Switch SUZUKI SX4 2006 1.G Service Workshop Manual

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

Downloaded from www.Manualslib.com manuals search engine 4A-11 Brake Control System and Diagnosis:
Master Cylinder and Brake Booster ComponentsS6RW0D4106010
CAUTION!
Never disassemble master cylinder and brake booster. Disassembly will spoil its original function.
If faulty condition is found, replace it with new one.

Master Cylinder Reservoir Removal and
Installation
S6RW0D4106011
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Clean outside of reservoir and master cylinder.
2) Disconnect fluid level switch coupler (1) and clamp
(3) from reservoir (2).
4 2
2
1
(b) 10
9 8
7
11 12
6
3
5(a)
I7RW01410017-03
1. Reservoir 6. O-ring 11. Brake vacuum hose
: Be sure to direct location mark (12) to upward as
shown in figure.
2. Grommet
: Apply brake fluid. 7. Brake booster : 18N⋅m (1.8kgf-m, 13.0 lb-ft)
3. Master cylinder 8. Clevis pin : 13N⋅m (1.3kgf-m, 9.5lb-ft)
4. Reservoir connect pin 9. Clip : Do not reuse.
5. Master cylinder fixing nut 10. Gasket : Apply grease to piston rod
(Grease included in spare parts to master
cylinder or brake booster.)
2
13
I7RW01410009-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-12
3) Drain brake fluid in reservoir.
4) Disconnect clutch reservoir hose from reservoir (M/T
model).
5) Remove reservoir connector pin (1) by using special
tool and then reservoir.
Special tool
(A): 09916–44310
Installation
1) When using new grommets (2), lubricate them with
the same fluid as the one to fill reservoir with.
Then press-fit grommets (2) to master cylinder (3).
2) Install reservoir (1) to master cylinder.
3) Drive in reservoir connector pin (2) by using special
tool (A). Till both of its ends at the right and left of
reservoir (1) becomes the same length.
Special tool
(A): 09916–44310 4) Connect clutch reservoir hose to reservoir (M/T
model).
5) Connect fluid level switch coupler (1) and clamp (3)
to reservoir (2).
6) Fill reservoir with specified brake fluid up to its MAX
level.
7) After completing the work, bleed air from brake
system referring to “Air Bleeding of Brake System”
and bleed air from clutch system referring to“Air
Bleeding of Clutch System in Section 5C” (M/T
model).
8) Check each installed parts for fluid leakage.
9) Perform brake test and check fluid leakage.
Master Cylinder Removal and InstallationS6RW0D4106012
Removal
CAUTION!
• Never disassemble master cylinder since
the master cylinder is supplied as
assembly parts.
If faulty condition is found, replace it with
new one.
• Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be
damaged by brake fluid, flush it with water
immediately if any fluid is spilled.

1) Clean outside of master cylinder.
2) Disconnect fluid level switch coupler (1) and clamp
(3) from reservoir (2).
1 (A)I5JB0A410013-02
1
2
2
3
I7RW01410010-02
I7RW01410011-01
2
13
I7RW01410009-01
2
13
I7RW01410009-01

Downloaded from www.Manualslib.com manuals search engine 4A-13 Brake Control System and Diagnosis:
3) Drain brake fluid in reservoir.
4) Disconnect clutch reservoir hose from reservoir (M/T
model).
5) Disconnect brake pipes (1) connected to master
cylinder.
6) Remove master cylinder fixing nuts (2).
7) Remove master cylinder (3) and O-ring.
Installation
1) Install new O-ring (2) to master cylinder assembly
(1).
2) Apply grease to piston rod “A”.
Use specified grease in spare to master cylinder or
brake booster as supply parts.
3) Install master cylinder assembly (1) to brake booster
(3) and tighten master cylinder fixing nuts to
specified torque.
Tightening torque
Master cylinder fixing nut (a): 18 N·m (1.8 kgf-
m, 13.0 lb-ft)4) Connect brake pipe to master cylinder and tighten
flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
5) Connect clutch reservoir hose to reservoir and install
reservoir hose clamp (M/T model).
6) Connect fluid level switch connector and clamp.
7) Fill reservoir with specified brake fluid up to its MAX
level.
8) After completing the work, bleed air from brake and
clutch system referring to “Air Bleeding of Brake
System” and bleed air from clutch system referring to
“Air Bleeding of Clutch System in Section 5C” (M/T
model).
9) Check each installed parts for fluid leakage.
10) Check brake pedal for play referring to “Brake Pedal
Play Inspection”.
11) Perform brake test and check fluid leakage.
Master Cylinder InspectionS6RW0D4106013
• Depress brake pedal a few times and retain brake
pedal. If pedal gone down, replace the brake master
cylinder assembly.
• Check master cylinder for leakage, corrosion and
smooth operation.
• Inspect distance “a” to be the following.
If measurement is out of specification, replace master
cylinder assembly.
Distance
“a”: 72.0 mm (2.83 in.) or more
2
1
3I7RW01410012-01
(a)3
2
1
"A"
I7RW01410019-01
(a)I7RW01410013-01
I7RW01410014-01

Downloaded from www.Manualslib.com manuals search engine 4D-3 Parking Brake:
Parking Brake Lever Removal and InstallationS6RW0D4406003
Removal
1) Remove console box.
2) Block vehicle wheels and release parking brake
lever.
3) Disconnect lead wire of parking brake switch at
coupler.
4) Loosen parking brake cable adjusting nut (1).
5) Remove parking brake lever bolts (1) and then
remove parking brake lever assembly (2) with
equalizer (3).
NOTE
Don’t disassemble parking brake lever
switch. It must be removed and installed as a
complete switch assembly.

Installation
1) Install in reverse order of removal procedure.
Check equalizer inclined angle.
Tightening torque
Parking brake lever bolt (a): 26 N·m (2.6 kgf-m,
19.0 lb-ft)
2) After all parts are installed, parking brake lever
needs to be adjusted. Refer to “Parking Brake
Inspection and Adjustment”.
3) Check brake drum for dragging and brake system for
proper performance. After removing vehicle from
hoist, brake test should be performed.
I4RS0A440004-01
I5RW0A440002-01
I5RW0A440003-01

Downloaded from www.Manualslib.com manuals search engine 4E-1 ABS:
Brakes
ABS
Precautions
Precautions in Diagnosing TroublesS6RW0D4500001
To ensure that the trouble diagnosis is done accurately
and smoothly, observe the following and follow “ABS
Check”.
• Diagnostic information stored in ABS control module
memory can be cleared as well as checked by using
SUZUKI scan tool. Before using 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 vehicle 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” and “Precaution for CAN
Communication System in Section 00” before
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 hydraulic unit / control
module connector (1), pull up lock lever (2) of
connector.
When connecting, set the connector on ABS hydraulic
unit / control module assembly and pull down the lock
lever (2) until it locks.
• Communication of ECM, BCM, combination meter,
4WD control module (if equipped), keyless start
control module (if equipped), TCM (if equipped), data
link connector and ABS control module is established
by CAN (Control Area Network).
Therefore, be sure to read “Precautions for Installing
Mobile Communication Equipment in Section 00”
before inspection and handling CAN communication
line.
Precautions in On-Vehicle ServiceS6RW0D4500002
When connector is connected to ABS hydraulic unit /
control module assembly, do not disconnect connectors
of sensors with ignition switch ON. Otherwise, DTC will
be set in ABS control module.
[A]: Disconnect C: Pull up to disconnect
[B]: Connect D: Pull down to connect
2 1
CD
[A]
[B]
I5RW0A450001-01

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

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-4
Schematic and Routing Diagram
ABS SchematicS6RW0D4502001
13
2
8
6
5 7
12
4
15
17
1614
9
18
19
11 10
20
21221323
INPUTOUTPUT
ABS control module
Wheel speed sensor (LR)
Wheel speed sensor (RF)
G sensor
(4WD model only)Wheel speed sensor (LF)Pump motor
driver (transistor)
Solenoid valve power
supply 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
“ABS” warning lamp
“EBD” warning lamp
(Brake warning lamp)Data link connector
ABS hydraulic unit/control
module assembly
Wheel speed sensor (RR)
Brake light switch
CAN driver
Combination meter
Wheel speed signal
ECM
Wheel speed signal
ABS avtive signal
ABS avtive signal
4WD control module
(4WD model only)
Solenoid valve
driver (transistor)
I7RW01450016-01

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

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)