2005 SUZUKI JIMNY engine warning light

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-7
Brake warning light
turns on when brake
is appliedBrake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Insufficient amount of brake fluid Add brake fluid.
Faulty P & Differential valve (Differential switch) Replace.
Brake warning light
fails to turn on even
when parking brake is
appliedBulb burnt out Replace bulb.
Brake warning light circuit open Repair circuit.
ABS warning light
does not turn on for 2
sec. after ignition
switch has turned ON.Bulb burnt out Replace bulb.
ABS warning light circuit open, if equipped with
ABS (including check relay)Check system referring to “TABLE-
A” in Section 5E.
ABS warning light
remains on after igni-
tion switch has turned
on for 2 sec.Malfunctioning ABS, if equipped with ABS Check system referring to “TABLE-
B” in Section 5E. Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-11
Rear Drum Brake Shoe Adjustment
Rear brake has self-adjusting mechanism but it does require
adjustment for proper drum to shoe clearance when brake shoe
has been replaced or brake drum has been removed for some
other service.
Adjustment is automatically accomplished by depressing brake
pedal about 30 times with approximately 30 kg (66 Ibs) load after
all parts are installed.
Then check brake drum for dragging and brake system for proper
performance. After lowering vehicle from hoist, brake test should
be performed.
Parking Brake Inspection and Adjustment
INSPECTION
Hold center of parking brake lever grip and pull it up with 20 kg
(44 Ibs) force.
With parking brake lever pulled up as above, count ratchet
notches.
There should be 6 to 8 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 but-
ton.
One click sound corresponds to one notch.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 lamp lights sometimes during driv-
ing, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake system for
leakage.
Correct leaky points and then refill to specified level.
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.

Downloaded from www.Manualslib.com manuals search engine 5E-2 ANTILOCK BRAKE SYSTEM (ABS)
General Description
The ABS (Antilock Brake System) is a system to prevent each wheel to lock during hard braking or braking on a
slippery road by controlling the fluid pressure from master cylinder to each brake (either brake caliper or wheel
cylinder).
The ABS of this vehicle monitors all four wheels (four sensors) and controls all four wheels when the system is
active.
The component parts of this ABS includes following parts in addition to those of the conventional brake system.
Wheel speed sensor senses revolution speed of each wheel and sends outputs to ABS control module.
In this ABS, ABS hydraulic unit (actuator assembly), ABS control module, pump motor transistor and fail-
safe transistor are combined as one component.
ABS control module 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 operates according to signal from ABS control module and controls fluid pressure applied
to wheel cylinder of each of 4 wheels.
Fail-safe transistor which supplies power to solenoid valve in ABS hydraulic unit.
Pump motor transistor supplies power to pump motor in ABS hydraulic unit.
“ABS” warning lamp lights to inform abnormality when system fails to operate properly.
G sensor which detects body deceleration speed.
1. Front disc brake 5. Brake master cylinder / booster
2. Proportioning valve [A] : For LH steering vehicle
3. Rear drum brake [B] : For RH steering vehicle
4. ABS hydraulic unit / control module assembly

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-5
ABS Control Module
Self-diagnosis function
ABS control module diagnoses conditions of the system compo-
nent 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 lamp as described below.
1) When ignition switch is turned ON, “ABS” warning lights for 2
seconds to check its bulb and circuit.
2) When no abnormality has been detected (the system is in
good condition), “ABS” warning lamp turns OFF after 2 sec-
onds.
3) When an abnormality in the system is detected, “ABS” warn-
ing lamp lights and the area where that abnormality lies is
stored in the memory in ABS control module.
4) When Diag. switch terminal of monitor connector is
grounded, the abnormal area is output as DTC.
For procedure to clear all DTC’s, refer to the item “Diagnostic
Trouble Code (DTC) Clearance” in this section.
Fail-safe function
When an abnormality occurs (an abnormal DTC is detected),
ABS control module turns OFF the fail-safe transistor which sup-
plies power to ABS hydraulic unit. Thus, with ABS not operating,
brakes function just like the brake system of the vehicle without
ABS.SYSTEM CONDITIONDIAGNOSIS
SWITCH
TERMINAL“ABS”
WARNING
LAMP
In good
condition
at presentNo trouble in the past Open OFF
Grounded DTC 12
Trouble occurred in
the pastOpen OFF
Grounded History DTC
Abnormal-
ity exists
at presentNo trouble in the past Open ON
Grounded Current DTC
Trouble occurred in
the pastOpen ON
GroundedCurrent and
history DTC
NOTE:
The current code and the history code are displayed
without any classification.
1. Ignition switch 4. ABS control module
2.“ABS” warning lamp 5. Sensed information
3. Monitor connector 6. Output
3-1. Diag. switch terminal 7. Lamp driver module
3-2. Ground terminal

Downloaded from www.Manualslib.com manuals search engine 5E-6 ANTILOCK BRAKE SYSTEM (ABS)
Diagnosis
To ensure that the trouble diagnosis is done accurately and smoothly, observe “Precautions in Diagnosing Trou-
bles” and follow “ABS Diagnostic Flow Table”.
Precaution in Diagnosing Troubles
If the vehicles was operated in any of the following ways, “ABS” warning lamp 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 Electronic Circuit Service” in Section 0A before inspection and observe
what is written there.
Be sure to use the trouble diagnosis procedure as described in the flow table. Failure to follow the flow table
may result in incorrect diagnosis. Some other diag. trouble code may be stored by mistake in the memory of
ABS control module during inspection.
ABS Diagnostic Flow Table
Refer to the following for the details of each step.
Step Action Yes No
1 Perform customer complaint analysis, problem symptom confir-
mation and diagnostic trouble code check record and clear-
ance.
Is there any trouble code?Go to Step 2. Go to Step 5.
2 Perform driving test.
Is trouble symptom identified?Go to Step 3. Go to Step 6.
3 Check diagnostic trouble code.
Is it malfunction code?Go to Step 4. Go to Step 5.
4 Inspect and repair referring to applicable diagnostic trouble
code table in this section. Then perform final confirmation test
after clearing diagnostic trouble code.
Is trouble recur?Go to Step 7. End.
5 Inspect and repair referring to “Diagnosis Table” in Section 5.
Then perform final confirmation test after clearing diagnostic
trouble code.
Is trouble recur?Go to Step 7. End.
6 Check for intermittent problems referring to “Intermittent and
Poor Connection” in Section 0A and related circuit of trouble
code recorded in Step 3. Then perform final confirmation test
after clearing diagnostic trouble code.
Is trouble recur?Go to Step 7. End.
7 Perform diagnostic trouble code check record and clearance.
Is there any trouble code?Go to Step 4. Go to Step 5.

Downloaded from www.Manualslib.com manuals search engine 5E-8 ANTILOCK BRAKE SYSTEM (ABS)
2) DRIVING TEST
Test drive the vehicle at 40 km/h for more than a minute and check if any trouble symptom (such as abnor-
mal lighting of “ABS” warning lamp) exists.
If the malfunction DTC is confirmed again at ignition switch ON, driving test as described in above is not nec-
essary. Proceed to Step 3.
3) DIAGNOSTIC TROUBLE CODE CHECK
Recheck diagnostic trouble code referring to “DTC Check” in this section.
4) DIAGNOSTIC TROUBLE CODE FLOW TABLE
According to Diagnostic Flow Table for the diagnostic trouble code confirmed in Step 3, locate the cause of
the trouble, namely in a sensor, switch, wire harness, connector, actuator, ABS control module or other part
and repair or replace faulty parts.
5)“DIAGNOSIS TABLE” IN SECTION 5
Check the parts or system suspected as a possible cause referring to “Diagnosis Table” in Section 5 and
based on symptoms appearing on the vehicle (symptoms obtained through Step 1)-a, 1)-b and 2) and repair
or replace faulty parts, if any.
6) CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
Intermittent Trouble in Section 0A and related circuit of trouble code recorded in Step 1)-c.
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 and perform test driving and confirm
that a normal code is indicated.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-11
Diagnostic Trouble Code (DTC) Table
DTC
(displayed on
SUZUKI scan
tool)DTC
(indicated by
ABS warn-
ing lamp)ABS warning light flashing
patternDIAGNOSTIC ITEMS
–12 Normal
C1015 15 G sensor circuit (for 4WD model only)
C1016 16 Stop lamp switch circuit
C1021 21 RF
Wheel speed sensor circuit and/or sen-
sor ring C1025 25 LF
C1031 31 RR
C1035 35 LR
C1022 22 RF
C1026 26 LF
C1032 32 RR
C1036 36 LR
C1041 41
RFHold solenoid valve circuit
C1042 42 Release solenoid valve circuit
C1045 45
LFHold solenoid valve circuit
C1046 46 Release solenoid valve circuit
C1055 55
RearHold solenoid valve circuit
C1056 56 Release solenoid valve circuit

Downloaded from www.Manualslib.com manuals search engine 5E-12 ANTILOCK BRAKE SYSTEM (ABS)
System Circuit
C1057 57 Power source
C1061 61 ABS pump motor circuit
C1063 63 ABS solenoid valve circuit
C1071 71 ABS control module
1. Battery 5-5. Solenoid valves 14. Stop lamp switch
2. Main fuses 6. Combination meter 15. ECM
3. Ignition switch 7. Right rear wheel speed sensor 16. G sensor
4. Circuit fuses 8. Left rear wheel speed sensor 17. 4WD switch (for 4WD model only)
5. ABS hydraulic unit / control module assem-
bly9. Right front wheel speed sensor 18. 4WD indicator lamp (for 4WD model only)
5-1. Terminal arrangement for ABS hydraulic unit
/ control module assembly10. Left front wheel speed sensor 19. 4WD controller (for 4WD model only)
5-2. ABS fail-safe transistor 11. Data link connector 20.“ABS” warning lamp
5-3. ABS pump motor transistor 12. Monitor connector 21. ABS lamp driver module
5-4. Pump motor 13. Stop lamp
DTC
(displayed on
SUZUKI scan
tool)DTC
(indicated by
ABS warn-
ing lamp)ABS warning light flashing
patternDIAGNOSTIC ITEMS