2008 SUZUKI SWIFT Eps system

Downloaded from www.Manualslib.com manuals search engine Charging System: 1J-7
With Charging Equipment
CAUTION!
When jump starting engine with charging
equipment, be sure equipment used is 12-
volt and negative ground. Do not use 24-volt
charging equipment. Using such equipment
can cause serious damage to electrical
system or electronic parts.

Battery Dismounting and RemountingS7RS0B1A06002
WARNING!
When handling battery, following safety
precautions should be followed:
• Hydrogen gas is produced by battery. A flame or spark near battery may cause the
gas to ignite.
• Battery fluid is highly acidic. Avoid spilling on clothing or other fabric. Any spilled
electrolyte should be flushed with large
quantity of water and cleaned immediately.

Dismounting
1) Disconnect negative cable (1).
2) Disconnect positive cable (2).
3) Remove retainer (3).
4) Remove battery (4).
Remounting 1) Reverse removal procedure.
2) Tighten battery cables securely.
Water Pump / Generator Drive Belt Tension
Inspection and Adjustment
S7RS0B1A06003
WARNING!
Disconnect negative cable at battery before
checking and adjusting belt tension.

1) Inspect belt for cranks, cuts, deformation, wear and clealiness. If it is necessary to replace belt, refer to
“Water Pump / Generator Drive Belt Removal and
Installation”.
2) Check belt for tension. Belt is in proper tension when it deflects the following specification under thumb
pressure (about 10 kg or 22 lb.).
If belt tension is out of spec ification, go to next steps.
Water pump / generator drive belt tension
“a”
Existing belt: 4.5 – 5.5 mm (0.18 – 0.22 in.) as
deflection / 10 kg (22 lbs)
New belt: 3.5 – 4 mm (0.14 – 0.16 in.)as deflection
/ 10 kg (22 lbs)
5. Body ground bolt
1
3 5
2
4
I4RS0B1A0006-01
“a”
I5JB0A1A0008-01

Downloaded from www.Manualslib.com manuals search engine 2B-15 Front Suspension:
Front Suspension Frame, Stabilizer Bar and/or Bushings ComponentsS7RS0B2206014
Front Suspension Frame, Stabilizer Bar and/or
Bushings Removal and Installation
S7RS0B2206015
WARNING!
Do not touch exhaust system to avoid danger
of being burned when it is still hot.
Any service on exhaust system should be
performed when it is cool.
When removing front suspension frame, be
sure to apply some supporting equipment
(such as mission jack) under it at well-
balanced position in the center section so as
to prevent from its drop.

Removal
CAUTION!
Be sure to set front wheels (tires) in straight
direction and remove ignition key from key
cylinder before performing the following
steps; otherwise, contact coil of air bag
system may get damaged.

1) Remove steering joint cover.
2) Make alignment marks (1) on pinion shaft (2) and joint of steering lower shaft (3) for a guide during
reinstallation.
3) Loosen joint bolt (steering column side) (4) and remove joint bolt (pin ion shaft side) (5) and
disconnect steering lower shaft (3) from pinion shaft
(2).
I6RS0C220016-01
A: View A 4. Stabilizer bar mounting
bracket bolt 8. Suspension control arm mounting bolt : 50 N
⋅m (5.0 kgf-m, 36.5 lb-ft)
1. Stabilizer bar 5. Stabilizer joint 9. Front suspension frame : 150 N⋅m (15.0 kgf-m, 108.5 lb-ft)
2. Stabilizer bushing 6. Stabilizer joint nut10. Front suspension frame mounting bolt : 95 N ⋅m (9.5 kgf-m, 68.0 lb-ft)
3. Stabilizer mounting bracket 7. Suspension control arm : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft) : Do not reuse.
5
2
1
5
34
3
I4RS0B630013-01

Downloaded from www.Manualslib.com manuals search engine 4D-3 Parking Brake:
6) Release parking brake lever and then make sure that there is no drag in rear wheel.
If there is, repeats go to step 2).
7) Make sure that the number of notch is between 4 and 9 when operating parking brake lever.
8) If the number of notch is not between 4 and 9, replace parking brake cable and/or inspect rear
brake caliper.
Parking brake stroke
When lever is pulled up at 200 N (20kg, 44lbs) : 4
to 9 notches
Parking Brake Cable Removal and InstallationS7RS0B4406002
Removal
NOTE
When it is necessary to remove both right
and left parking brake cables, repeat below
steps 2) and 5) on right and left wheels.

1) Hoist vehicle.
2) Remove wheel.
3) Disconnect parking brake cable from equalizer (parking brake lever) and clamps.
4) Disconnect parking brake cable from lever referring to “Rear Disc Brake Caliper Removal and Installation
in Section 4C”.
5) 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”.
Tightening torque
Parking brake lever bolt: 25 N·m (2.5 kgf-m, 18.0
lb-ft)
Parking cable clamp bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
Parking cable bracket bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Adjust parking brake cable. Refer to “Parking Brake Inspection and Adjustment”.
• Check brake disc for dragging and brake system for proper performance. Brake test should be performed.
Parking Brake Lever Removal and InstallationS7RS0B4406003
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.

I4RS0A440004-01
I4RS0A440005-01

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” proced ure, 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 performi ng 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 for more than a minute
and check if any trouble symptom (such as abnormal
lighting of ABS warn ing light) exists.
If the malfunction DTC is co nfirmed 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, con nector, 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 CheckS7RS0B4504002
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
S7RS0B4504003
NOTE
Perform this check on a level place.

1) Turn ignition switch ON with parking brake applied.
2) Check that EBD warning lig ht (brake warning light)
(1) is turned ON.
3) Release parking brake with ignition switch ON and check that EBD warning lig ht (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 4E-13 ABS:
ABS Warning Light Does Not Come ON at Ignition Switch ONS7RS0B4504008
Wiring Diagram
Circuit Description
Operation (ON/OFF) of ABS warning light is controlled by ABS contro l module through lamp driver module in
combination meter.
If the antilock brake system is in good condition, ABS control module turns 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 la mp driver module when the
connector of ABS control module is disconnected.
Troubleshooting
WHT/BLU
BLK 12V
9
BLK
E03-14
E03-13
E03-26
WHT/RED
GRN/ORNE03-7WHT/BLUGRN
1
2
3
48
RED/BLK
76
5
10
E03-112V[A]
E03
15
16
17
18
19
20
21
22
23
24
25 2
3
4
5
6
7
8
9
10
11
12
1
13
14
26
BLK/ORN
E03-12
E03-6
REDWHT
10
G28-8
G28-10
REDWHTE46-1
E46-2
RED/BLK
RED/BLK
RED
RED
WHT
WHT
12
13
11
10
G37-2
G37-4
I6RS0C450007-01
[A]: ABS hydraulic unit / control module connector (viewed from terminal side) 5. Combination meter 10. CAN driver
1. Battery 6. ABS warning light 11. BCM
2. Main fuse box 7. EBD warning light (Brake warning light) 12. Brake fluid level switch
3. Ignition switch 8. Lamp driver module 13. Parking brake switch
4. Circuit fuse box 9. ABS hydraulic unit / control module assembly
Step Action YesNo
1 1) Turn ignition switch to ON position.
Do other warning lights come ON? Go to Step 2.
Go to Step 3.
2 1) Connect scan tool to DLC with ignition switch turned OFF.
2) Turn ignition switch to ON position and check DTC.
Is there DTC U1073? Go to “DTC U1073:
Control Module
Communication Bus
Off”.
Substitute a known-
good combination meter
and recheck. If ABS
warning light remains
OFF, substitute a
known-good ABS
hydraulic unit / control
module assembly and
recheck.
3 Is Circuit fuse fo r combination meter in good condition? Go to Step 4.Replace fuse and check
for short circuit to
ground.

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-14
ABS Warning Light Comes ON SteadyS7RS0B4504009
Wiring Diagram
Refer to “ABS Warning Light Does Not Come ON at Ignition Switch ON”.
Circuit Description
Operation (ON/OFF) of ABS wa rning light is controlled by ABS contro l module through lamp driver module in
combination meter.
If the Antilock brake system is in good condition, ABS control module turns ABS warning lig ht 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 c ontrol module. Also, it is turned ON continuously by la mp driver module when the
connector of ABS control module is disconnected.
Troubleshooting 4 Check CAN communication circuit between combination
meter and ABS control module referring to “DTC U1073:
Control Module Communication Bus Off”.
Is CAN communication circuit in good condition? Go to Step 5.
Repair or replace.
5 1) Remove combination meter wit h ignition switch turned
OFF.
2) Check for proper connection to “RED/BLK” and “BLK/ ORN” wire of combinat ion meter connector.
3) If OK, turn ON ignition switch and measure voltage at “PPL/RED” wire of combi nation meter connector and
vehicle body ground.
Is it 10 – 14 V? Go to Step 6.
Repair power supply
circuit for combination
meter.
6 1) Measure resistance between “BLK/ORN” wire of combination meter connector and vehicle body ground.
Is resistance less than 2
Ω? Replace combination
meter.
“BLK/ORN” circuit open
or high resistance.
Step Action Yes No
Step
Action YesNo
1 1) Perform diagnostic trouble code check.
Is there any DTC(s)? Go to applicable DTC
diag. flow.
Go to Step 2.
2 Are main fuses for ABS pump motor and ABS solenoid in
good condition? Go to Step 3.
Replace fuse and check
circuit for short to
ground.
3 1) Turn ignition switch to OFF.
2) Disconnect ABS control module connector.
3) Check for proper connection to ABS control module connector at terminals “E03-7”, “E03-13” and “E03-26”.
4) If OK then turn ignition switch to ON position and measure voltage between terminal “E03-7” and vehicle
body ground.
Is it 10 – 14 V? Go to Step 4.
“GRN/ORN” circuit
open.
4 1) Turn ignition switch to OFF position. 2) Check for proper connection to ABS control module connector at terminals “E03-1” and “E03-14”.
3) If OK then turn ignition switch to ON position and measure voltage between each terminal of “E03-1”,
“E03-14” and vehicle body ground.
Are they 10 – 14 V? Go to Step 5.
“WHT/RED” and/or
“WHT/BLU” circuit
open.

Downloaded from www.Manualslib.com manuals search engine 4F-14 Electronic Stability Program:
Step 2: Driving Test
Test the vehicle at 40 km/h for more than a minute including left and right turns and check if any trouble symptom
(such as ESP ® warning lamp and/or ABS warning lamp) exists.
If the malfunction DTC is confirmed at ignition switch ON, proceed to Step 3.
If the malfunction DTC is not confirmed at ignition switch ON, proceed to Step 6.
Step 3: DTC Check
Recheck DTC referring to “DTC Check”.
Step 4: ESP ® Check
According to ESP ® 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 obtain ed through Steps 1 and 2 and repair or replace faulty
parts, if any).
Step 6: Intermittent Problem Check
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 ESP ® is free from any abnormal conditions. If what has been
repaired is related to the malfunction DTC, clear the DTC once referrin g to “DTC Clearance” and perform test driving
and confirm that no DTC is indicated.
ESP ® Warning lamp CheckS7RS0B4604022
1) Turn ignition switch ON.
2) Check that ESP ® warning lamp (1) comes ON for
about 2 seconds and then goes off.
If any faulty condition is found, advance to “ESP ®
Warning Lamp Does Not Come ON at Ignition Switch
ON” or “ESP ® Warning Lamp Comes ON Steady”.
ABS Warning Lamp CheckS7RS0B4604046
1) Turn ignition switch ON.
2) Check that ABS warning lamp (1) comes ON for
about 2 seconds and then goes off.
If any faulty condition is found, advance to “ABS
Warning Lamp Does Not Come ON at Ignition Switch
ON” or “ABS Warning Lamp Comes ON Steady”.
1
I6RS0B460009-01
11
I4RS0A450007-01

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-21
Stability control (ACTIVE, INACTIVE): This indicates
stability control in acti vation / deactivation.
TCS control (brake) ( ACTIVE, INACTIVE): This
indicates brake function of TCS in activation /
deactivation.
TCS control (engine) (ACTIVE, INACTIVE): This
indicates torque control of TCS in activation /
deactivation. ESP®
off state (cont) (ESP ® ON, ESP ® OFF): State
of ESP ® OFF switch.
Steering angle Sen (Neutral, NON newtral): This
indicates steering wheel angle measured by steering
angle sensor is in straight-ahead or not.
Visual InspectionS7RS0B4604059
Check the following parts and systems visually.
ESP ® Warning Lamp Does Not Come ON at Ignition Switch ONS7RS0B4604008
Wiring Diagram
Circuit Description
Operation (ON/OFF) of ESP ® warning lamp is controlled by ESP ® control module through lamp driver module in
combination meter.
If ESP ® system is in good condition, ESP ® control module turns ESP ® warning lamp 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, ESP ® warning lamp is
turned ON continuously by ESP ® control module. Also, it is turned ON continuously by lamp driver module when the
connector of ESP ® control module is disconnected.Inspection Item Referring section
Battery Level, leakage “Battery Description in Section 1J”
Connectors of electric wire
harness Disconnection, friction“Intermittent and Poor Connec
tion Inspection in Section
00”
Fuses Burning
Brake fluid Level, leakage “Brake Fluid Level Inspection in Section 4A”
Other parts that can be checked visually
[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
WHTGRN
3
E85-13
E85-44REDWHT6 5E46-1E46-2
4 10
6
E85-16
E85-47BLKBLK
8
9
BLK/ORN
REDWHT
REDWHT
G37-4G37-2
G28-10G28-8
G28-16
12V
12VE85-32E85-1
E85-35
WHT/REDWHT/BLU
GRN/ORN
6
2
1
7 1112[B]
G37
E46124
53
67
891011121314124
53
67
891011
1213141516171819202122
[C] G28
12345678910111213141516
17181920212223242526272829303132
G28-31
RED/BLK
I6RS0B460010-01
[A]: ESP ® control module connector (viewed from terminal side) 3. Ignition switch 8. ESP ® warning lamp
[B]: BCM connector (viewed from harness side) 4. Junction block assembly 9. Lamp driver module
[C]: Combination meter connector (viewed from harness side) 5. BCM (included in junction
block assembly) 10. ESP
® hydraulic unit / control module assembly
1. Battery 6. CAN driver 11. Junction connector
2. Main fuse box 7. Combination meter 12. To steering angle sensor