2008 SUZUKI SWIFT isc

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 Electronic Stability Program: 4F-55
Sensor Calibration (Using SUZUKI Scan Tool)1) Set steering wheel in straight-ahead position.
2) Connect SUZUKI scan tool to data link connector (DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position and confirm that
only any of DTC(s) C1075, C1076 and/or C1077 is
detected. If any other DTC are detected, repair the
detected DTC.
4) Park and level the vehicle with parking brake, stop engine with ignition switch ON, set steering in
straight and without step ping on the brake pedal.
NOTE
Hold the above condition in Step 4) to
calibrate sensor correctly until sensor
calibration is completed.

5) Select menu “SENSOR CALIBRATION” under
“MISC. TEST” mode of SUZUKI scan tool and
calibrate sensor. Refer to scan tool operator's
manual for further derails.
6) After completing the calibra tion, turn ignition switch
to OFF position and disconnect SUZUKI scan tool
from DLC. Steering Angle Sensor Calibration (Not Using
SUZUKI Scan Tool)
1) Set steering wheel in straight-ahead position.
2) Connect battery terminals and/or fuse and start engine.
NOTE
When power is not supplied to the steering
angle sensor by removing battery or fuse,
DTC C1075 is detected and SLIP indicator
lamp (1) flashes.
If DTC other than C1075 is detected, SLIP
indicator lamp flushes and other indicator
illuminate. In that case, repair the detected
DTC first.

3) Drive vehicle straight on level ground at 15 km/h (9.5 mph) or above for few seconds without spinning
wheels. And confirm that SLIP indicator lamp is OFF.
ESP ® Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection
S7RS0B4606027
CAUTION!
Never disassemble ESP ® hydraulic unit /
control module assembly, loosen blind plug
or remove motor. Pe rforming any of these
prohibited services will affect original
performance of ESP ® hydraulic unit / control
module assembly.

Check hydraulic unit for fluid leakage.
If any, repair or replace.
(A)
1
I4RS0B450003-01
1
I6RS0B460028-02

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 Electronic Stability Program: 4F-57
3) Remove front brake pipe referring to “Front Brake Hose / Pipe Removal and In stallation in Section 4A”.
4) Remove ESP ® hydraulic unit / control module with
bracket from vehicle by removing bracket bolts.
5) Remove bolt (4) and pull out ESP ® hydraulic unit /
control module assembly (1) from bracket (3) using
flat end rod or the like (2).
Installation 1) Install hydraulic unit / co ntrol module assembly and
by reversing removal procedure.
Tightening torque
Brake pipe flare nut: 16 N·m (1.6 kgf-m, 11.5 lb-
ft)
ESP ® hydraulic unit / control module assembly
bolt: 9 N·m (0.9 kgf-m, 6.5 lb-ft)
ESP ® hydraulic unit / control module assembly
bracket bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage.
4) Connect SUZUKI Scan Tool.
5) Turn ignition switch to ON position. And SLIP indicator lamp flush. (Other than replace with new
one) If other than SLIP indicator lamp light, check
DTC and repair it.
6) Turn ignition switch to ON position. And ESP®
warning lamp, SLIP indicator lamp, ESP ® OFF
lamp, Brake warning lamp lights and ABS warning
lamp flush. (Replace new one)
7) Check DTC.
NOTE
If any DTC(s) other than C1075, C1076 or
C1078 are detected, sensor calibration can
not be completed. Repair the detected it(s)
first.

8) Perform “Sensor Calibration”.
9) Perform “ESP ® Hydraulic Unit Operation Check”.
10) Turn ignition switch to OFF position once and then
ON position. In this state, make sure that indicator
light and warning light turns off.
11) Check DTC(s) are not stored in hydraulic unit / control module.
Front / Rear Wheel Speed Sensor On-Vehicle
Inspection
S7RS0B4606028
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

Output Voltage Inspection
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Disconnect wheel speed grommet from vehicle body.
5) Set up measuring devices as shown in figure, the resistance to 115 Ω and the power supply voltage
to12 V.
4
1
2 3
I6RS0B460030-02
[A]: Front wheel speed sensor 3. “WHT” wire terminal
[B]: Rear wheel speed sensor 4. “BLK” wire terminal
1. Wheel speed sensor connector 5. Power supply (12 V)
2. Resistance (115 Ω)
V
2
5
4 1
3
43
1
[A]
[B]
I6RS0B460031-02

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-62 Electronic Stability Program:
4) 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.
5) When brake pedal is released, check “Master Cyl Press” under “DATA LIST” of SUZUKI scan tool.
If pressure is out of specification, replace ESP ®
hydraulic unit / cont rol module assembly.
Master cylinder pressure specification
Brake pedal released: 0 ± 0.8 MPa (0 ± 8 kg/cm2, 0
± 113 psi)
6) Hoist vehicle and remove right-side front wheel.
7) Connect special tool with rubber hose (1) to Front brake caliper bleeder plug (2).
Special tool
(A): 09956–02311
8) When bleeder plug loosen and depress brake pedal to make special tool gauge reading 10 MPa (100 kg/
cm
2, 1422 psi), check “Master Cyl Press” under
“DATA LIST” of SUZUKI scan tool.
If pressure displayed on SUZUKI scan tool is out of
specification, replace ESP ® hydraulic unit / control
module assembly.
Master cylinder pressure specification
Brake pedal depressed 10 MPa (100 kg/cm2, 1422
psi): 10 ± 1.2 MPa (100 ± 12 kg/cm2, 1422 ± 170
psi)
9) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
10) Tighten bleeder plug and bleed air from brake system, referring to “Air Bleeding of Brake System in
Section 4A”.
Yaw Rate / G Sensor Assembly On-Vehicle
Inspection
S7RS0B4606017
Lateral G Inspection
1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Park and level the vehicle with parking brake and fix wheels with chokes.
3) Check yaw rate / G sensor assembly installation
condition. 4) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
5) 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.
6) Check “G Sensor (lateral)” under “DATA LIST” of SUZUKI scan tool in the following vehicle conditions.
• Level condition
• Right-up condition
• Left-up condition
If Lateral G condition is ou t of specification, replace
yaw rate / G sensor assembly.
Lateral G sp ecification
2
(A)
1
I6JB01460025-01
Vehicle condition G Sensor (lateral)
Level condition 0 ± 0.1 G
Right-up condition 0.1 ± 0.1 G
Left-up condition –0.1 ± 0.1 G
[A]: Right-up condition “a”: Approx 350 mm (13.78 in.)
[B]: Left-up condition 1. Safety stand
(A)
1
I4RS0B450003-01
[A]
[B]“a”
1
“a”1
I6RS0B460039-02

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