High voltage SUZUKI SWIFT 2006 2.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine 1J-4 Charging System:
Diagnostic Information and Procedures
Battery InspectionS7RS0B1A04001
Common Causes of Failure
A battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the
battery performs satisfactorily during te st but fails to operate properly for no apparent reason, the following are some
factors that may point to the cause of trouble:
• Accessories left on overnight or for an extended period without the generator operating.
• Slow average driving speeds for short periods.
• Electrical load exceeding generator output partic ularly with addition of aftermarket equipment.
• Defects in charging system such as high resistance, s lipping drive belt, loose generator output terminal, faulty
generator or voltage regulator, Refer to “Generator Symptom Diagnosis”.
• Battery abuse, including failure to keep battery cable terminals clean and tight or loose battery hold down.
• Mechanical problems in electrical sys tem such as shorted or pinched wires.
Visual Inspection
Check for obvious damage, such as cracked or broken case or cover, that could permit loss of electrolyte. If obvious
damage is noted, replace battery. Determine cause of damage and correct as needed.
Generator Symptom DiagnosisS7RS0B1A04002
CAUTION!
• Do not mistake polarities of “IG” terminal and “L” terminal.
• Do not create short circuit between “IG” and “L” terminals. Always connect these terminals through a lamp.
• Do not connect any load between “L” and “E” terminals.
• When connecting charger or booster battery to vehicle battery, refer to “Jump Starting in Case of Emergency”.

Trouble in charging system will show up as one or more of the following conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow cranking or indicator dark.
3) An overcharged battery as evidenced by ex cessive spewing of electrolyte from vents.
Condition Possible cause Correction / Reference Item
Noisy generator Loose drive belt Adjust or replace drive belt.
Loose drive belt pulley Tighten by specified torque.
Loose mounting bolts Tighten by specified torque.
Worn or dirty bearings Replace.
Defective diode or stator Replace.
Charge light does not
light with ignition ON and
engine off Fuse blown
Replace fuse and check for shorted circuit.
Indicator lamp (LED) faulty Replace combination meter.
Wiring connection loose Tighten loose connection.
IC regulator or field coil faulty Replace.
Poor contact between brush and slip
ring Repair or replace.
Charge light does not go
out with engine running
(battery requires frequent
recharging) Drive belt loose or worn
Adjust or replace drive belt.
IC regulator or generator faulty Replace.
Wiring faulty Repair wiring.

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Generator Test (Undercharged Battery Check)S7RS0B1A04003
This condition, as evidenced by slow cranking or
indicator clear with dark or light yellow dot can be
caused by one or more of the following conditions even
though indicator lamp may be operating normal.
The following procedure also applies to cars with
voltmeter and ammeter.1) Make sure that undercharged condition has not been caused by accessories left on for extended period of
time.
2) Check drive belt for proper tension.
3) If battery defect is suspected, refer to “Battery Description”.
4) Inspect wiring for defects. Check all connections for tightness and cleanliness, battery cable connections
at battery, starting motor, ignition ground cable and
no “C” terminal circuit at ground.
5) Connect switch (6), load (5), battery (4), voltmeter (3) and ammeter (2) to generator (1) as shown in
figure.
Voltmeter: Set between generator “B” terminal
and ground.
Ammeter: Set between generator “B” terminal
and battery (+) terminal.
NOTE
Use fully charged battery.

6) Measure current and voltage.
No-Load Check 1) Run engine from idling up to 2000 rpm and read meters.
NOTE
Turn off switches of all accessories (wiper,
heater etc.).

Specification for undercharged battery (No-load
check)
Current: 10 A
Voltage: 14.2 – 14.8 V (at 20 °C, 68 °F)
NOTE
Consideration should be taken that voltage
will differ somewhat with regulator case
temperature as shown in figure.

2) Using service wire, ground “C” terminal (1) of
generator.
3) Measure voltage between “B” terminal of generator and body ground.
Voltage: 12.5 – 13.1 V (at 20 °C, 68 °F)
• If voltage is higher than standard value
If voltage is higher than standard value, check ground
of brushes.
If brushes are not grounded, replace IC regulator.
If voltage is lower than standard value, proceed to the
following check.
Load Check 1) Run engine at 2000 rpm and turn on head light and blower motor.
2) Measure current. If measure current is less than 30 A, repair or
replace generator.
IYSQ011A0007-01
[A]: Regulated voltage (V)
[B]: Heat sink temperature ( °C)
16.0
15.5
15.0
14.5
14.0
13.5
13.0
-30 0 20
[A]
[B]
68
22120 (˚C)
248 (˚F)
(V)
I6RS0B1A1002-01
I5JB0A1A0011-01

Downloaded from www.Manualslib.com manuals search engine 1J-6 Charging System:
Generator Test (Overcharged Battery Check)S7RS0B1A04004
1) To determine battery condition, refer to “Battery Description”.
2) If obvious overcharge condition exists as evidenced by excessive spewing of electrolyte, measure
generator “B” terminal voltage at engine 2000 rpm. 3) If measured voltage is higher than upper limit value,
proceed to disassemble generator.
4) Check ground of brushes. If brushes are not grounded, replace IC regulator. Then check field coil
for grounds and shorts, referring to “Generator
Inspection”.
Repair Instructions
Jump Starting in Case of EmergencyS7RS0B1A06001
CAUTION!
If vehicle is manual transaxle model and has
a catalytic converter, do not push or tow it to
start. Damage to its emission system and/or
to other parts may result.

Both booster and discharged battery should be treated
carefully when using ju mper cables. Follow the
procedure outlined as follows, being careful not to cause
sparks.
WARNING!
• Departure from these conditions or procedure described as follows could
result in:
– Serious personal injury (particularly to eyes) or property damage from such
causes as battery explosion, battery
acid, or electrical burns.
– Damage to electronic components of either vehicle.
• Remove rings, watches, and other jewelry. Wear approved eye protection.
• Be careful so that metal tools or jumper cables do not contact positive battery
terminal (or metal in contact with it) and
any other metal on vehicle, because a
short circuit could occur. • Never expose battery to open flame or
electric spark. Batteries generate gas
which is flammable and explosive.
• Do not allow battery fluid to contact eyes, skin, fabrics, or painted surface as fluid is
a corrosive acid. Flush any contacted area
with water immediately and thoroughly.
• Batteries should always be kept out of reach of children.
• Do not connect negative cable directly to negative terminal of dead battery.

1) Set parking brake and place automatic transaxle in PARK (NEUTRAL on manual transaxle). Turn off
ignition, turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line, add distilled water.
3) Attach end of one jumper cable to positive terminal of booster battery and the other end of the same
cable to positive terminal of discharged battery. (Use
12-volt battery only to jump start engine).
4) Attach one end of the remaining negative cable to negative terminal of booster battery, and the other
end to a solid engine ground (such as exhaust
manifold) at least 45 cm (18 in.) away from battery of
vehicle being started.
5) Start engine of vehicle with booster battery and turn off electrical accessories. Then start engine of the
vehicle with discharged battery.
16.0
15.5
15.0
14.5
14.0
13.5
13.0 -30 0 20
[C]
[D]
68
22120 (˚C)
248 (˚F)
(V)
I6RS0C1A0001-02

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-14
ABS Warning Light Comes ON SteadyS7RS0B4504009
Wiring Diagram
Refer to “ABS Warning Light Does Not Come ON at Ignition Switch ON”.
Circuit Description
Operation (ON/OFF) of ABS wa rning light is controlled by ABS contro l module through lamp driver module in
combination meter.
If the Antilock brake system is in good condition, ABS control module turns ABS warning lig ht 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 light is
turned ON continuously by ABS c ontrol module. Also, it is turned ON continuously by la mp driver module when the
connector of ABS control module is disconnected.
Troubleshooting 4 Check CAN communication circuit between combination
meter and ABS control module referring to “DTC U1073:
Control Module Communication Bus Off”.
Is CAN communication circuit in good condition? Go to Step 5.
Repair or replace.
5 1) Remove combination meter wit h ignition switch turned
OFF.
2) Check for proper connection to “RED/BLK” and “BLK/ ORN” wire of combinat ion meter connector.
3) If OK, turn ON ignition switch and measure voltage at “PPL/RED” wire of combi nation meter connector and
vehicle body ground.
Is it 10 – 14 V? Go to Step 6.
Repair power supply
circuit for combination
meter.
6 1) Measure resistance between “BLK/ORN” wire of combination meter connector and vehicle body ground.
Is resistance less than 2
Ω? Replace combination
meter.
“BLK/ORN” circuit open
or high resistance.
Step Action Yes No
Step
Action YesNo
1 1) Perform diagnostic trouble code check.
Is there any DTC(s)? Go to applicable DTC
diag. flow.
Go to Step 2.
2 Are main fuses for ABS pump motor and ABS solenoid in
good condition? Go to Step 3.
Replace fuse and check
circuit for short to
ground.
3 1) Turn ignition switch to OFF.
2) Disconnect ABS control module connector.
3) Check for proper connection to ABS control module connector at terminals “E03-7”, “E03-13” and “E03-26”.
4) If OK then turn ignition switch to ON position and measure voltage between terminal “E03-7” and vehicle
body ground.
Is it 10 – 14 V? Go to Step 4.
“GRN/ORN” circuit
open.
4 1) Turn ignition switch to OFF position. 2) Check for proper connection to ABS control module connector at terminals “E03-1” and “E03-14”.
3) If OK then turn ignition switch to ON position and measure voltage between each terminal of “E03-1”,
“E03-14” and vehicle body ground.
Are they 10 – 14 V? Go to Step 5.
“WHT/RED” and/or
“WHT/BLU” circuit
open.

Downloaded from www.Manualslib.com manuals search engine 4E-17 ABS:
5 1) Turn ignition switch to OFF position.2) Check for proper connection to ABS hydraulic unit / control module connector at terminals “E03-13” and
“E03-26”.
3) If OK, measure resistance between each terminal of “E03-13”, “E03-26” and vehicle body ground.
Are resistance less than 2
Ω? Go to Step 6. Ground circuit for ABS
hydraulic unit / control
module open or high
resistance.
6 1) Check if communication is possible by trying communication with other controller (ECM, BCM or
SDM).
Is it possible to commun icate with other controller? Go to Step 7. Repair open in common
section of serial data
circuit (“PPL/WHT” wire
circuit) used by all
controllers or short to
ground or power circuit
which has occurred
somewhere in serial
data circuit (“PPL/WHT”
wire circuit).
7 1) Turn ignition switch to ON position.
2) Measure voltage between terminal B of data link connector and vehicle body ground.
Is voltage 10 – 12 V? Go to step 8. Terminal B circuit open
or shorted to ground.
8 1) Turn ignition switch to OFF position. 2) Measure resistance between the following terminals;• Terminal G of data link connector and vehicle body ground.
• Terminal G1 of data link connector and vehicle body ground.
Is each resistance 1
Ω or less? Go to step 9. Terminal G and/or G1
circuit open or high
resistance.
9 1) Turn ignition switch to OFF position. 2) Check proper connection at “E03-5” (“PPL/WHT” wire) terminal for serial data circuit.
3) If OK, then check resistance between “E03-5” (“PPL/ WHT” wire) terminal and “PPL/WHT” wire terminal (2) for
serial data circuit in DLC (1).
Is resistance 1
Ω or less? Substitute a known-
good ABS hydraulic unit
/ control module and
recheck.
Repair high resistance
or open in “PPL/WHT”
wire circuit for anti lock
brake system.
Step Action Yes No
I4RS0A450013-02

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-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