2004 SUZUKI SWIFT low battery

Downloaded from www.Manualslib.com manuals search engine 4F-42 Electronic Stability Program:
DTC C1061: Pump Motor and/or Motor Driver Circuit FailureS7RS0B4604054
Wiring Diagram
DTC Detecting Condition and Trouble Area5
Check power supply circuit from battery
1) Measure voltage between terminals “E85-1” and “E85-
16”, “E85- 47" with engine running.
Are voltage 18
± 1.0 V or less? Poor connection of
“E85-1”, “E85-16” and/
or “E85-47” terminals. If
the terminals are in
good condition,
substitute a known-
good ESP
® hydraulic
unit / control module
assembly and recheck. Check charging system
referring to “Generator
Test (Overcharged
Battery Check) in
Section 1J”.
Step Action Yes No
[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
4
51
2
WHT/RED3
12V
M
12V
BLK
BLK
E85-16
E85-47
E85-32
I6RS0B460024-02
[A]: ESP
® control module connector (viewed from
terminal side) 2. Main fuse box 4. Pump motor
1. Battery 3. Pump motor driver (transistor) 5. ESP® hydraulic unit / control module assembly
DTC Detecting ConditionTrouble Area
Defective pump motor and/or motor power supply voltage
is too low. • Pump Motor and/or Motor Driver power supply circuit
• ESP
® control module

Downloaded from www.Manualslib.com manuals search engine 4F-54 Electronic Stability Program:
Repair Instructions
ESP® Hydraulic Unit Operation CheckS7RS0B4606025
1) Check that basic brake system other than ESP ® 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 braked ragging 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 press / depress in “HYDRAULIC CONTROL TEST”
under “miscellaneous test” (“MISC. TEST”) mode of
SUZUKI scan tool.
Refer to SUZUKI scan tool operator’s manual for
further details.
8) Perform the following checks with help of another person.
• Depressurization checkStep on brake pedal (1) 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 whether the wheel rotates freely due
to brake depressurization. • Pressurization check
Step off brake pedal (1) 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 whether the wheel locks due to brake
pressurization.
NOTE
Pressurization / Depressurization by SUZUKI
scan tool is available for 0.5 second.

9) Check for all 4-wheels condition 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.
Sensor CalibrationS7RS0B4606015
CAUTION!
If any DTC(s) other than C1075, C1076 or
C1078 are detected, sensor calibration can
not be completed. Repair the detected DTC
first.

NOTE
Steering angle sensor calibration is needed
when battery, “DOME” fuse or the steering
angle sensor is removed.
This sensor calibration can be done with/
without SUZUKI Scan Tool.
When ESP ® control module and/or yaw rate /
G sensor assembly is removed, sensor
calibration is needed with SUZUKI Scan Tool.

(A)
1
I4RS0B450003-01
I4RH01450021-01

Downloaded from www.Manualslib.com manuals search engine 4F-56 Electronic Stability Program:
ESP® Hydraulic Unit / Control Module Assembly Removal and InstallationS7RS0B4606037
CAUTION!
Never disassemble ESP ® hydraulic unit / control module assembly loosen blind plug or remove motor.
Performing any of these proh ibited services will affect original performance of ESP ® hydraulic unit /
control module assembly.

Removal
CAUTION!
• Do not give an impact to hydraulic unit.
• Use care not to allow dust to enter hydraulic unit.
• Do not place hydraulic unit on its side or upside down. Handling it in inappropriate
way will affect its original performance.

1) Disconnect negative (–) cable from battery.
2) Disconnect ESP ® control module connector (1) as
shown in figure.
3 1
(c)
2
(b)
(a)4
(a)
4
5
6
(b)
5
(c)
6
(d)
(d) 4
4
I7RS0B460012-01
1. ESP ® hydraulic unit / control module
assembly 5. ESP
® hydraulic unit / control module
assembly bolt : 25 N
⋅m (2.5 kgf-m, 18.0 lb-ft)
2. Bracket 6. ESP ® hydraulic unit / control module
assembly bracket bolt : 19 N
⋅m (1.9 kgf-m, 13.5 lb-ft)
3. ESP ® control module connector : 16 N ⋅m (1.6 kgf-m, 11.5 lb-ft)
4. Brake pipe flare nut : 9 N ⋅m (0.9 kgf-m, 6.5 lb-ft)
[A]: DisconnectC: 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 4F-58 Electronic Stability Program:
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
Front Wheel Speed Sensor Removal and
Installation
S7RS0B4606029
Removal
1) Disconnect negative (–) cable from battery.
2) Disconnect front wheel speed sensor coupler (1).
3) Hoist vehicle and remove wheel.
4) Remove harness clamp, clamp bolts (2) and grommet (3).
5) Remove front wheel speed sensor (4) from knuckle.
NOTE
• Do not pull wire harness when removing front wheel speed sensor.
• Do not cause damage to surface of front wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

[A]: Voltage [B]: Time
I5JB0A450027-01
I5JB0A450028-02
3
2
4 1
I6RS0B460032-02

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-59
Installation
CAUTION!
Do not pull or twist wire harness more than
necessary when installing front wheel speed
sensor.

1) Check that no foreign material is attached to sensor(1) and mating encoder (2).
2) Install it by reversing removal procedure.
Tightening torque
Front wheel speed sensor bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
Front wheel speed sensor harness clamp bolt
(b): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
3) Check that there is no clearance between sensor and knuckle.
Front Wheel Speed Sensor InspectionS7RS0B4606030
Check sensor for damage.
If any malcondition is found, replace.
Rear Wheel Speed Sensor Removal and
Installation
S7RS0B4606031
CAUTION!
• Do not pull wire harness when removing rear wheel speed sensor.
• Do not cause damage to surface of rear wheel speed sensor and do not allow dust,
etc. to enter its installation hole.

Removal
1) Disconnect negative (–) cable from battery.
2) Remove quarter inner trim to brake referring to
“Floor Carpet Removal and Installation in Section
9H”.
3) Turn over floor carpet (2) and disconnect connector (1) of wheel speed sensor.
[A]: OK [B]: NG
(b)
1
[A][B]
11
2
(a)
I6RS0B460033-02
I5JB0A450031-01
2
2
1
I6RS0B460035-02

Downloaded from www.Manualslib.com manuals search engine 4F-64 Electronic Stability Program:
Removal1) Disconnect negative (–) cable at battery.
2) Remove front console box referring to “Console Box Components in Section 9H”.
3) Disconnect connector from yaw rate / G sensor
assembly.
4) Remove yaw rate / G sens or assembly from sensor
bracket.
Installation 1) Before installing yaw rate / G sensor assembly (1),
check installing condition as follows.
• Deformations around sensor installation area (2) (in sensor bracket).
• Foreign matters on mating surface between sensor and sensor bracket.
2) Install yaw rate / G sensor assembly (1) to floor panel.
Tightening torque
Yaw rate / G sensor assembly nut (a): 8 N·m (0.8
kgf-m, 6.0 lb-ft)
3) Connect connector to yaw rate / G sensor assembly.
4) Install console box referring to “Console Box Components in Section 9H”.
5) Connect negative (–) cable to battery.
6) After completing installation, calibrate yaw rate / G
sensor assembly referring to “Sensor Calibration”.Yaw Rate / G Sensor InspectionS7RS0B4606019
• Check sensor for dents, cracks or deformation.
• Check sensor connector (sensor side and harness
side) and sensor connector lock mechanism for
damage or crack.
• Check connector terminals for bend, corrosion or rust.
If it is found faulty, replace yaw rate / G sensor assembly.
Steering Angle Sensor On-Vehicle InspectionS7RS0B4606020
CAUTION!
Before each inspection, confirm steering
angle sensor calibration is completed.
If calibration is incompleted, calibrate sensor
referring to “Sensor Calibration”.

1) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
(a)
1
(a)
2I6RS0B460041-02
I6JB01460031-01
(A)
1
I4RS0B450003-01

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-65
2) Turn ignition switch to ON position and select menu
“DATA LIST” mode of SUZUKI scan tool.
Refer to scan tool operator's manual for further
derails.
3) Check “Steering angle Sen” under “DATA LIST” of SUZUKI scan tool in th e following steering wheel
conditions.
• Front wheels in straight-ahead position
• Rotate steering wheel a round in clockwise (counter clockwise) from straight-ahead position
If steering angle condition is out of specification,
replace steering angle sensor.
Steering angle Specification
Steering Angle Sensor Removal and InstallationS7RS0B4606021
Refer to “Steering Angle Sensor Removal and
Installation in Section 6B”.
Steering Angle Sensor InspectionS7RS0B4606022
• Check sensor for dents, cracks or deformation.
• Check sensor connector (sensor side and harness
side) and sensor connector lock mechanism for
damage or crack.
• Check connector terminals for bend, corrosion or rust.
If it is found faulty, replace steering angle sensor (1).
ESP ® OFF Switch Removal and InstallationS7RS0B4606023
Removal
1) Disconnect negative (–) cable at battery.
2) Remove rear console box referring to “Console Box Components in Section 9H”.
3) Disconnect ESP ® OFF switch coupler.
4) Remove ESP ® OFF switch (1) from rear console
box (2).
Installation
Reverse removal procedure.
ESP ® OFF Switch InspectionS7RS0B4606024
Check for continuity between terminals at each switch
position.
If check result is not as specified, replace ESP ® OFF
switch.
Vehicle condition Steering angle
Front wheels in straight-
ahead position 0
± 3 °
Rotate steering wheel a
round in clockwise 360
± 3°
Rotate steering wheel a
round in counterclockwise –360
± 3 °
I6JB01460032-01
1
I6JB01460033-01
[A]: Free [B]: Push
1
I6RS0B460042-02
[A]
[B]2345
2
3
4
1
5
I6RS0B460043-02

Downloaded from www.Manualslib.com manuals search engine 4F-66 Electronic Stability Program:
Specifications
Tightening Torque SpecificationsS7RS0B4607001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
NOTE
The specified tightening torque is also described in the following.
“ESP® Hydraulic Unit / Control Module Assembly Removal and Installation”

Special Tools and Equipment
Special ToolS7RS0B4608001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake pipe flare nut 16 1.6 11.5 )
ESP ® hydraulic unit / control module assembly
bolt 90.9 6.5)
ESP ® hydraulic unit / control module assembly
bracket bolt 25 2.5 18.0)
Front wheel speed sensor bolt 11 1.1 8.0 )
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 )
Yaw rate / G sensor assembly nut 8 0.8 6.0 )
09956–02311SUZUKI scan tool
Brake pressure gauge —
) 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.) / ) / ) /
) / ) / ) / )