect negative cable from battery.
2) Disconnect front wheel speed sensor coupler (1).
3) Hoist vehicle and remove wheel.
4) Remove harness clamp, clamp bolt (2) and grommet (3).
5) Remove front wheel speed sensor (4) from knuckle.
CAUTION!
• Do not pull wire ha rness 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 installation hole.

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): 25 N·m (2.5
kgf-m, 18.0 lb-ft)
Front wheel speed sensor harness clamp bolt
(b): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
CAUTION!
Do not pull or twist wire harness more than
necessary when installing front wheel speed
sensor.

3) Check that there is no clearance between sensor
and knuckle.
Front Wheel Speed Sensor InspectionS7RS0B4506007
• Check sensor for damage.
If any malcondition is found, replace.
3
1
2
4
I6RS0C450017-01[A]: OK [B]: NG
[A][B]
11
(a)
(b)
1
2
I6RS0C450018-01
I5JB0A450031-01

Downloaded from www.Manualslib.com manuals search engine 4E-33 ABS:
Rear Wheel Speed Sensor Removal and
Installation
S7RS0B4506008
Removal1) Disconnect negative (–) cable from battery.
2) Remove quarter inner trim to brake referring to “Floor Carpet Removal a nd Installation in Section
9H”.
3) Turn over floor carpet (2) and disconnect connector (1) of wheel speed sensor.
4) Hoist vehicle and remove wheel.
5) Remove harness clamp (1) and clamp bolts (2).
6) Remove rear wheel speed sensor (3) from knuckle.
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. enter its installation hole.

Installation
Reverse removal procedure for installation noting the
following.
• Check that no foreign material is attached to sensor (1) and mating encoder (2).
• Be sure to install wheel speed sensor (1) and its bolt at the correct position as shown in figure.
Tighten sensor bolt and harness clamp bolts to
specified torque.
Tightening torque
Rear wheel speed sensor bolt (a): 11 N·m (1.1 kgf-
m, 8.0 lb-ft)
Rear wheel speed sensor harness clamp bolt (a):
11 N·m (1.1 kgf-m, 8.0 lb-ft)
CAUTION!
Do not pull or twist wire harness more than
necessary when installing rear wheel speed
sensor.

• Check that there is no clearance between sensor and brake back plate.
2
2
1
I6RS0B460035-02
3
2
1
I6RS0B460036-02
[A]: OK [B]: NG
1
(b)
[A][B]
11
(a)
2
I6RS0B460037-02

Downloaded from www.Manualslib.com manuals search engine 4E-35 ABS:
Specifications
Tightening Torque SpecificationsS7RS0B4507001
NOTE
The specified tightening torque is also described in the following.
“Front Wheel Speed Sensor Components Location”
“Rear Wheel Speed Sensor Components Location”
“ABS Hydraulic Unit / Control Module Assembly Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B4508001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5 )
ABS hydraulic unit / c ontrol module assembly
bolt 90.9 6.5)
ABS hydraulic unit / c ontrol module assembly
bracket bolt 25 2.5 18.0)
Front wheel speed sensor bolt 25 2.5 18.0 )
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 )
09950–78220SUZUKI scan tool
Flare nut wrench (10 mm) —
) 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. ) / )