Part SUZUKI SWIFT 2008 2.G Service Workshop Manual

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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

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Problem symptom confirmation
Check if what the customer claimed in “Customer
Questionnaire” is actually found in the vehicle and if that
symptom is found, whether it is identified as a failure.
(This step should be shared with the customer if
possible.) Check warning lights related to brake system
referring to “EBD Warning Light (Brake Warning Light)
Check” and “ABS Warning Light Check”.
DTC check, record and clearance
Perform “DTC Check” proced ure, record it and then
clear it referring to “DTC Clearance”.
Recheck DTC referring to “DTC Check”.
When DTC which is recorded at DTC check procedure is
detected again after performi ng DTC clearance, go to
“Step 4: ABS Check: ” to proceed the diagnosis.
When DTC which is recorded at DTC check procedure is
not indicated anymore after performing DTC clearance,
ABS control module does not perform the system
diagnosis, or temporary abnormality may occur,
therefore go to “Step 2: Driving Test: ” to proceed the
diagnosis.
Step 2: Driving Test
Test drive the vehicle at 40 km/h for more than a minute
and check if any trouble symptom (such as abnormal
lighting of ABS warn ing light) exists.
If the malfunction DTC is co nfirmed again at ignition
switch ON, driving test as described is not necessary.
Proceed to Step 3.
Step 3: DTC Check
Recheck DTC referring to “DTC Check”.
Step 4: ABS Check
According to ABS Check for the DTC 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.
Step 5: Brakes Diagnosis
Check the parts or system suspected as a possible
cause referring to “Brakes Symptom Diagnosis in
Section 4A” and based on symptoms appearing on the
vehicle (symptom obtained through Steps 1 and 2 and
repair or replace faulty parts, if any).
Step 6: Check for Intermittent Problem
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, con nector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of trouble code recorded in Step 1
to 3.
Step 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 referring to “DTC Clearance” and perform
test driving and confirm that no DTC is indicated.ABS Warning Light CheckS7RS0B4504002
1) Turn ignition switch ON.
2) Check that ABS warning light (1) comes ON for
about 2 seconds and then goes off.
If any faulty condition is found, advance to “ABS
Warning Light Does Not Come ON at Ignition Switch
ON” or “ABS Warning Light Comes ON Steady”.
EBD Warning Light (Brake Warning Light)
Check
S7RS0B4504003
NOTE
Perform this check on a level place.

1) Turn ignition switch ON with parking brake applied.
2) Check that EBD warning lig ht (brake warning light)
(1) is turned ON.
3) Release parking brake with ignition switch ON and check that EBD warning lig ht (brake warning light)
goes off.
If it doesn’t go off, go to “EBD Warning Light (Brake
Warning Light) Comes ON Steady”.
11
I4RS0A450007-01
BRAKE
1
I4RS0A450008-01

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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

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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

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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. ) / )

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Perform sensor calibration according to “Sensor Calibration”.
Precautions in Speedometer Test or Other TestsS7RS0B4600005
When performing speedometer or other tests using speedometer tester or chassis dynamometer, ESP® function must
be deactivated by ESP ® OFF switch or using SUZUKI scan to ol to complete the tests correctly.
When using SUZUKI scan tool, set to the “MISC. TEST” mode to stop the ESP ® function. Refer to SUZUKI scan tool
operator's manual for further details.
General Description
Electronic Stability Program DescriptionS7RS0B4601006
Electronic Stability Program (ESP ®) is an auxiliary function to enable the vehicle to av oid a danger safely while the
vehicle is running, stopping or turning.
Electronic Stability Program (ESP ®) consists of following functions.
ESP ® is a registered trademark of Daimler Chrysler AG.
Antilock Brake System (ABS)
This system prevents tire locking which may occur when br ake is applied suddenly or on slippery roads. With this
function, as the vehicle body is kept in the stable state an d tires unlocked, the driver can avoid any obstacle by turning
the steering wheel.
Electronic Brake force Distribution (EBD)
This function distributes braking force of front and rear wheels properly according to the vehicle load condition.
With this function, the braking force of the front and rear wheels is controlled for the optimum effect to secure the
maximum braking force regardless of the loadage.
Traction Control System (TCS)
This system controls the engine and brake to prevent the dr iving wheels from spinning at the time of starting and
accelerating. Particularly, this fu nction is helpful for safe driving on muddy or icy roads. When ESP ® control module
detects wheel spinning using information from the yaw rate sensor and wheel speed sensor, it lower the engine torque
by closing the electronic controlled thro ttle and controlling ignition. At the same time, brake is applied to the spinning
tire.
Stability Control
This function controls the vehicle body in the stable state by controlling the engine and braking so as to prevent the
vehicle from over-steering or under-steering while turning.
When under-steering occurs, this function lowers the engine torque and applies brake to the inner rear wheel in the
vehicle forward direction so as to pr event the vehicle from moving outward.
When over-steering occurs, this function applies brake to the outer front wheel in the vehicle forward direction so as to
prevent the vehicle from moving inward. Sensor Procedures required calibration
Steering angle sensor • Power is not su pplied to steering angle sensor. (battery, fuse and/or connector is
removed.)
• Steering angle sensor is replaced.
• Power is not supplied to ESP ® control module. (battery, fuse and/or connector is
removed.)
• ESP® hydraulic unit / control module assembly is replaced.
Master cylinder pressure sensor • ESP® hydraulic unit / control module assembly is removed or replaced.
Yaw rate / G sensor assembly • Yaw rate / G sensor assembly is removed or replaced.
• ESP® hydraulic unit / control module assembly is replaced.

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Yaw rate / G sensor
The yaw rate / G sensor consists of the yaw rate (angular velocity in the vehicle turning direction) sensor and right-left
G (acceleration in right-left direction) sensor and is mounted to the P/S controller B/K at the lower part of the center
console. It detects the angular velocity in the vehicle turn ing direction and movement in the right-left direction, and
then it sends that information to ESP ® control module.
Wheel speed sensor
The vehicle speed is detected by the hall IC type wheel speed sensor (1) and encoder (4). The wheel speed sensor is
fixed to the knuckle and includes a hall IC (3) having 2 hall elements (2).
The encoder consisting of a permanent ma gnet which has S/N electrodes turns inside of the wheel hub along with the
wheel. The wheel speed sensor outputs alternate current.
As the cycle of the alternate current is in proportion to the revolution speed of the encoder, this AC signal (5) is
converted into the voltage signal in the ESP ® control module (6) for detection of the wheel speed.
ESP ® Hydraulic Unit / Control Module
Assembly Description
S7RS0B4601002
ESP ® control module is a component of ESP ® hydraulic
unit / control module assembly and has the following
functions.
Self-Diagnosis Function
ESP ® control module monitors each input and output
signals. When ESP ® control module detects any
malfunction, some of ABS warning lamp (1), EBD
warning lamp (brake warning lamp) (2), ESP ® warning
lamp (3), SLIP indicator lamp (4), ESP ® OFF lamp (5)
are turned ON and indicate the abnormality to driver.
• When ignition switch is turned ON, ABS warning lamp, EBD warning lamp, ESP ® warning lamp, SLIP
indicator lamp and ESP ® OFF lamp light for 2
seconds to check its circuit.
• When no abnormality is detected (the system is in good condition), ABS warning lamp, EBD warning
lamp, ESP ® warning lamp, SLIP indicator lamp and
ESP ® OFF lamp turn OFF after 2 seconds.
• When an abnormality in the system is detected, some of ABS warning lamp, EBD warning lamp (brake
warning lamp), ESP ® warning lamp, SLIP indicator
lamp and/or ESP ® OFF lamp are turned ON and the
area where that abnormality lies is stored in the
memory in ESP ® control module. Fail-Safe Mode
When ESP
® control module detects abnormality, the
system goes into fail-safe mode. And some of functions
of ABS, TCS, stability control system are shut down. For
details of fail safe mode, re fer to “Fail-Safe Table”.
S
N
S
N
S
N
N
S
N
S
12V
2
3
1
5
4
6I7RS0B460003-01
3245
1
I6RS0B460001-01

Downloaded from www.Manualslib.com manuals search engine 4F-14 Electronic Stability Program:
Step 2: Driving Test
Test the vehicle at 40 km/h for more than a minute including left and right turns and check if any trouble symptom
(such as ESP ® warning lamp and/or ABS warning lamp) exists.
If the malfunction DTC is confirmed at ignition switch ON, proceed to Step 3.
If the malfunction DTC is not confirmed at ignition switch ON, proceed to Step 6.
Step 3: DTC Check
Recheck DTC referring to “DTC Check”.
Step 4: ESP ® Check
According to ESP ® Check for the DTC 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.
Step 5: Brakes Diagnosis
Check the parts or system suspected as a possible cause referring to “Brakes Symptom Diagnosis in Section 4A” and
based on symptoms appearing on the vehicle (symptom obtain ed through Steps 1 and 2 and repair or replace faulty
parts, if any).
Step 6: Intermittent Problem Check
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section 00” and related circuit of trouble code recorded in Step 1 to 3.
Step 7: Final Confirmation Test
Confirm that the problem symptom has gone and the ESP ® is free from any abnormal conditions. If what has been
repaired is related to the malfunction DTC, clear the DTC once referrin g to “DTC Clearance” and perform test driving
and confirm that no DTC is indicated.
ESP ® Warning lamp CheckS7RS0B4604022
1) Turn ignition switch ON.
2) Check that ESP ® warning lamp (1) comes ON for
about 2 seconds and then goes off.
If any faulty condition is found, advance to “ESP ®
Warning Lamp Does Not Come ON at Ignition Switch
ON” or “ESP ® Warning Lamp Comes ON Steady”.
ABS Warning Lamp CheckS7RS0B4604046
1) Turn ignition switch ON.
2) Check that ABS warning lamp (1) comes ON for
about 2 seconds and then goes off.
If any faulty condition is found, advance to “ABS
Warning Lamp Does Not Come ON at Ignition Switch
ON” or “ABS Warning Lamp Comes ON Steady”.
1
I6RS0B460009-01
11
I4RS0A450007-01

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Stability control (ACTIVE, INACTIVE): This indicates
stability control in acti vation / deactivation.
TCS control (brake) ( ACTIVE, INACTIVE): This
indicates brake function of TCS in activation /
deactivation.
TCS control (engine) (ACTIVE, INACTIVE): This
indicates torque control of TCS in activation /
deactivation. ESP®
off state (cont) (ESP ® ON, ESP ® OFF): State
of ESP ® OFF switch.
Steering angle Sen (Neutral, NON newtral): This
indicates steering wheel angle measured by steering
angle sensor is in straight-ahead or not.
Visual InspectionS7RS0B4604059
Check the following parts and systems visually.
ESP ® Warning Lamp Does Not Come ON at Ignition Switch ONS7RS0B4604008
Wiring Diagram
Circuit Description
Operation (ON/OFF) of ESP ® warning lamp is controlled by ESP ® control module through lamp driver module in
combination meter.
If ESP ® system is in good condition, ESP ® control module turns ESP ® 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, ESP ® warning lamp is
turned ON continuously by ESP ® control module. Also, it is turned ON continuously by lamp driver module when the
connector of ESP ® control module is disconnected.Inspection Item Referring section
Battery Level, leakage “Battery Description in Section 1J”
Connectors of electric wire
harness Disconnection, friction“Intermittent and Poor Connec
tion Inspection in Section
00”
Fuses Burning
Brake fluid Level, leakage “Brake Fluid Level Inspection in Section 4A”
Other parts that can be checked visually
[A] E85
161
15
2
3
4
5
6
7
8
9
10
11
12
13
14
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
3233
34
35
36
37
38
39
40
41
42
43
44
45
46
47
WHTGRN
3
E85-13
E85-44REDWHT6 5E46-1E46-2
4 10
6
E85-16
E85-47BLKBLK
8
9
BLK/ORN
REDWHT
REDWHT
G37-4G37-2
G28-10G28-8
G28-16
12V
12VE85-32E85-1
E85-35
WHT/REDWHT/BLU
GRN/ORN
6
2
1
7 1112[B]
G37
E46124
53
67
891011121314124
53
67
891011
1213141516171819202122
[C] G28
12345678910111213141516
17181920212223242526272829303132
G28-31
RED/BLK
I6RS0B460010-01
[A]: ESP ® control module connector (viewed from terminal side) 3. Ignition switch 8. ESP ® warning lamp
[B]: BCM connector (viewed from harness side) 4. Junction block assembly 9. Lamp driver module
[C]: Combination meter connector (viewed from harness side) 5. BCM (included in junction
block assembly) 10. ESP
® hydraulic unit / control module assembly
1. Battery 6. CAN driver 11. Junction connector
2. Main fuse box 7. Combination meter 12. To steering angle sensor

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DTC Troubleshooting
DTC 1020: Master Cylinder Pressure Sensor Power Supply FailureS7RS0B4604028
DTC Detecting Condition and Trouble Area
DTC Troubleshooting1) Turn ignition switch to OFF position.
2) Check for proper connection from harness to ESP ® control module.
3) If OK, substitute an ESP ® hydraulic unit / control module assembly with correct part number.
4) Recheck system.
Step Action Yes No
1 Was “Electronic Stability Pr ogram Check” performed? Go to Step 2. Go to “Electronic
Stability Program
System Check”.
2 Check brake fluid level
1) Check brake fluid level in reservoir.
Is brake fluid level upper than the minimum level? Go to Step 3. Replenish brake fluid to
reservoir.
3 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 DTC U1073 and/or U1140 detected? Go to applicable diag.
flow.
Go to Step 3.
4 Check brake fluid level switch
1) Turn ignition switch to OFF position.
2) Disconnect brake fluid level switch connector.
3) Check for proper connection at each terminal of brake
fluid level switch connector.
4) If OK, then check brake fluid level switch referring to “Brake Fluid Level Switch Inspection in Section 9C”.
Is check result OK? Go to Step 5. Replace brake fluid
level switch.
5 Check brake fluid level switch circuit
1) Disconnect BCM connector.
2) Check for proper connection to BCM connector at “E46-
5” terminal.
3) If OK, then check resistance between “E46-5” terminal and vehicle body ground.
Is resistance infinity? Go to Step 6. “BLKL/RED” wire circuit
is shorted to ground.
6 Check BCM
1) Connect brake fluid level switch connector and BCM
connector.
2) Check voltage at “E46-5” terminal of BCM referring to “Inspection of BCM and its Circuits in Section 10B”.
Is voltage in good condition? Substitute a known-
good ESP
® hydraulic
unit / control module
assembly and recheck. Check BCM power and
ground circuit. If circuit
is OK, substitute a
known-good BCM and
recheck.
DTC Detecting Condition
Trouble Area
Power supply voltage to master cylinder pressure sensor
in ESP® hydraulic unit / control mo dule assembly is out of
specification. • ESP
® control module