brake sensor SUZUKI GRAND VITARA 1999 2.G Owners Manual

3E-4 REAR SUSPENSION
5) Apply grease “A” to axle shaft inner oil seal lip as shown in
the figure.
“A” : Grease 99000-25010
6) Apply water tight sealant “B” to mating surfaces of brake
back plate and rear axle hub (2).
“B” : Water tight sealant 99000-31110
7) Install rear axle shaft to rear axle housing and tighten bear-
ing retainer nuts to specified torque.
Rear axle shaft length “L”
Left side : 700.5 mm (27.6 in.)
Right side : 769.5 mm (30.3 in.)
Tightening torque
Bearing retainer nut (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
8) Tighten wheel speed sensor bolt to specified torque (if
equipped with ABS).
Tightening torque
Wheel speed sensor bolt (b) : 21 N·m (2.1 kg-m, 15.5 lb-ft)
9) Refill rear axle housing with new specified gear oil.
Refer to “MAINTENANCE SERVICE” in Section 7F.
10) Install brake drum. Refer to “BRAKE DRUM” in Section 5C.
1. Axle housing
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.
(b)

3E-6 REAR SUSPENSION
5) Apply thread lock cement to thread of propeller shaft flange
bolt if reused. Install propeller shaft to joint flange aligning
match marks and torque flange nuts to specification.
“A” : Cement 99000-32110
Tightening torque
Propeller shaft nut (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
Tightening Torque Specification
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Shock absorber nut 29 2.9 21.0
Shock absorber lower nut 85 8.5 61.5
Lower rod bolt and nut 100 10.0 72.5
Upper rod bolt and nut 100 10.0 72.5
Lateral rod bolt 100 10.0 72.5
Differential carrier bolt 55 5.5 40.0
Propeller shaft nut 60 6.0 43.5
Brake pipe flare nut 16 1.6 11.5
Bearing retainer nut 50 5.0 36.5
Differentiation gear oil filler & drain plug (filler plug) 50 5.0 36.5
Differentiation gear oil filler & drain plug (drain plug) 27 2.7 16.0
Wheel nut 100 10.0 72.5
Wheel speed sensor bolt 21 2.1 15.5
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
Brake fluid DOT 3Brake reservoir tank
Sealant SUZUKI BOND NO. 1215
(99000-31110)Joint seam of axle and brake back plate
Joint seam of bearing retainer and brake
back plate
Joint seam of differential carrier and axle
housing
Drain plug
Mating surface of oil seal and axle housing
Gear oil For gear oil information, refer to Section 7FDifferential gear (Rear axle housing)
Thread lock
cementTHREAD LOCK CEMENT SUPER 1322
(99000-32110)Rear propeller shaft flange bolts

PARKING AND REAR BRAKE 5C-3
On-Vehicle Service
Parking Brake CableBrake Drum
INSPECTION
Brake drum
Inspect drum for cleanliness. Check wear of its braking surface by
measuring its inside diameter.
Whenever brake drums are removed, they should be thoroughly
cleaned and inspected for cracks, scores, deep grooves.Brake dram inside diameter “a ”
S ta n dard : 2 54 mm (9.99 in .)
S erv ic e L im it : 2 56 m m ( 10.07 i n.)
1. Parking brake switch 6. Equalizer 11. Color ring 16. Crossmember 21. Parking brake cable nut
2. Parking brake lever 7. Pin 12. Cable 17. Chassis frame Tightening torque
3. Parking brake lever bolt 8. Equalizer 13. Grommet 18. Hanger
4. Floor 9. Adjust rod 14. Bolt 19. Rear axle
5. Locking nut 10. Coupler 15. Clamp (if equipped) 20. G-sensor (if equipped)

ANTILOCK BRAKE SYSTEM (ABS) 5E2-1
5E2
SECTION 5E2
ANTILOCK BRAKE SYSTEM (ABS)
CONTENTS
General Description ..................................... 5E2-3
Components/Parts Location ....................... 5E2-3
ABS Hydraulic Unit/control Module
Assembly .................................................... 5E2-4
Self-diagnosis function ........................... 5E2-4
Fail-safe function .................................... 5E2-5
Diagnosis ...................................................... 5E2-5
Precautions in Diagnosing Troubles .......... 5E2-5
ABS Diagnostic Flow Table ........................ 5E2-6
ABS Warning Lamp Check ........................ 5E2-9
EBD Warning Lamp (Brake Warning Lamp)
Check ......................................................... 5E2-9
Diagnostic Trouble Code (DTC) Check
(Using ABS Warning Lamp) ..................... 5E2-10
Diagnostic Trouble Code (DTC) Check
(Using SUZUKI Scan Tool) ...................... 5E2-11
Diagnostic Trouble Code (DTC)
Clearance ................................................. 5E2-11
Diagnostic Trouble Code (DTC) Table ..... 5E2-12
System Circuit .......................................... 5E2-14Table-A ABS Warning Lamp Circuit Check
– Lamp Does Not Come “ON” at Ignition
Switch ON ................................................ 5E2-15
Table-B ABS Warning Lamp Circuit Check
– Lamp Comes “ON” Steady.................... 5E2-16
Table-C ABS Warning Lamp Circuit Check
– The Lamp Flashes Continuously While
Ignition Switch Is ON ................................ 5E2-17
Table-D Code (DTC) Is Not Outputted
Even with Diagnosis Switch Terminal
Connected to Ground............................... 5E2-18
Table-E EBD Warning Lamp (Brake
Warning Lamp) Check – Lamp Comes
“ON” Steady ............................................. 5E2-19
DTC C1015 (DTC 15) – G Sensor Circuit
and 4WD Lamp Circuit ............................. 5E2-20
DTC C1021 (DTC 21), DTC C1022
(DTC 22) – Right-Front Wheel Speed
Sensor Circuit or Sensor Ring ................. 5E2-22
DTC C1025 (DTC 25), DTC C1026
(DTC 26) – Left-Front Wheel Speed WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to Section 5E1 of the Service Manual
mentioned in the FOREWORD of this manual.
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.

5E2-2 ANTILOCK BRAKE SYSTEM (ABS)
Sensor Circuit or Sensor Ring ................. 5E2-22
DTC C1031 (DTC 31), DTC C1032
(DTC 32) – Right-Rear Wheel Speed
Sensor Circuit or Sensor Ring ................. 5E2-22
DTC C1035 (DTC 35), DTC C1036
(DTC 36) – Left-Rear Wheel Speed
Sensor Circuit or Sensor Ring ................. 5E2-22
DTC C1041 (DTC 41) – Right-Front Inlet
Solenoid Circuit ........................................ 5E2-24
DTC C1045 (DTC 45) – Left-Front Inlet
Solenoid Circuit ........................................ 5E2-24
DTC C1055 (DTC 55) – Rear Inlet
Solenoid Circuit ........................................ 5E2-24
DTC C1042 (DTC 42) – Right-Front
Outlet Solenoid Circuit ............................. 5E2-24
DTC C1046 (DTC 46) – Left-Front Outlet
Solenoid Circuit ........................................ 5E2-24
DTC C1056 (DTC 56) – Rear Outlet
Solenoid Circuit ........................................ 5E2-24
DTC C1057 (DTC 57) – Power Source Circuit....................................................... 5E2-25
DTC C1061 (DTC 61) – ABS Pump Motor
Circuit....................................................... 5E2-26
DTC C1063 (DTC 63) – ABS Fail-Safe
Relay Circuit ............................................ 5E2-27
DTC C1071 (DTC 71) – ABS Control
Module ..................................................... 5E2-28
On-Vehicle Service .................................... 5E2-29
Precautions .............................................. 5E2-29
ABS Hydraulic Unit Operation Check
(Using SUZUKI Scan Tool) ...................... 5E2-29
ABS Hydraulic Unit Operation Check
(Not Using Suzuki Scan Tool).................. 5E2-29
ABS Hydraulic Unit/Control Module
Assembly ................................................. 5E2-31
Rear Sensor Rotor (Retainer Ring) ......... 5E2-33
Tightening Torque Specification.............. 5E2-34
Special Tool ............................................... 5E2-34

ANTILOCK BRAKE SYSTEM (ABS) 5E2-3
General Description
Components/Parts Location
The ABS (Antilock Brake System) controls the fluid pressure applied to the wheel cylinder of each brake from
the master cylinder so that each wheel is not locked even when hard braking is applied.
This ABS has also the following function.
While braking is applied, but before ABS control becomes effective, braking force is distributed between the
front and rear so as to prevent the rear wheels from being locked too early for better stability of the vehicle.The
main component parts of this ABS include the following parts in addition to those of the conventional brake sys-
tem.
Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.
ABS warning lamp which lights to inform abnormality when system fails to operate properly.
ABS hydraulic unit/control module assembly is incorporated ABS control module, ABS hydraulic unit (actua-
tor assembly), fail-safe relay and pump motor relay.
–ABS control module which 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 which operates according to signal from ABS control module to control fluid pressure
applied to wheel cylinder of each 4 wheels.
–Fail-safe relay (solenoid valve) relay which supplies power to solenoid valve in ABS hydraulic unit and
pump motor relay.
–Pump motor relay which supplies power to pump motor in ABS hydraulic unit.
G sensor which detects body deceleration speed. (For 4WD model only)
This ABS is equipped with Electronic Brake force Distribution (EBD) system that controls a fluid pressure of rear
wheels to best condition, which is the same function as that of proportioning valve, by the signal from wheel sen-
sor independently of change of load due to load capacity and so on. And if the EBD system fails to operate prop-
erly, the brake warning lamp lights to inform abnormality.
1. Wheel speed sensor (Right-front) 6. Wheel speed sensor (Left-rear) 11. G sensor (For 4WD model only)
2. Stop lamp switch 7. Ground 12. Wheel speed sensor rotor (ring)
3. Data link connector 8. Diagnosis connector (Black connector) 13. 4WD switch (For 4WD model only)
4.“ABS” warning lamp 9. Wheel speed sensor (Left-front) 14. EBD warning lamp (Brake warning lamp)
5. Wheel speed sensor (Right-rear) 10. ABS hydraulic unit/control module assembly
(with ABS pump motor relay and fail-safe relay)
NOTE:
Above figure shows left-hand steering vehicle.
For right-hand steering vehicle, parts with (*) are installed at the side of symmetry.

5E2-8 ANTILOCK BRAKE SYSTEM (ABS)
b) 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 cus-
tomer if possible.) Check warning lamps related to brake system referring to “EBD WARNING LAMP
(BRAKE WARNING LAMP) CHECK” and “ABS WARNING LAMP CHECK” in this section.
c) Diagnostic Trouble Code (DTC) Check, Record and Clearance
Perform “DIAGNOSTIC TROUBLE CODE CHECK” procedure in this section, record it and then clear it
referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section.
If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again
when the ignition switch is turned ON, attempt to diagnose the trouble based on the DTC recorded in this
step may mislead the diagnosis or make diagnosing difficult. Proceed to Step 2) to check control module for
proper self-diagnosis function.
If the malfunction DTC which was once displayed and then cleared can be detected (indicated) again when
ignition switch is turned ON, proceed to Step 3).
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 light) 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” as shown in the following page.
4) DIAGNOSTIC TROUBLE CODE FLOW TABLE
According to Diagnostic flow table for the diagnostic trouble code 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.
5)“DIAGNOSIS” IN “BRAKES” SECTION
Check the parts or system suspected as a possible cause referring to “DIAGNOSIS” in “BRAKES” section
and based on symptoms appearing on the vehicle (symptom obtained through Steps 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 “GENERAL INFORMATION” section 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 no DTC is indicated.

5E2-10 ANTILOCK BRAKE SYSTEM (ABS)
Diagnostic Trouble Code (DTC) Check (Using
ABS Warning Lamp)
1) Perform ABS WARNING LAMP CHECK described above.
2) Using service wire (4), connect diagnosis switch terminal (2)
of monitor coupler (1) to ground (3).
3) Turn ignition switch ON.
4) Read flashing of ABS warning lamp which represents DTC
as shown in example below and write it down. When more
than 2 DTCs are stored in memory, flashing for each DTC is
repeated three times starting with the smallest DTC number
in increasing order.
For details of DTC, refer to “DTC TABLE”.
Example : When right-front wheel speed sensor circuit opens (DTC 21)
5) After completing the check, turn ignition switch off, discon-
nect service wire from monitor coupler.

5E2-12 ANTILOCK BRAKE SYSTEM (ABS)
4) Repeat disconnecting and reconnecting of service wire
between diagnosis and ground terminals 5 times or more at
about 1sec. interval within 10 seconds.
5) Turn ignition switch OFF and disconnect service wire from
monitor coupler.
6) Perform “DRIVING TEST” (Step 2 of “ABS DIAGNOSTIC
FLOW TABLE” in this section) and “DTC CHECK” and con-
firm that normal DTC (DTC 12) is displayed ; not malfunction
DTC.
Diagnostic Trouble Code (DTC) Table
O : Open
S : Short
T : About 10 seconds
NOTE:
It is also possible to clear DTC by using SUZUKI scan
tool. Refer to Cartridge Manual for procedure to clear
DTC.
CAUTION:
Be sure to perform “ABS DIAGNOSTIC FLOW TABLE” before starting diagnosis.
DTC
(displayed
on SUZUKI
scan tool)DTC
(indicated by
ABS warning
lamp)ABS warning lamp flashing
patternDIAGNOSTIC ITEMS
NO DTC 12 Normal
C1015 15 G sensor circuit and 4WD lamp circuit
C1021 21 RF
Wheel speed sensor circuit C1025 25 LF
C1031 31 RR
C1035 35 LR

ANTILOCK BRAKE SYSTEM (ABS) 5E2-13
C1022 22 RF
Wheel speed sensor circuit
or sensor ring C1026 26 LF
C1032 32 RR
C1036 36 LR
C1041 41
RFInlet solenoid valve circuit
C1042 42 Outlet solenoid valve circuit
C1045 45
LFInlet solenoid valve circuit
C1046 46 Outlet solenoid valve circuit
C1055 55
REARInlet solenoid valve circuit
C1056 56 Outlet solenoid valve circuit
C1057 57 Power source
C1061 61 ABS pump motor and/or motor relay circuit
C1063 63 Fail safe-relay
C1071 71 ABS control moduleDTC
(displayed
on SUZUKI
scan tool)DTC
(indicated by
ABS warning
lamp)ABS warning lamp flashing
patternDIAGNOSTIC ITEMS