relay SUZUKI GRAND VITARA 1999 2.G Service User Guide

YH4
GRAND
VITARA
1B-20 AIR CONDITIONING (OPTIONAL)
A / C CONTROLLER VOLTAGE VALUES TABLE
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC1-1B/WController main
power supplyGround to
engine (Fig. B)10 ± 14 voltsIgnition switch ON with engine
stopped
AC1-2B/YController main
groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
AC1 4Or
Refrigerant
p
ressure switchGround to
0 ± 1 volt
Refrigerant pressure within 225 kPa
(2.3 kg / cm
2, 32.7 psi) to 2548 kPa
(26 kg / cm
2, 370 psi) with engine
running
AC1-4Orpressure switch
inputengine (Fig. B)
10 ± 14 volts
Refrigerant pressure below
196 kPa (2.0 kg / cm
2, 28 psi) or
above 3140 kPa (32 kg / cm
2, 455 psi)
with engine running
AC1 7G/B
A / C switch input
and / or defroster
Ground to
8 ± 14 volts
Blower fan motor switch and A / C or
defroster position switch (see NOTE)
ON with engine running
AC1-7G/Bposition switch
input (see NOTE)engine (Fig. B)
0 ± 1.5 volts
Blower fan motor switch or A / C or
defroster position switch (see NOTE)
OFF with engine running
AC1 9Gr/W
Signal input from
ECM (A / C ON
Ground to10 ± 14 voltsApprove of A / C ON
AC1-9Gr/W(
permission
signal)engine (Fig. B)0 ± 1 voltA / C ON forbid
AC1-13Y/B
Signal output to
ECM (A / C ON
request signal)Ground to engine
(Fig. B)0 ± 1.5 volts
Blower fan motor switch and A / C or
defroster position switch (see NOTE)
ON with engine running at evaporator
thermistor temperature input more
than approx. 2.5
C (less than 2.5 V
(5840
)) and refrigerant pressure
switch is ON
10 ± 14 voltsExcept the above-mentioned with
engine running
AC1-16P
Compressor
magnet clutch
relay outputGround to engine
(Fig. B)0 ± 1 volt
Blower fan motor switch and A / C or
defroster position switch ON with
engine running at evaporator
thermistor temperature input more
than approx. 2.5
C (less than 2.5 V
(5840
)), refrigerant pressure
switch ON and signal input from ECM
ON
10 ± 14 voltsExcept the above-mentioned with
engine running

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-21
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC2-1L/YSensor groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
1.5 volts
(3150
)Evaporator thermistor temperature at
approx. 15C (59F) with engine
running
AC2-2W/B
Evaporator
thermistor
temperature
(evaporator temp.
sensor) input
Ground to engine
(Fig. B)
2.62 volts
(6.311
)
Evaporator thermistor temperature at
approx. 1C (34F) with engine
running
* If the temperature is less than
approx. 1C, in this case
compressor and condenser fan
should be stop (come back at more
than approx. 2.5C (less than
5840
, 2.5 V))
H25
engine
E61-27 /
G16 J20Gr/W
Signal output to
A / C controller
(A / C ON
Ground to engine
(Fig C)
10 ± 14 volts
Required A / C ON (terminal AC-A13)
at engine running with normal
condition (refer to ªINSPECTION OF
ECM AND ITS CIRCUITº in Section
6E)
G16, J20
engines
E61-8
(
permission
signal)(Fig. C)
0 ± 1 volt
Except the above-mentioned with
engine running
In this case compressor should be
stop
H25
engine
E61-28 /
Y/B
Signal input from
A / C controller
Ground to engine
0 ± 1.5 voltsRequire A / C ON
G16, J20
engines
E61-17Y/B(A / C ON request
signal)
g
(Fig. C)
10 ± 14 voltsTurn off the A / C
H25
engine
E61-5 /
G16, J20
engines
E61-22
Y/L
A / C condenser
cooling fan relay
outputGround to engine
(Fig. C)0 ± 1 volt

Blower fan motor switch and A / C or
defroster position switch (see
NOTE) ON with engine running at
evaporator thermistor temperature
input more than approx. 2.5C (less
than 2.5 V (5840
)), refrigerant
pressure switch ON and signal
input from ECM ON

Engine coolant temperature sensor
more than 113C (236F) with
engine running
10 ± 14 voltsExcept the above-mentioned with
engine running
NOTE:
Defroster position switch circuit is equipped with LH vehicle only.

YH4
GRAND
VITARA
3. Compressor and condenser cooling fan fuse
1B-48 AIR CONDITIONING (OPTIONAL)
A / C COMPRESSOR RELAY AND A / C
CONDENSER COOLING FAN RELAY
INSPECTION
1) Disconnect negative (±) cable at battery.
2) Remove condenser cooling fan motor relay (2) and / or compres-
sor relay (1) from vehicle.
3) Check that there is no continuity between terminal ªcº and ªdº.
If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal ªbº of relay.
Connect battery negative (±) terminal ªaº of relay.
Check continuity between terminal ªcº and ªdº.
If there is no continuity when relay is connected to the battery,
replace relay.

YH4
GRAND
VITARA
5-6 BRAKES
ConditionPossible CauseCorrection
Brake warning light
turns on after
engine start
Parking brake applied.

Insufficient amount of brake fluid.

Brake fluid leaking from brake line.

Brake warning light circuit faulty.

Malfunctioning EBD system, if equipped
with ABS.Release parking brake and check
that brake warning light turns off.
Add brake fluid.
Investigate leaky point, correct it and
add brake fluid.
Repair circuit.
Check system referring to
ªDIAGNOSISº of ABS section.
Brake warning light
turns on when
brake is applied
Brake fluid leaking from brake line.

Insufficient amount of brake fluid.Investigate leaky point, correct it and
add brake fluid.
Add brake fluid.
Brake warning light
fails to turn on
even when parking
brake is applied
Bulb burnt out.

Brake warning light circuit open.Replace bulb.
Repair circuit.
ABS warning light
does not turn on
for 2 sec. after
ignition switch has
turned ON
Bulb burnt out.

ABS warning light circuit open, if equipped
with ABS. (including check relay)Replace bulb.
Check system referring to
ªDIAGNOSISº of ABS section.
ABS warning light
remains on after
ignition switch has
turned on for 2 sec.
Malfunctioning ABS, if equipped with ABS.Check system referring to
ªDIAGNOSISº of ABS section.

YH4
GRAND
VITARA
Diagnostic Trouble Code (DTC) Table 5E1-14. . .
System Circuit 5E1-15. . . . . . . . . . . . . . . . . . . . . . .
Table ± A ªABSº Warning Lamp Circuit
Check ± Lamp does not come ªONº
at ignition switch on 5E1-16. . . . . . . . . . . . . . . . . .
Table ± B ªABSº Warning Lamp Circuit
Check ± Lamp comes ªONº steady 5E1-17. . . .
Table ± C ªABSº Warning Lamp Circuit
Check ± The lamp flashes continuously
while ignition switch is on5E1-18 . . . . . . . . . . . . . .
Table ± D Code (DTC) is not Outputted
even with Diag. Switch Terminal
Connected to Ground 5E1-19. . . . . . . . . . . . . . . .
Table ± E EBD Warning Lamp (Brake
Warning Lamp) Check-lamp Comes
ªONº Steady 5E1-20. . . . . . . . . . . . . . . . . . . . . . . .
DTC 15 ± G Sensor Circuit 5E1-21. . . . . . . . . . . .
DTC 21, 22, 25, 26, 31, 32, 35 or 36
± Wheel Speed Sensor Circuit 5E1-23. . . . . . . .
DTC 41, 45 or 56 ± Solenoid Circuit 5E1-26. . . . .
DTC 57 ± Solenoid and Pump Motor
Power Source Circuit 5E1-27. . . . . . . . . . . . . . . .
DTC 61 ± ABS Pump Motor Circuit 5E1-28. . . . . .
DTC 63 ± ABS Fail-Safe Relay Circuit 5E1-29. . .
DTC 71 ± ABS Control Module 5E1-30. . . . . . . . .
ON-VEHICLE SERVICE5E1-31 . . . . . . . . . . . . . . . .
Precaution 5E1-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS Hydraulic Unit Operation Check 5E1-31. . . .
ABS Hydraulic Unit / Control Module
Assembly 5E1-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic unit inspection 5E1-32. . . . . . . . . . . . . Removal 5E1-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-33. . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor 5E1-34. . . . . . . . . . . .
Output voltage inspection 5E1-34. . . . . . . . . . . .
Removal 5E1-35. . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor inspection 5E1-35. . . . . . . . . . . . . . . . . .
Sensor rotor inspection 5E1-35. . . . . . . . . . . . . .
Installation 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . .
Front Sensor Rotor 5E1-36. . . . . . . . . . . . . . . . . . .
Removal 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Speed Sensor 5E1-37. . . . . . . . . . . .
Output voltage inspection 5E1-37. . . . . . . . . . . .
Removal 5E1-37. . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor inspection 5E1-38. . . . . . . . . . . . . . . . . .
Sensor rotor inspection 5E1-38. . . . . . . . . . . . . .
Installation 5E1-38. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Sensor Rotor 5E1-39. . . . . . . . . . . . . . . . . . . .
Removal 5E1-39. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-39. . . . . . . . . . . . . . . . . . . . . . . . .
G Sensor 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . .
Transfer 4WD Switch 5E1-41. . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS5E1-41 . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5E1-42 . . . . . . . . . . . . . . . . . . . . . .
5E1-2 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
GENERAL DESCRIPTION
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 is a 4-wheel type
which controls the fluid pressure applied to the wheel cylinder of each of the four brakes to prevent each wheel
from getting locked.
The component parts of this ABS includes following parts in addition to those of the conventional brake system.

Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.

In this ABS, ABS hydraulic unit (actuator assembly), ABS control module, pump motor relay and fail-safe relay
are combined as one component.

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 of 4 wheels.

Fail-safe (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.

ªABSº warning lamp which lights to inform abnormality when system fails to operate properly.

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 sensor
independently of change of load due to load capacity and so on. And if the EBD system fails to operate properly,
the brake warning lamp lights to inform abnormality.

YH4
GRAND
VITARA
1. Front disk brake
2. Rear drum brake
3. ABS hydraulic unit / control module assembly
with ABS pump motor
relay and fail-safe relay
4. Brake master cylinder / Reservoir
LH steering vehicle
RH steering vehicle
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-3
BRAKE HOSE / PIPE ROUTING

YH4
GRAND
VITARA
1. Wheel speed sensor (Right-front)
2. Stop lamp switch
3. ABS control module
4. Wheel speed sensor (Right-rear)
5. Diagnosis connector
6. Data link connector7. Wheel speed sensor (Left-rear)
8. ªABSº warning lamp
9. ABS pump motor relay
10. ABS fail-safe relay (Solenoid valve relay)
11. Lamp drive module
12. Wheel speed sensor (Left-front)13. ABS hydraulic unit
14. G sensor (For 4WD model only)
15. 4WD switch (For 4WD model only)
16. ABS hydraulic unit / control module assembly
(with ABS pump motor & fail-safe relays)
17. ªEBDº warning lamp (Brake warning lamp)
Wheel speed sensor (LR)
Wheel speed sensor (LF)
Wheel speed sensor (RF)
Wheel speed sensor (RR)
Stop lamp switch
G sensor (For 4WD model only)
Diag. switch terminal
Battery Voltage
4WD switch (For 4WD model only)
Pump motor relay
Pump motor
LF inlet solenoid
LF outlet solenoid
LR inlet solenoid
LR outlet solenoid
Rear inlet solenoid
Rear outlet solenoid
ªABSº warning lamp
Brake warning lamp
Data link connector
Fail-safe relay
Hydraulic unit
OUTPUTINPUT
ABS control
module
ABS hydraulic unit / control
module assembly
PCM or ECMIdle up
5E1-4 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
SYSTEM SCHEMATIC

YH4
GRAND
VITARA
1. Wheel speed sensor
(Right-front)
2. Stop lamp switch
3. Data link connector
4. ªABSº warning lamp
5. Wheel speed sensor
(Right-rear)6. Wheel speed sensor
(Left-rear)
7. Ground
8. Diagnosis connector (Black connector)
9. Wheel speed sensor
(Left-front)10. ABS hydraulic unit/control module assembly
with ABS pump motor relay
and fail-safe relay
11. G sensor (For 4WD model only)
12. Wheel speed sensor rotor (ring)
13. 4WD switch (For 4WD model only)
14. EBD warning lamp (Brake warning lamp)
LH steering vehicle
RH steering vehicle
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-5
ABS COMPONENT PARTS LOCATION

YH4
GRAND
VITARA
1. Diagnosis connector
(6 pins connector)
2. Ground terminal3. Diag. switch terminal
4. Service wire
5E1-6 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
ABS HYDRAULIC UNIT/CONTROL MODULE
ASSEMBLY
ABS control module is a component of ABS hydrauli unit / control
module assembly and has the following functions.
Self-Diagnosis Function
ABS control module diagnoses conditions of the system compo-
nent parts (whether or not there is any abnormality) all the time and
indicates the results (warning of abnormality occurrence and DTC)
through the ªABSº warning lamp as described below.
1) When ignition switch is turned ON, ªABSº warning lamp lights for
2 seconds to check its bulb and circuit.
2) When no abnormality has been detected (the system is in good
condition), ªABSº warning lamp turns OFF after 2 seconds.
3) When the vehicle starts to move after the ignition switch is turned
ON (more than one wheel speed sensor signals are inputted),
solenoid valves and motor of ABS hydraulic unit operate once
one after another for electrical check.
During this check, motor operation sound may be heard but that
means nothing abnormal.
4) When an abnormality in the system is detected, ªABSº warning
lamp lights and the area where that abnormality lies is stored in
the memory of EEPROM in ABS control module.
5) When Diag. switch terminal of diagnosis connector (monitor
connector) is grounded, the abnormal area is output as DTC. It
is indicated by flashing of ªABSº warning lamp. (Refer to the
table below. )
ABS WARNING LAMP
SYSTEM CONDITIONDiag. switch
terminal is not
groundedDiag. switch
terminal is
grounded
In good condi-
No trouble in
the pastOFFDTC 12g
tion at presentTrouble occur-
red in the pastOFFHistory DTC
Abnormality
exists at
No trouble in
the pastONCurrent DTC
exists at
presentTrouble occur-
red in the pastONCurrent and
history DTCs
For procedure to clear all DTC's, refer to the item ªDiagnostic
Trouble Code Clearanceº in this section.
Also ABS control module turns ON EBD warning lamp (brake warn-
ing lamp) depending on the trouble that detected by the module and
EBD warning lamp does not indicate DTC as well as ªABSº warning
lamp.
Fail-Safe Function
When an abnormality occurs (an abnormal DTC is detected), ABS
control module turns OFF the fail-safe relay which supplies power
to ABS hydraulic unit. Thus, with ABS not operating, brakes func-
tion just like the brake system of the vehicle not equipped with ABS.

YH4
GRAND
VITARA
5E1-14 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
DIAGNOSTIC TROUBLE CODE (DTC) TABLE
DTC
(indicated
DTC
(displayedVOLTMETER INDICATION(indicated
by ABS
i
(dis layed
on
SUZUKI
VOLTMETER INDICATION
(or ªABSº warning
lflhi tt)
DIAGNOSTIC AREA
warning
lamp)SUZUKI
scan tool)
lamp flashing pattern)
15C1015G sensor (for 4WD model only)
21C1021Right-21C1021g
front
25C1025Left-25C1025front
31C1031Right-31C1031g
rear
35C1035Left-35C1035rearWheel speed sensor circuit and rotor
22C1022Right-Wheel speed sensor circuit and rotor
22C1022g
front
26C1026Left-26C1026front
32C1032Right-32C1032g
rear
36C1036Left-36C1036rear
41C1041Right-Inlet solenoid circuit41C1042
g
frontOutlet solenoid circuit
45C1045Left-Inlet solenoid circuit45C1046frontOutlet solenoid circuit
56C1055RearInlet solenoid circuit56C1056RearOutlet solenoid circuit
57C1057Solenoid and pump motor power source circuit
61C1061ABS pump motor (in hydraulic unit) circuit
63C1063ABS fail-safe relay circuit
71C1071ABS control moduleInternal malfunction
12±Normal