System SUZUKI GRAND VITARA 2000 2.G Service Workshop Manual

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GRAND
VITARA
1. Parking brake cable
2. Equalizer
3. Pin
4. Parking brake lever bolt
5. Parking brake lever assembly
5C-4 PARKING AND REAR BRAKE
INSTALLATION
1) Install in reverse order of REMOVAL procedure.
Check equalizer inclined angle.
Angle ªaº: within 15 degrees
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
2) After all parts are installed, parking brake lever needs to be ad-
justed. Refer to PARKING BRAKE INSPECTION AND AD-
JUSTMENT in Section 5.
3) Check brake drum for dragging and brake system for proper per-
formance.

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1. Brake back plate
2. Cable cap
3. Brake cable
1. Parking brake shoe lever
2. Spring
3. Nipple end
5C-6 PARKING AND REAR BRAKE
INSTALLATION
Install parts in reverse order of removal procedure, noting the fol-
lowing.
1) Install brake cable cap to brake back plate securely as shown in
figure.
NOTE:
Color ring or tape on brake cable is for the purpose of identi-
fication. Use cable with the same colored ring as before re-
moval.
2) Install brake cable spring and nipple end to parking brake shoe
lever securely as shown in figure.
3) For brake shoe installation, refer to steps 1) and 4) of BRAKE
SHOE INSTALLATION of this section.
4) For brake drum installation, refer to steps 1) and 3) of BRAKE
DRUM INSTALLATION of this section.
5) For proper routing and secure clamping of parking brake cable.
6) For installation of cable to parking brake lever, refer to PARKING
BRAKE LEVER INSTALLATION of this section.
7) Upon completion of installation, adjust cable. (Refer to PARK-
ING BRAKE CHECK AND ADJUSTMENT in Section 5.) Then
check brake drum for dragging and brake system for proper per-
formance. After removing vehicle from hoist, brake test should
be performed.

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2
1. Wheel cylinder
2. Gasket
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts
PARKING AND REAR BRAKE 5C-13
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to steps 1) to 5) of BRAKE SHOE
INSTALLATION.
NOTE:
Be sure to bleed brake system. (for bleeding operation, re-
fer to BLEEDING BRAKES in Section 5.)
INSTALLATION (For gasket sealed type)
1) Install gasket to joint seam of wheel cylinder and brake back
plate. Then take off bleeder plug cap from brake pipe and con-
nect pipe (or pipes) to wheel cylinder just enough to prevent fluid
from leaking.
NOTE:
Be sure to check gasket for deterioration or any damage be-
fore installation and replace if found defective.
2) Tighten wheel cylinder to brake back plate to specified torque.
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to BRAKE SHOE INSTALLA-
TION.
NOTE:
Be sure to bleed brake system. Refer to ªCHECK AND AD-
JUSTMENTº in BRAKES section.

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5C-16 PARKING AND REAR BRAKE
1. Brake back plate
2. Cable cap
3. Parking brake cable
6) Install wheel cylinder, and tighten wheel cylinder bolts and
brake pipe flare nut (or nuts) to specified torque. (Refer to steps
1) to 4) of WHEEL CYLINDER INSTALLATION of this section.)
7) Install parking brake cable to brake back plate.
8) Install brake shoes, referring to steps 1) to 4) of BRAKE SHOE
INSTALLATION.
9) Install brake drum. Refer to steps 1) to 2) of BRAKE DRUM
INSTALLATION in this section.
10) Refill differential housing with new specified gear oil. Refer to
ªMAINTENANCE SERVICEº in Section 7E for refill.
11) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to BLEEDING BRAKES in Section 5.)
12) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
13) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load three to ten times so as to obtain proper drum-
to-shoe clearance.
Adjust parking brake cable. (For adjustment, refer to PARKING
BRAKE CHECK AND ADJUSTMENT in Section 5.)
14) Tighten rear center console box screws.
15) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
16) Check each installed part for oil leakage.

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5E1
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-1
GENERAL DESCRIPTION5E1- 2 . . . . . . . . . . . . . .
Brake Hose / Pipe Routing 5E1- 3. . . . . . . . . . . . . .
System Schematic 5E1- 4. . . . . . . . . . . . . . . . . . . .
ABS Component Parts Location 5E1- 5. . . . . . . .
ABS Hydraulic Unit/Control Module
Assembly 5E1- 6. . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5E1- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precaution in Diagnosing Troubles 5E1- 7. . . . . .
ABS Diagnostic Flow Table 5E1- 8. . . . . . . . . . . . EBD Warning Lamp (Brake Warning
Lamp) Check 5E1-11. . . . . . . . . . . . . . . . . . . . . . .
ªABSº Warning Lamp Check 5E1-11. . . . . . . . . . .
Diagnostic Trouble Code (DTC) Check
(Using ªABSº Warning Lamp) 5E1-11. . . . . . . . .
DTC Check (Using SUZUKI Scan
Tool) 5E1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Clearance 5E1-13. . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5E1
ANTILOCK BRAKE SYSTEM (ABS)
(OPTIONAL)
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 autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº 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
ªLOCKº 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:
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.
CONTENTS

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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.

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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

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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

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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

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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.