2006 SUZUKI SX4 AIR

Downloaded from www.Manualslib.com manuals search engine Parking Brake: 4D-2
Repair Instructions
Parking Brake Inspection and AdjustmentS6RW0D4406001
Inspection
Hold center of parking brake lever grip and pull it up with
200 N (20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count
ratchet notches. There should be 4 – 9 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 button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable
referring to adjustment procedure so as to obtain
specified parking brake stroke.
NOTE
Check tooth tip of each notch for damage or
wear.
If any damage or wear is found, replace
parking brake lever.

Adjustment
NOTE
Make sure for the following conditions before
cable adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Start engine and then brake pedal has
been depressed at least 3 times with about
300 N (30 kg, 66 lbs) load.
• Parking brake lever has been pulled up a
few times with about 200 N (20 kg, 44 lbs)
load.
If parking brake cable is replaced with new
one, pull up parking brake lever a few
times with about 500 N⋅m (50 kg, 110 lbs)
force.

After confirming that the conditions are all satisfied,
adjust parking brake lever stroke by loosening or
tightening adjust nut (1).
NOTE
Check brake drum for dragging after
adjustment.

Parking brake stroke
When lever is pulled up at 200 N (20 kg, 44 lbs): 4 to
9 notches
Parking Brake Cable Removal and InstallationS6RW0D4406002
Removal
NOTE
When it is necessary to remove both right
and left parking brake cables, repeat below
steps 2) and 6) on right and left wheels.

1) Hoist vehicle.
2) Remove wheel.
3) Disconnect parking brake cable from equalizer
(parking brake lever) and clamps.
4) Remove brake drum. Refer to “Rear Brake Drum
Removal and Installation in Section 4C”.
5) Disconnect parking brake cable from brake shoe
lever referring to “Rear Brake Shoe Removal and
Installation in Section 4C”.
6) Remove parking brake cable and parking cable
bracket.
Installation
Install it by reversing removal procedure, noting the
following points.
• Install clamps properly referring to “Parking Brake
Cable Construction”.
• Tighten bolts and nuts to specified torque referring to
“Parking Brake Cable Construction”.
• Adjust parking brake cable. Refer to “Parking Brake
Inspection and Adjustment”.
• Check brake drum for dragging and brake system for
proper performance. Brake test should be performed.
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Downloaded from www.Manualslib.com manuals search engine ABS: 4E-8
Component Location
ABS Components LocationS6RW0D4503001
Diagnostic Information and Procedures
ABS CheckS6RW0D4504001
Refer to the following items for the details of each step.
1
2
6
2
6
26
264
5
7
3
8
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1. ABS hydraulic unit / control module assembly 5. EBD warning light (Brake warning light)
2. Wheel speed sensors 6. Wheel speed sensor encoder (included in wheel hub assembly)
3. Brake light switch 7. Data link connector
4. ABS warning light 8. G sensor (4WD model)
Step Action Yes No
1) Malfunction analysis
1) Perform “Customer complaint analysis: ”.
2) Perform “Problem symptom confirmation: ”.
3) Perform “DTC check, record and clearance: ” and
recheck DTC.
Is there any malfunction DTC?Go to Step 4. Go to Step 2.
2) Driving test
1) Perform “Step 2: Driving Test: ”.
Is trouble symptom identified?Go to Step 3. Go to Step 6.
3) DTC check
1) Perform “DTC Check”.
Is it malfunction code?Go to Step 4. Go to Step 5.
4) ABS check
1) Inspect and repair referring to applicable DTC flow.
Does trouble recur?Go to Step 5. Go to Step 7.
5) Brakes diagnosis
1) Inspect and repair referring to “Brakes Symptom
Diagnosis in Section 4A”.
Does trouble recur?Go to Step 3. Go to Step 7.

Downloaded from www.Manualslib.com manuals search engine 4E-9 ABS:
Step 1: Malfunction Analysis
Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown in the following will facilitate collecting information to the
point required for proper analysis and diagnosis.
Customer questionnaire (Example) 6) Check for intermittent problem
1) Check intermittent troubles referring to “Intermittent and
Poor Connection Inspection in Section 00” and related
circuit of trouble code recorded in Step 1.
Does trouble recur?Go to Step 4. Go to Step 7.
7) Final confirmation test
1) Perform “Step 7: Final Confirmation Test: ”.
Does trouble recur?Go to Step 3. End. Step Action Yes No
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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”.
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BRAKE
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Downloaded from www.Manualslib.com manuals search engine 4E-11 ABS:
DTC CheckS6RW0D4504004
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector
(1).
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Read DTC according to instructions displayed on
SUZUKI scan tool and print it or write it down. Refer
to SUZUKI scan tool operator’s manual for further
details.
NOTE
If SUZUKI scan tool can not communicate
ABS hydraulic unit / control module, perform
“Serial Data Link Circuit Check”.

5) After completing the check, turn ignition switch off
and disconnect SUZUKI scan tool from DLC.
DTC TableS6RW0D4504005
CAUTION!
Be sure to perform “ABS Check” before
starting diagnosis.

DTC ClearanceS6RW0D4504006
WARNING!
When performing a driving test, select a safe
place where there is neither any traffic nor
any traffic accident possibility and be very
careful during testing to avoid occurrence of
an accident.

After repair or replace malfunction part(s), clear all DTCs
by performing the following procedure or using SUZUKI
scan tool.
1) Connect SUZUKI scan tool to data link connector in
the same manner as when making this connection
for DTC check.
2) Turn ignition switch to ON position.
3) Erase DTC according to instructions displayed on
scan tool. Refer to scan tool operator’s manual for
further derails.
NOTE
For DTC C1022, C1026, C1032, C1036 and
C1061, confirm that ABS warning light turns
off after performing Step 2 of “Test Driving”
under “ABS Check”, and then clear the DTCs.

4) After completing the clearance, turn ignition switch
OFF and disconnect scan tool from data link
connector.
5) Perform “Driving Test” (Step 2 of “ABS Check”) and
“DTC Check” and confirm that NO DTC is displayed
on scan tool. DTC (displayed on
SUZUKI scan tool)Diagnostic Items
NO DTC Normal
)C1013 Control module mismatch
) C1015 G sensor circuit (for 4WD model)
)C1016 Brake light switch
)C1021 RF
Wheel speed sensor circuit )C1025 LF
)C1031 RR
)C1035 LR
)C1022 RF
Wheel speed sensor or
encoder )C1026 LF
)C1032 RR
)C1036 LR
)C1033 Wheel speed sensor deviation
(A)
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)C1041 RF
Inlet solenoid )C1045 LF
)C1051 RR
)C1055 LR
)C1042 RF
Outlet solenoid )C1046 LF
)C1052 RR
)C1056 LR
) C1057Power supply voltage too high / too
low
) C1061 Pump motor circuit
) C1063Solenoid valve power supply driver
circuit
) C1071 Control module internal defect DTC (displayed on
SUZUKI scan tool)Diagnostic Items

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-12
Scan Tool DataS6RW0D4504007
The parameter data below are values measured with the
scan tool when the normally operating vehicle is under
the following conditions. When taking measurements for
comparison by using the scan tool, be sure to check that
the vehicle is under the following conditions.
• Apply parking brake and block wheels.
• Ignition switch ON.
• Turn OFF air conditioner (if equipped).
• Apply no load to power steering (if equipped). (Don’t
turn it)
• Turn OFF all electric loads (except ignition).
• No DTC.
• ABS is not operated. (Normal braking operation)Scan Tool Data Definition
Battery Volt (V)
Battery Voltage is an analog input signal read by the
ABS control module. Certain ABS control module
functions will be modified if the battery voltage falls
below or rises above programmed thresholds.
Pump Motor Driver (V)
This parameter indicates the operational condition of the
pump motor driver (transistor).
RF Wheel Speed, LF Wheel Speed, RR Wheel Speed
and LF Wheel Speed (km/h, MPH)
Wheel speed is an ABS control module internal
parameter. It is computed by reference pulses from the
wheel speed sensor.
Brake Switch (ON, OFF)
This switch signal informs the ABS control module
whether the brake is active or not.
G Sensor (G)
4WD model: Vehicle acceleration is measured by G
sensor and output to ABS control module as the linear
voltage.
2WD model: Fixed 2.54 G.
Solenoid Valve Power Supply Driver (ON, OFF)
ABS control module monitor the supply voltage to
solenoid valve power supply driver. If the voltage is
supplied, ON is displayed. Beside, OFF is displayed.
Inlet Solenoid RF, Inlet Solenoid LF, Inlet Solenoid
RR, Inlet Solenoid LR (ON, OFF)
This parameter indicates the operational condition of the
inlet solenoid valve.
Outlet Solenoid RF, Inlet Solenoid LF, Inlet Solenoid
RR, Inlet Solenoid LR (ON, OFF)
This parameter indicates the operational condition of the
outlet solenoid valve. Scan Tool
DataStandards Condition
) Battery
Voltage10.0 – 16.0 V —
) Pump
Motor Driver0.0 V —
) RF Wheel
Speed0 km/h, 0.0 MPH Vehicle stop
) LF Wheel
Speed0 km/h, 0.0 MPH Vehicle stop
) RR Wheel
Speed0 km/h, 0.0 MPH Vehicle stop
) LR Wheel
Speed0 km/h, 0.0 MPH Vehicle stop
) Brake
SwitchONBrake pedal
depressed
OFFBrake pedal
released
) G sensor0.00G
(4WD model)Place vehicle on the
level
2.54G
(2WD model)Place vehicle on the
level
) Solenoid
Valve Power
Supply DriverON Ignition switch ON
) Inlet
SolenoidRF
OFF Vehicle stop LF
RR
LR
) Outlet
SolenoidRF
OFF Vehicle stop LF
RR
LR

Downloaded from www.Manualslib.com manuals search engine 4E-15 ABS:
ABS Warning Light Comes ON SteadyS6RW0D4504009
Wiring Diagram
Refer to “Warning Diagram” under “ABS Warning Light Does Not Come ON at Ignition Switch ON”.
Circuit Description
Refer to “Circuit Description” under “ABS Warning Light Does Not Come ON at Ignition Switch ON”.
Troubleshooting 3Combination meter power source circuit check
1) Remove combination meter with ignition switch turned
OFF.
2) Check for proper connection to “RED/BLK” and “BLK”
wire of combination meter connector.
3) If OK then turn ON ignition switch and measure voltage
at “RED/BLK” wire of combination meter connector and
vehicle body ground.
Is it 10 - 14 V?Go to Step 4. Repair power source
circuit for combination
meter.
4Combination meter ground circuit check
1) Measure resistance between “BLK” wire of combination
meter connector and vehicle body ground.
Is resistance less than 2
Ω?Substitute a known-
good combination meter
and recheck.“BLK” circuit open or
high resistance. Step Action Yes No
Step Action Yes No
1DTC check
1) Perform diagnostic trouble code check.
Is there any DTC(s)?Go to Step 7 of “ABS
Check”.Go to Step 2.
2ABS hydraulic unit / control module assembly power
and ground circuit check
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.
3CAN communication line circuit check
1) Turn ignition switch to OFF position.
2) Disconnect connectors of all control modules
communicating by means of CAN.
3) Check for proper connection to CAN communication line
wire.
4) If OK then check CAN communication line circuit
between control modules for open, short and high
resistance.
Is each CAN communication line circuit in good condition?Substitute a known-
good combination meter
and recheck. If warning
light remains ON,
substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.Repair circuit and
recheck.

Downloaded from www.Manualslib.com manuals search engine 4E-17 ABS:
Serial Data Link Circuit CheckS6RW0D4504011
Wiring Diagram5CAN communication line circuit check
1) Turn ignition switch to OFF position.
2) Disconnect connectors of all control modules
communicating by means of CAN.
3) Check for proper connection to CAN communication line
wire.
4) If OK then check CAN communication line circuit
between control modules for open, short and high
resistance.
Is each CAN communication line circuit in good condition?Substitute a known-
good combination meter
and recheck. If EBD
warning light remains
OFF, substitute a
known-good BCM and/
or ABS hydraulic unit /
control module
assembly and recheck.Repair CAN
communication line
circuit. Step Action Yes No
11+BBBG
G1
12V
14BLU
REDWHTE08 [C]
1
2
3
4
5
6
7 12
13
14
15
16
17
18
19
20
21
228
9
10
11
23
24
25
26WHTGRN
3
E08-2
E08-13REDWHT 5
4 12
9
E08-23BLK
67
BLK
REDWHTG241-7G241-10
G241-16
12V
E08-25E08-24
E08-9
WHT/REDWHT/BLU
GRN/ORN
9
2
1
13
G241-31
RED/BLK
8
REDWHTREDWHT
9
10
E08-16 G04-4
G04-2
G04-1
G04-3 E04-1
E04-2
[D]
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17
18 19 20 21 22G041 2 3 4 5 6 7
8 9 10 11 12 13 14E04
G241 [E]
132 4 5 6 7 8 9 10111213141516
17 1918 20 2122 23 24 25 26 27 28 29 30 31 32 [A]
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