front light SUZUKI SX4 2006 1.G Service User Guide
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2006, Model line: SX4, Model: SUZUKI SX4 2006 1.GPages: 1556, PDF Size: 37.31 MB
Page 569 of 1556
Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1
Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1
Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System
Construction (If Equipped) ................................ 4A-2
Front Brake Hose / Pipe Construction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4
Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7
Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-7
Brake Fluid Level Inspection ............................... 4A-8
Brake Light Switch Adjustment ........................... 4A-8
Air Bleeding of Brake System ............................. 4A-8
Front Brake Hose / Pipe Removal and
Installation ......................................................... 4A-9
Rear Brake Hose / Pipe Removal and
Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-10
Master Cylinder and Brake Booster
Components.................................................... 4A-11
Master Cylinder Reservoir Removal and
Installation ....................................................... 4A-11
Master Cylinder Removal and Installation......... 4A-12
Master Cylinder Inspection ............................... 4A-13
Booster Operation Inspection ........................... 4A-14
Brake Booster Removal and Installation ........... 4A-15
Brake Booster Inspection .................................. 4A-15
Booster Push Clevis Rod Adjustment ............... 4A-16
Specifications..................................................... 4A-16
Tightening Torque Specifications ...................... 4A-16
Special Tools and Equipment ........................... 4A-16
Recommended Service Material ....................... 4A-16
Special Tool ...................................................... 4A-16
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and
Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Caliper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and
Assembly........................................................... 4B-4
Front Disc Brake Caliper Inspection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .......................................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipment .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes.............................................. 4C-1
Repair Instructions ..............................................4C-1
Rear Drum Brake Components ...........................4C-1
Rear Brake Drum Removal and Installation ........4C-2
Rear Brake Drum and Shoe Inspection ..............4C-2
Rear Brake Shoe On-Vehicle Inspection ............4C-3
Rear Brake Shoe Removal and Installation ........4C-3
Rear Brake Shoe Inspection ...............................4C-4
Wheel Cylinder Removal and Installation ...........4C-4
Wheel Cylinder Inspection ..................................4C-5
Brake Back Plate Removal and Installation ........4C-5
Specifications .......................................................4C-6
Tightening Torque Specifications ........................4C-6
Special Tools and Equipment .............................4C-6
Recommended Service Material .........................4C-6
Parking Brake .......................................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1
Repair Instructions ..............................................4D-2
Parking Brake Inspection and Adjustment ..........4D-2
Parking Brake Cable Removal and
Installation .........................................................4D-2
Parking Brake Lever Removal and Installation ....4D-3
Page 570 of 1556
Downloaded from www.Manualslib.com manuals search engine 4-ii Table of Contents
Specifications .......................................................4D-4
Tightening Torque Specifications ........................4D-4
ABS ............................................................4E-1
Precautions........................................................... 4E-1
Precautions in Diagnosing Troubles ................... 4E-1
Precautions in On-Vehicle Service...................... 4E-1
General Description ............................................. 4E-2
ABS Description .................................................. 4E-2
ABS Hydraulic Unit / Control Module
Assembly Description ....................................... 4E-3
CAN Communication System Description........... 4E-3
Schematic and Routing Diagram ........................ 4E-4
ABS Schematic ................................................... 4E-4
ABS Wiring Circuit Diagram ................................ 4E-5
Component Location ........................................... 4E-8
ABS Components Location ................................. 4E-8
Diagnostic Information and Procedures ............ 4E-8
ABS Check .......................................................... 4E-8
ABS Warning Light Check................................. 4E-10
EBD Warning Light (Brake Warning Light)
Check .............................................................. 4E-10
DTC Check........................................................ 4E-11
DTC Table ......................................................... 4E-11
DTC Clearance ................................................. 4E-11
Scan Tool Data ................................................. 4E-12
ABS Warning Light Does Not Come ON at
Ignition Switch ON .......................................... 4E-13
ABS Warning Light Comes ON Steady ............. 4E-15
EBD Warning Light (Brake Warning Light)
Comes ON Steady .......................................... 4E-16
Serial Data Link Circuit Check .......................... 4E-17
DTC C1013: Control Module Mismatch ............ 4E-20
DTC C1015: G Sensor Circuit (4WD Model)..... 4E-21
DTC 1016: Brake Light Switch .......................... 4E-22
DTC C1021 / C1022 / C1025 / C1026 / C1031
/ C1032 / C1035 / C1036: Wheel Speed
Sensor Circuit / Sensor or Encoder ................ 4E-23
DTC C1033: Wheel Speed Sensor Deviation ... 4E-25
DTC C1041 / C1042 / C1045 / C1046 / C1051
/ C1052 / C1055 / C1056: Inlet / Outlet
Solenoid .......................................................... 4E-26DTC C1057: Power Supply Voltage Too High
/ Too Low ........................................................ 4E-27
DTC C1061: Pump Motor Circuit ...................... 4E-28
DTC C1063: Solenoid Valve Power Supply
Driver Circuit ................................................... 4E-29
DTC C1071: Control Module Internal Defect .... 4E-30
ABS Hydraulic Unit / Control Module
Assembly Power and Ground Circuit Check ... 4E-30
Repair Instructions ............................................ 4E-31
ABS Hydraulic Unit Operation Check................ 4E-31
ABS Hydraulic Unit / Control Module
Assembly Components ................................... 4E-32
ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4E-33
ABS Hydraulic Unit / Control Module
Assembly Removal and Installation ................ 4E-33
Front and Rear Wheel Speed Sensor On-
Vehicle Inspection ........................................... 4E-34
Front Wheel Speed Sensor Removal and
Installation ....................................................... 4E-35
Front and Rear Wheel Speed Sensor
Inspection ........................................................ 4E-36
Rear Wheel Speed Sensor Removal and
Installation (4WD Model) ................................. 4E-36
Rear Wheel Speed Sensor Removal and
Installation (2WD Model) ................................. 4E-36
Front Wheel Speed Sensor Encoder On-
Vehicle Inspection ........................................... 4E-37
Front Wheel Speed Sensor Encoder Removal
and Installation ................................................ 4E-37
Rear Wheel Speed Sensor Encoder On-
Vehicle Inspection ........................................... 4E-37
Rear Wheel Speed Sensor Encoder Removal
and Installation ................................................ 4E-37
G Sensor Removal and Installation (4WD
Model) ............................................................. 4E-38
G Sensor Inspection (4WD Model) ................... 4E-38
Specifications ..................................................... 4E-39
Tightening Torque Specifications ...................... 4E-39
Special Tools and Equipment ........................... 4E-39
Special Tool ...................................................... 4E-39
Page 575 of 1556
Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-4
Rear Brake Hose / Pipe ConstructionS6RW0D4101003
Diagnostic Information and Procedures
Brakes Diagnosis NoteS6RW0D4104001
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both light
and heavy pedal forces at various speeds to determine if
the vehicle stops evenly and effectively. Also drive
vehicle to see if it leads to one side or the other without
brake application. If it does, check the tire pressure, front
wheel alignment and front suspension attachments for
looseness. See diagnosis table for other causes.
Brake Fluid Leaks
Check the master cylinder fluid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low level indicates a leak in the
system. In such a case, check the entire brake system
for leakage. If even a slight evidence of leakage is noted,
the cause should be corrected or defective parts should
be replaced.Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may
cause the brake fluid to boil or the rubber components
(piston cups and brake hoses) in the hydraulic system to
deteriorate.
If the above fluid is included in the system, replace the
master cylinder assembly and other rubber components
(hoses). The master cylinder assembly is disassemble
parts to maintain the performance.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to
contaminated fluid.
I6RW0D410001-01
1. To left rear brake hose 5. Left rear brake hose to left brake
2. To right rear brake hose 6. Right rear brake hose to right brake
3. Left rear brake hose : 16 N⋅m (1.6 kgf-m, 12.0 lb-ft)
4. Right rear brake hose
Page 577 of 1556
Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-6
Dragging brakes (Without
a very light drag is
present in all brakes
immediately after pedal is
released)Master cylinder pistons not returning
correctlyReplace master cylinder.
Restricted brake pipes or hosesCheck for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakesCheck and adjust to correct specifications.
Weakened or broken return springs in
the drum brakeReplace.
Sluggish parking brake cables or linkageRepair or replace.
Wheel cylinder or caliper piston stickingRepair as necessary.
Badly worn piston seal in caliperReplace piston seal.
Improper brake pedal free heightCheck brake pedal free height.
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged wheel bearingsReplace wheel bearings.
Distorted steering knuckle or rear wheel
spindle or rear axle shaftReplace knuckle or rear wheel spindle or rear
axle shaft.
Excessive disc lateral runoutCheck per instructions. If not within
specifications, replace or machine disc.
Rear drums out of roundCheck runout.
Repair or replace drum as necessary.
Braking noiseGlazed brake pad and/or brake shoeRepair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoeReplace brake shoe.
Loose front wheel bearingsReplace wheel hub.
Distorted backing plates or loose
mounting boltsReplace or retighten securing bolts.
Contact wear indicator to brake discReplace brake pads.
Brake warning light lights
after engine startParking brake appliedRelease parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faultyRepair circuit.
Malfunctioning EBD systemCheck system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is appliedBrake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is appliedBrake warning light circuit faultyReplace bulb or repair circuit.
ABS warning light turns
on after engine startMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light turns
on when brake is appliedMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light after
ignition switch has turned
ON Bulb burnt outReplace bulb.
Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light flashesNew ABS hydraulic unit / control module
assembly installed.Perform “ABS Hydraulic Unit Operation Check
in Section 4E”. Condition Possible cause Correction / Reference Item
Page 579 of 1556
Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-8
Brake Fluid Level InspectionS6RW0D4106004
CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.
NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning light lights sometimes
during driving, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.
1) Check master cylinder, reservoir and reservoir hose
(if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX (1) and
MIN marks (2) on reservoir.
Brake Light Switch AdjustmentS6RW0D4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and brake light
switch
“a”: 0.5 – 1.5 mm (0.02 – 0.05 in.)
Air Bleeding of Brake SystemS6RW0D4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.
Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper or wheel cylinder farthest from
master cylinder and then at front caliper of
the same brake line. Do the same on the
other brake line.
1
2
I7RW01410004-01
1. Right front brake caliper 3. Right rear wheel cylinder
2. Left front brake caliper 4. Left rear wheel cylinder
I5RW0A410005-01
I7RW01410005-01
Page 607 of 1556
Downloaded from www.Manualslib.com manuals search engine ABS: 4E-2
General Description
ABS DescriptionS6RW0D4501001
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.
Rear wheel speed sensor of 4WD vehicle is
integrated in rear wheel hub assembly and supplied
as rear wheel hub assembly part.
Front wheel speed sensor and rear wheel speed
sensor of 2WD model are separated from wheel hub
assembly and supplied as spare parts.
• ABS warning light which lights to inform abnormality
when system fails to operate properly.• ABS hydraulic unit / control module assembly is
incorporated ABS control 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 supply 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.
• G sensor which detects body deceleration speed for
4WD model.
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 proportioning valve, by the signal from
wheel sensor independently of change of load due to
load capacity and so on. And if the EBD system fails to
operate properly, the brake warning light lights to inform
abnormality.
Page 608 of 1556
Downloaded from www.Manualslib.com manuals search engine 4E-3 ABS:
ABS Hydraulic Unit / Control Module Assembly
Description
S6RW0D4501002
ABS control module is a component of ABS hydraulic
unit / control module assembly and has the following
functions.
Self-Diagnosis Function
ABS control module diagnoses 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 the 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.
CAN Communication System DescriptionS6RW0D4501003
Refer to “CAN Communication System Description in Section 1A” for CAN communication system description. ABS
control module communicates control data with each control module as follows.
ABS Control Module Transmission Data
1
I4RS0A450001-01
Wheel speed signal (Front-right)
Wheel speed signal (Front-left)
Wheel speed signal (Rear-right)
Wheel speed signal (Rear-left)
ABS active
ABS indication
EBD indicationCombination Meter
TransmitDATA
ABS control module ECM 4WD control module
I7RW01450001-06
Page 610 of 1556
Downloaded from www.Manualslib.com manuals search engine 4E-5 ABS:
ABS Wiring Circuit DiagramS6RW0D4502002 1. ABS hydraulic unit / control module assembly 9. Brake light switch 17. Wheel speed sensor (Left-rear)
2. ABS control module 10. ABS warning light 18. Battery
3. ABS hydraulic unit 11. EBD warning light (Brake warning light) 19. Ignition switch
4. Solenoid valve power supply driver (transistor)12. Light driver module 20. G sensor (4WD model)
5. Solenoid valve driver (transistor) 13. Data link connector 21. ECM
6. Pump motor driver (transistor) 14. Wheel speed sensor (Right-front) 22. Combination meter
7. Solenoid valve 15. Wheel speed sensor (Left-front) 23. 4WD control module
8. Pump motor 16. Wheel speed sensor (Right-rear)
BLU
WHT12VGRN/ORN 34
30E08-9
RED
WHT26
WHT/RED
12V
E08-7
19GRN
GRN
E08-16
12V
21REDRED/BLK
12V
BLKWHTE08-22 E08-11
23BLKWHTLT GRN/BLKLT GRN
12V
E08-10 E08-21
E08-23
E08-26
E08-1E08-12
24BLKWHT
12V
YELBRNE08-19 E08-2027
1 2
E08-6
9
9
9
WHTRED
12VE08-25
M
BLK
BLK
WHT/BLUWHT/RED
WHT/BLUE08-24
WHT
E08 [C] [A]
1
2
3
4
5
6
7 12
13
14
15
16
17
18
19
20
21
228
9
10
11
23
24
25
26
GRN/WHT
22
12V
BLKWHTWHTWHT/BLKE08-17 E08-18
GRN/ORN28
2033
31
29
25
32
GRN/YELE08-3GRN/BLK10
8
17
18
+BB
RED/BLKRED/BLK
REDWHTREDWHT
RED
BLK
WHT
14 13 12 76 5
1516
REDWHT
11
RED
WHT
9 9
E08-13E08-2
99
I6RW0D450004-01
Page 611 of 1556
Downloaded from www.Manualslib.com manuals search engine ABS: 4E-6
17+BB
18BLU
WHT12VGRN/ORN 34
30E08-9
RED
WHT 1226
WHT/RED
12V
E08-7
19GRN
GRN
E08-16
12V
5
76
21REDRED/BLK
12V
BLKWHTE08-22 E08-11
23BLKWHTLT GRN/BLKLT GRN
12V
E08-10 E08-21
E08-23
E08-26
E08-1E08-12
24BLKWHT
12V
YELBRNE08-19 E08-20
27
1 2
RED/BLK
WHTRED
WHTRED
WHTRED9
E08-2E08-13WHT
E08-6
RED
9
9
11
9
9
9
REDWHT
WHTRED
12VE08-25
M
BLK
BLK
WHT/BLUWHT/RED
WHT/BLUE08-24
WHT
E08 [A]
1
2
3
4
5
6
7 12
13
14
15
16
17
18
19
20
21
228
9
10
11
23
24
25
26
GRN/WHT
22
12V
BLKWHTWHTWHT/BLKE08-17 E08-18
GRN/ORN28
2033
31
29
25
15
32
GRN/YELE08-3GRN/BLK
8
12V
12V
13
14RED/BLK
RED/BLU
WHTRED6
16
10
BLK [B]
I6RW0D450001-02
[A]: Junction block with BCM 10. G sensor (4WD model) 22. Right-front wheel speed sensor
[B]: Junction block without BCM 11. 4WD control module 23. Left-rear wheel speed sensor
[C]: Terminal arrangement of ABS control module
connector (viewed from terminal side)12. BCM 24. Right-rear wheel speed sensor
1. Battery 13. Brake fluid level switch 25. ABS hydraulic unit / control module assembly
2. Main fuse box 14. Parking brake switch 26. Brake light switch
3. Ignition switch 15. CAN junction connector 27. Brake light
4. Junction block assembly 16. Keyless start control module 28. To ECM and shift lock relay (A/T model)
5. Combination meter 17. Data link connector (DLC) 29. Pump motor driver (transistor)
6. ABS warning light 18. To BCM, 4WD control module, P/S control
module, HVAC control module (auto A/C
model) and SDM30. Pump motor
7. EBD warning light (brake warning light)19. ECM 31. Solenoid valve power supply driver
8. Light driver module 20. TCM (A/T model) 32. Solenoid valve
9. CAN driver 21. Left-front wheel speed sensor 33. Solenoid valve driver (transistor)
Page 612 of 1556
Downloaded from www.Manualslib.com manuals search engine 4E-7 ABS:
Te r m i n a l C i r c u i t
E081 CAN communication line (high) for ECM
2 CAN communication line (high) for BCM
3 G sensor ground (4WD model only)
4—
5—
6 G sensor signal (4WD mode only)
7 Brake light switch
8—
9 Ignition switch
10 Left-rear wheel speed sensor (–)
11 Left-front wheel speed sensor (+)
12 CAN communication line (low) for ECM
13 CAN communication line (low) for BCM
14 —
15 —
16 Data link connector
17 Right-front wheel speed sensor (–)
18 Right-front wheel speed sensor (+)
19 Right-rear wheel speed sensor (–)
20 Right-rear wheel speed sensor (+)
21 Left-rear wheel speed sensor (+)
22 Left-front wheel speed sensor (–)
23 Ground for solenoid valve
24 Power supply for solenoid valve
25 Power supply for pump motor
26 Ground for pump motor