500 SUZUKI SWIFT 2006 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine 1E-8 Engine Lubrication System:
Oil Pump ComponentsS7RS0B1506007
Oil Pump Removal and InstallationS7RS0B1506008
Oil pump is incorporated with timing chain cover.
For removal and installation, refer to “Timing Chain
Cover Removal and Installation in Section 1D”.
Oil Pump Disassembly and ReassemblyS7RS0B1506009
Disassembly1) Remove rotor plate (1) by removing its mounting bolts. 2) Remove outer rotor (1) and inner rotor (2).
3) Remove relief valve (1), spring (2) and retainer (3) by
removing circlip (4).
I4RS0A150010-01
1. Rotor plate 6. Rotor plate bolt10. Circlip
2. O-ring 7. Relief valve : 11 N⋅m (1.1 kgf-mm 8.0 lb-ft)
3. Outer rotor 8. Spring : Do not reuse.
4. Inner rotor 9. Retainer : Apply thin coat of engine oil to sliding surface.
5. Timing chain cover 10. Circlip
I2RH0B150018-01
I2RH0B150019-01
I2RH0B150020-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-9
Reassembly1) Wash, clean and then dry all disassembled parts.
2) Apply thin coat of engine oil to inner and outer rotors, oil seal lip portion, inside surfaces of oil pump case
and plate.
3) Install outer (1) and inner rotors (2) to oil pump case.
4) Apply engine oil to relief valve (1) and spring (2), and install them with retainer (3) and new circlip (4) to
rotor plate (5).
5) Install rotor plate and tighten all bolts to specified torque. After installing plate, check to be sure that
rotors turn smoothly by hand (0.3 N ⋅m (0.03 kgf-m,
0.25 lb-ft) torque or below).
Tightening torque
Oil pump rotor plate bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)Oil Pump InspectionS7RS0B1506010
Oil Seal
Check oil seal lip for fault or other damage. Replace as
necessary.
Oil Pump
• Check outer (1) and inner rotors (2), rotor plate, and oil pump case for excessive wear or damage.
• Check relief valve (1) for excessive wear or damage
and operates smoothly.
I2RH0B150019-01
I3RM0A150005-01
I2RH0B150022-01
I2RH0B150023-01
I2RH0B150019-01
I2RH0B150025-01

Downloaded from www.Manualslib.com manuals search engine 1E-10 Engine Lubrication System:
Radial clearance
Check radial clearance between outer rotor (1) and case
(2) using thickness gauge (3).
If clearance exceeds its limit, replace outer rotor or case.
Radial clearance between outer rotor and case for oil
pump
Limit: 0.310 mm (0.0122 in.)
Side clearance
Using straightedge (1) and thickness gauge (2),
measure side clearance.
If side clearance exceeds its limit, replace oil pump
assembly.
Side clearance for oil pump inner rotor
Limit: 0.15 mm (0.0059 in.)Relief valve spring free length and load
Check relief valve spring free length and load as shown
in the figure. If the measured valve spring length is lower
than the specification, replace relief valve spring.
Relief valve spring free length and load
I2RH0B150026-01
I2RH0B150027-01
Standard Limit
Free length 52.4 mm
(2.06 in.) —
Load at spring length
38.5 mm (1.52 in.) 79 N
(7.9 kgf, 17.5 lb) 69 N
(6.9 kgf, 15.0 lb)
I2RH01150023-01

Downloaded from www.Manualslib.com manuals search engine Parking Brake: 4D-2
Repair Instructions
Parking Brake Inspection and AdjustmentS7RS0B4406001
Inspection
Hold center of parking brake lever grip and pull it up with
200 N (20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count
ratchet notches. There should be 4 to 9 notches.
Also, check if both right and left rear wheels are locked
firmly.
To count number of notches easily, listen to click sounds
that ratchet makes while pulling parking brake lever
without pressing its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable
referring to adjustment procedure so as to obtain
specified parking brake stroke.
NOTE
Check tooth tip of each notch for damage or
wear.
If any damage or wear is found, replace
parking brake lever.

Adjustment
NOTE
Make sure for the following conditions before
cable adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Start engine and then brake pedal has been depressed at least 3 times with about
160 N (16.0 kg, 35.3 lbs) load.
• Parking brake lever (1) has been pulled up a few times with about 200 N (20 kg, 44 lbs)
load.
If parking brake cable is replaced with new
one, pull up parking brake lever a few
times with about 500 N ⋅m (50 kg, 110 lbs)
force.

1) Release parking brake lever (1).
2) Loosen parking brake lever adjust nut (2) fully.
3) Make sure that lever (3) contacts pin (4).
4) Pull up parking brake lever 1 notch.
5) Rotate rear wheel by hand and fasten parking lever adjust nut until dragging rear wheel lightly.
I4RS0B440002-01
1. Parking brake cable 2. Brake caliper
I4RS0A440003-01
I6RS0C440001-01
I6RS0C440002-01

Downloaded from www.Manualslib.com manuals search engine 4E-1 ABS:
Brakes
ABS
Precautions
Precautions in Diagnosing TroublesS7RS0B4500001
To ensure that the trouble diagnosis is done accurately
and smoothly, observe the following and follow “ABS
Check”.
• Diagnostic information stored in ABS cont rol module
memory can be cleared as well as checked by using
SUZUKI scan tool. Before us ing scan tool, read its
Operator’s (Instruction) Manual carefully to have good
understanding as to what functions are available and
how to use it.
• If the vehicles was operated in any of the following ways, ABS warning light may light momentarily but
this does not indicate anything abnormal in ABS.
– The vehicle was driven with parking brake pulled.
– The vehicle was driven with brake dragging.
– The vehicle was stuck in mud, sand, etc.
– Wheel spin occurred while driving.
– Wheel(s) was rotated while the vehicle was jacked up.
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe
what is written there.
• Be sure to use the trouble diagnosis procedure as described in “ABS Check”. Failure to follow it may
result in incorrect diagnosis. (Some other diagnosis
trouble code may be stored by mistake in the memory
of ABS control module during inspection.)
• When disconnecting ABS co ntrol module connector
(1), pull down lock lever (2) of connector.
When connecting, set the connector on ABS control
module assembly and pull up the lock lever (2) until it
locks. • Communication of ECM,
BCM, ABS control module,
keyless start control module (if equipped), and
combination meter is established by CAN (Controller
Area Network).
Therefore, be sure to read “Precautions for Installing
Mobile Communication Equipment in Section 00”
before inspection and handle CAN communication
line.
Precautions in On-Vehicle ServiceS7RS0B4500002
When connector is connected to ABS control module
assembly, do not disconnect connectors of sensors with
ignition switch ON. Otherwise, DTC will be set in ABS
control module.
Precautions in Hydraulic Unit Operation CheckS7RS0B4500003
ABS hydraulic unit / control module assembly function is
checked by correct wheel lock / release condition when
brake pressure is pressurized / depressurized using
SUZUKI scan tool. The hydraulic unit operation check
referring to “ABS Hydraulic Unit Operation Check”
should be performed to confirm the correct brake pipe
connection in the following cases.
• ABS hydraulic unit / cont rol module assembly was
replaced.
• Brake pipe and/or hose ware replaced.
[A]: Disconnect C: Pull down to disconnect
[B]: Connect D: Pull up to connect
21
C D
[A]
[B]
I4RH01450001-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-2
General Description
ABS DescriptionS7RS0B4501001
The ABS (Antilock Brake System) controls the fluid
pressure applied to the wheel cylinder of each brake
from the master cylinder so that each wheel is not locked
even when hard braking is applied.
This ABS has also the following function.
While braking is applied, but before ABS control
becomes effective, braking force is distributed between
the front and rear so as to prevent the rear wheels from
being locked too early for better stability of the vehicle.
The main component parts of this ABS include the
following parts in addition to those of the conventional
brake system.
• Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.
• ABS warning light which light s to inform abnormality
when system fails to operate properly.
• ABS hydraulic unit / cont rol module assembly is
incorporated ABS co ntrol module, ABS hydraulic unit
(actuator assembly), solenoid valve power supply
driver (transistor), solenoid valve driver (transistor),
pump motor driver (transistor).
– ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure
applied to each wheel cylinder based on signal
from each wheel speed sensor so as to prevent
wheel from locking.
– ABS hydraulic unit which operates according to signal from ABS control module to control fluid
pressure applied to wheel cylinder of each 4
wheels.
– Solenoid valve power supp ly driver (transistor)
which supplies power to solenoid valve in ABS
hydraulic unit.
– Solenoid valve driver (transistor) which controls each solenoid valves in ABS hydraulic unit.
– Pump motor driver (transistor) which supplies power to pump motor in ABS hydraulic unit.
This ABS is equipped with Electronic Brake force
Distribution (EBD) system that controls a fluid pressure
of rear wheels to best condition, which is the same
function as that of proportion ing valve, by the signal from
wheel sensor independently of change of load due to
load capacity and so on. An d if the EBD system fails to
operate properly, the brake warning light lights to inform
abnormality.
ABS Hydraulic Unit / Control Module Assembly
Description
S7RS0B4501002
ABS control module is a component of ABS hydraulic
unit / control module asse mbly and has the following
functions.
Self-Diagnosis Function
ABS control module diagnose s conditions of the system
component parts (whether or not there is any
abnormality) all the time and indicates the results
(warning of abnormality occurrence and DTC) through
the ABS warning light as described.
• When ignition switch is turned ON, ABS warning light lights for 2 seconds to check its circuit.
• When no abnormality has been detected (the system is in good condition), ABS warning light turns OFF
after 2 seconds.
• When an abnormality in th e system is detected, ABS
warning light lights and the area where that
abnormality lies is stored in the memory of EEPROM
in ABS control module.
1
I4RS0A450001-01

Downloaded from www.Manualslib.com manuals search engine 4E-3 ABS:
CAN Communication System DescriptionS7RS0B4501003
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description.
ABS communicates control data with each control module as follows.
ABS Transmission Data
ABS Reception Data
Combination
meter
Transmit DATA
ABS control
moduleECM
Torque request
Wheel speed signal (front right)
Wheel speed signal (front left)
Wheel speed signal (rear right)
Wheel speed signal (rear left)
ABS active
ABS indication on
EBD indication on
I6RS0C450001-01
ABS control moduleDATA
Receive
ECM
Brake pedal switch signal
I6RS0C450002-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-4
Schematic and Routing Diagram
ABS SchematicS7RS0B4502001
INPUTOUTPUT
ABS control moduleWheel speed sensor (LF)
Wheel speed sensor (LR)
Wheel speed sensor (RF)Battery Voltage
Ignition Voltage
Pump motor
driver (transistor)
Solenoid valve power
supply driver (transistor)
Solenoid valve
driver (transistor) Hydraulic unit
Pump motor
LF inlet solenoid valve
LF outlet solenoid valve
LR inlet solenoid valve
LR outlet solenoid valve
RF inlet solenoid valve
RF outlet solenoid valve
RR inlet solenoid valve
RR outlet solenoid valve
Data link connector
ABS hydraulic unit/control
module assembly
Wheel speed sensor (RR)
3 7
2
645
8 12
14
21
15
16
1
13
18
17
19
19
11
10
9
CAN driverStop lamp switch
Engine torque
ECM
ABS warning light
EBD warning light
Combination meter
Torque request
ECMWheel speed signal (LF)
Wheel speed signal (LR)
Wheel speed signal (RF)
Wheel speed signal (RR)
ABS active
I6RS0C450003-03

Downloaded from www.Manualslib.com manuals search engine 4E-5 ABS:
ABS Wiring Circuit DiagramS7RS0B4502002
1. ABS hydraulic unit / control module assembly 8.
Pump motor 15. Wheel speed sensor (Right-front)
2. ABS control module 9. Stop lamp switch 16. Wheel speed sensor (Left-front)
3. ABS hydraulic unit 10. ABS warning light 17. Wheel speed sensor (Right-rear)
4. Solenoid valve power supply driver (transistor) 11. EBD warnin g light (Brake warning light) 18. Wheel speed sensor (Left-rear)
5. Solenoid valve driver (transistor) 12. Lamp driver module 19. Battery
6. Pump motor driver (transistor) 13. 4 way joint 20. Ignition switch
7. Solenoid valve 14. Data link connector 21. ECM
[A]
14
1516171819202122232425 1
23456789101112
13
26 E03
a
WHT/BLU
BLKWHT/BLU
M
12V
9
10 11 12
13
BLKE03-14E03-1
E03-13
E03-26
YELBRN
14E03-24
LT GRN/BLKLT GRN
15
WHTWHT/BLK
16
RED
WHTBLK
WHTBLK
WHTBLK
WHTBLKRED/BLK
17
12V
PPL/WHT
18E03-5
1912V
5V
12V
23
24
VCC22
E03-25
E03-15E03-16
E03-19E03-18
E03-22E03-21
WHT/RED
WHT/RED
+BB
GRN/ORN
E03-7
WHT/BLUGRN
1
2
3
4
8
RED/BLK
E03-12
E03-6
RED
WHTE03-10E03-8
REDWHT
20 7
6
529
29
G28-8
G28-10
25
29
E23-3E23-18
GRN/WHT
21
PPL
12V
E23-20
12V
12V
12V
12V
REDWHTE46-1
E46-2
BLK
RED/BLK
RED/BLK
RED
RED
WHT
WHT
27
28
26
29
G37-2
G37-4
REDWHT
I6RS0C450004-01
[A]: Terminal arrangement of ABS hydraulic unit / control module assembly 10. Solenoid valve power supply driver
(transistor) 21. Brake light switch
a: Upside 11. ABS pump motor driver (transistor) 22. Power control unit

Downloaded from www.Manualslib.com manuals search engine 4E-7 ABS:
Component Location
ABS Components LocationS7RS0B4503001
Front Wheel Speed Sensor Components LocationS7RS0B4503002
14
5
3
2 2
2
2
6
6
6
6
7
8
I6RS0C450005-01
1. ABS hydraulic unit / control module assembly
5. EBD warning light (Brake warning light)
2. Wheel speed sensors 6. Wheel speed sensor rings
3. Stop lamp switch 7. Data link connector
4. ABS warning light 8. ECM
[A]
[B]
1 1
2
3
4
1
(a)
(b)
5I6RS0C450016-01
[A]: OK 2. Grommet5. Front wheel bearing
[B]: NG 3. Connector: 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1. Front wheel speed sensor 4. Sensor ring: 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)