2006 SUZUKI SX4 Ignition system

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

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-10
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” procedure, 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 performing 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 (25 MPH) for more than
a minute and check if any trouble symptom (such as
abnormal lighting of ABS warning light) exists.
If the malfunction DTC is confirmed 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, 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
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 CheckS6RW0D4504002
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
S6RW0D4504003
NOTE
Perform this check on a level place.

1) Turn ignition switch ON with parking brake applied.
2) Check that EBD warning light (brake warning light)
(1) is turned ON.
3) Release parking brake with ignition switch ON and
check that EBD warning light (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

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-14
Circuit Description
ABS control module transmits indication ON signal of ABS warning light to combination meter in order to turn ABS
warning light ON. And then, combination meter turns ABS warning light ON.
If the ABS is in good condition, ABS control module transmits indication ON signal to combination meter in order to
turn ABS warning light 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, ABS warning light is turned ON continuously by ABS control module. Also, it is turned ON
continuously by light driver module when ABS control module connector is disconnected.
Troubleshooting
G241 [D]
132 4 5 6 7 8 9 10111213141516
17 1918 20 2122 23 24 25 26 27 28 29 30 31 32E08 [C]
1
2
3
4
5
6
7 12
13
14
15
16
17
18
19
20
21
228
9
10
11
23
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26
G05 [E]
1 2 3 4 765 8 9 10 11 14 15 16
36 34 33 32 3135 24 23 2122 28 27 2526 37 39 38 4018 17 13 12 19 20
30 29
WHTGRN
3
E08-2
E08-13REDWHT 5
4 13
9
E08-23
E08-26BLKBLK
67
BLK
REDWHTG241-7G241-10
G241-16
12V
E08-25E08-24
E08-9
WHT/REDWHT/BLU
GRN/ORN
9
2
1
14
G241-31
RED/BLK
8
REDWHT9
12V
12V
11
12G05-7
G05-1G05-3
G05-8
RED/BLK
RED/BLU
10
[B]
I6RW0D450002-02
[A]: Junction block with BCM 6. ABS warning light
[B]: Junction block without BCM 7. EBD warning light (brake warning light)
[C]: ABS control module connector (viewed from terminal side) 8. Light driver module
[D]: Combination meter connector (viewed from terminal side) 9. CAN driver
[E]: BCM (viewed from harness side) 10. BCM
1. Battery 11. Brake fluid level switch
2. Main fuse box 12. Parking brake switch
3. Ignition switch 13. ABS hydraulic unit / control module assembly
4. Junction block assembly 14. CAN junction connector
5. Combination meter
Step Action Yes No
1Warning light check
1) Turn ignition switch to ON position.
Do other warning lights come ON?Substitute a known-
good combination meter
and recheck. If warning
light remains OFF,
substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.Go to Step 2.
2Fuse check
Is circuit fuse for combination meter in good condition?Go to Step 3. Replace fuse and check
for short circuit to
ground.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-16
EBD Warning Light (Brake Warning Light) Comes ON SteadyS6RW0D4504010
Wiring Diagram
Referring to “Wiring Diagram” under “ABS Warning Light Does Not Come ON at Ignition Switch ON”.
Circuit Description
EBD warning lamp (brake warning lamp) is controlled by ABS control module and BCM through lamp driver module in
combination meter.
If EBD system is in good condition, ABS control module turns EBD warning lamp ON at the ignition switch ON, keeps
it ON for 2 seconds and then turns it OFF.
EBD warning lamp is turned ON continuously at the following conditions.
• EBD system is an abnormality
• Connector of ABS control module is disconnected
• Parking brake switch is ON
• Brake fluid level is lower than minimum level
The information of parking brake switch and brake fluid level are transmitted from BCM to lamp driver module in
combination meter through CAN communication line.
Troubleshooting
Step Action Yes No
1Parking brake and brake fluid level check
1) Make sure that:
• Parking brake is completely released.
• Brake fluid level is upper than the minimum level.
Are the check results OK?Go to Step 2. Release parking brake
completely and/or
replenish brake fluid.
2ABS warning light operation check
1) Turn ignition switch to ON position.
Does ABS warning light come on steady?Perform “ABS Warning
Light Comes ON
Steady” previously
outlined.Go to Step 3.
3Parking brake switch circuit and brake fluid level switch
circuit check
1) Release parking brake completely, and replenish brake
fluid.
2) Disconnect BCM connectors with ignition switch turned
OFF.
3) Measure resistance between each parking brake switch
circuit, brake fluid level switch circuit and vehicle body
ground.
Are resistance
∞Ω?Go to Step 4. Check each applicable
circuit for short to
vehicle body ground. If
OK then check parking
brake switch and/or
brake fluid level switch.
4DTC check of BCM
1) Connect scan tool to data link connector with ignition
switch turned OFF.
2) Turn ignition switch to ON position and check DTC of
BCM.
Is there DTC U0073?Go to “DTC U0073 (No.
0073): Control Module
Communication Bus Off
in Section 10B”.Go to Step 5.

Downloaded from www.Manualslib.com manuals search engine 4E-27 ABS:
DTC C1057: Power Supply Voltage Too High / Too LowS6RW0D4504018
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
WHTGRN
34 5
E08-23BLK
12VE08-9GRN/ORN
2
1
[A]E08
1
2
3
4
5
6
7 12
13
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15
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228
9
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11
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26
I7RW01450009-03
[A]: ABS control module connector (viewed from terminal side) 2. Main fuse box 4. Junction block assembly
1. Battery 3. Ignition switch 5. ABS hydraulic unit control module assembly
DTC Detecting Condition Trouble Area
ABS control module power supply voltage is too high or
too low.• ABS control module power supply circuit
• ABS control module
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2Check ABS hydraulic unit / control module assembly
power and ground circuit
1) Check that ABS hydraulic unit / control module assembly
power supply circuit and ground circuit is in good
condition referring to “ABS Hydraulic Unit / Control
Module Assembly Power and Ground Circuit Check”.
Are check results OK?Go to Step 3 Repair ABS hydraulic
unit / control module
assembly power or
ground circuit.
3ABS hydraulic unit / control module power source
voltage check
1) Measure battery voltage with engine running at 3000
rpm.
Is voltage 15 V or less?Substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.

Downloaded from www.Manualslib.com manuals search engine 4E-31 ABS:
Troubleshooting
Repair Instructions
ABS Hydraulic Unit Operation CheckS6RW0D4506001
1) Check that basic brake system other than ABS is in
good condition.
2) Check that battery voltage is 11 V or more.
3) Hoist vehicle.
4) Set transmission to neutral (P range for A/T) and
release parking brake.
5) Turn each wheel gradually by hand to check if brake
dragging 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 Step Action Yes No
1Check fuse
Are main fuses and circuit fuses for ABS in good condition?Go to Step 2. Replace fuse and check
for short circuit to
ground.
2Check ABS control module power supply circuit
1) Turn ignition switch to OFF position.
2) Disconnect ABS control module connector.
3) Check for proper connection to ABS control module
connector at terminals “E08-9”, “E08-23”, “E08-24”, and
“E08-25”.
4) If OK, then turn ignition switch to ON position and
measure voltage between terminal “E08-9” and vehicle
body ground.
Is it 10 – 14 V?Go to Step 3. “GRN/ORN” circuit
open.
3Pump motor and solenoid valve power supply circuit
1) Turn ignition switch to OFF position.
2) Measure voltage between each terminal of “E08-24”,
“E08-25” and vehicle body ground.
Are they 10 – 14 V?Go to Step 4. “WHT/BLU” and/or
“WHT/RED” circuit
open.
4Check ABS hydraulic unit / control module assembly
ground circuit
1) Measure resistance between terminal “E08-23” and
vehicle body ground.
Is resistance less than 2
Ω?ABS hydraulic unit /
control module
assembly power and
ground circuits are in
good condition.“BLK” circuit open or
high resistance.
(A)
1
I5RW0A450007-01