Od off SUZUKI GRAND VITARA 2000 2.G Service Service Manual

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1. Wheel cylinder
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts1. Bleeder plug cap
5C-12 PARKING AND REAR BRAKE
WHEEL CYLINDER
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Loosen brake pipe flare nut (or nuts) but only within the extent
that fluid does not leak.
4) Remove wheel cylinder mounting bolts. Disconnect brake pipe
(or pipes) from wheel cylinder and put wheel cylinder bleeder
plug cap onto pipe to prevent fluid from spilling.
INSPECTION
Inspect wheel cylinder disassembled parts for wear, cracks, corro-
sion or damage.
NOTE:
Clean wheel cylinder components with brake fluid.
INSTALLATION (For non sealed type)
1) Take off bleeder plug cap from brake pipe and connect pipe (or
pipes) to wheel cylinder just enough to prevent fluid from leak-
ing.
2) Tighten wheel cylinder to brake back plate to specified torque.
Tightening Torque
(a): 8.5 N
.m (0.85 kg-m, 6.5 lb-ft)
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)

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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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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.

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ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-9
1-1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the
point required for proper analysis and diagnosis.
CUSTOMER QUESTIONNAIRE (EXAMPLE)
Customer's name:Model:VIN:
Date of issue:Date Reg.Date of problem:Mileage:
Problem Symptoms

ªABSº warning light abnormal: fails to turn on/fails to go off /
flashes

Abnormal noise while vehicle is running: from motor, from valve,
other__________________

Wheel is locked at braking:

Pump motor does not stop (running):

Braking does not work:

Other:
Frequency of occurrence
Continuous/Intermittent ( times a day, a month) /
other______________
Conditions for Occurrence
of Problem

Vehicle at stop & ignition switch ON:

When starting: at initial start only / at every start / Other______________

Vehicle speed: while accelerating / while decelerating / at stop /
while turning / while running at constant speed /
other________________

Road surface condition: Paved road / rough road / snow-covered
road / other_________________

Chain equipment:
Environmental Condition
Weather: fair / cloudy / rain / snow / other___________________

Temperature: F (C)
Diagnostic Trouble Code

First check: Normal code/malfunction code ( )

Second check after
test drive: Normal code / malfunction code ( )

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Example: When right-front wheel speed sensor circuit opens (DTC 21)
1. Diagnosis connector
(6 pins connector)
2. Ground terminal3. Diag. switch terminal
4. Service wire
Voltmeter indicator
(or ªABSº warning
lamp)HIGH
(ON)
LOW
(OFF)
Time (sec.)
1. EBD warning lamp
(brake warning lamp)
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-11
EBD WARNING LAMP (BRAKE WARNING
LAMP) CHECK
NOTE:
Perform this check on a level place.
1) Turn ignition switch ON with parking brake applied.
2) Check that brake warning lamp is turned ON.
3) Release parking brake with ignition switch ON and check that
EBD warning lamp (brake warning lamp) goes off.
If it doesn't go off, go to ªTABLE-Eº in this section.
ªABSº WARNING LAMP CHECK
1) Turn ON the ignition switch.
2) Check that ªABSº warning lamp lights for about 2 seconds and
then goes OFF.
If anything faulty is found, advance to Diagnostic table ± A, B or
C.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
(USING ªABSº WARNING LAMP)
1) Using service wire, connect diag. switch terminal of diagnosis
connector to ground.
2) Turn ignition switch ON.
3) Read flashing of ªABSº warning lamp which represents DTC as
shown in example below and write it down. When more than 2
DTC's are stored in memory, deflection and flashing for each
DTC is repeated three times starting with the smallest DTC num-
ber in increasing order.
For details of DTC, refer to ªDTC Tableº.

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5E1-12 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
NOTE:
ªABSº warning lamp indicates only following DTC's, DTC
12 which means that no malfunction DTC is stored and his-
tory DTC which indicates history trouble area. When there
is a current trouble, ªABSº warning lamp remains ON and
therefore DTC is not indicated.
4) After completing the check, turn ignition switch off and discon-
nect service wire from DIAG. connector.

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ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-13
1. Data link connector (DLC)
1. Diagnosis connector (6 pins connector)
2. Ground terminal
3. Diag. switch terminal
4. Service wire
DTC CHECK (USING SUZUKI SCAN TOOL)
1) After setting cartridge for ABS to SUZUKI scan tool, connect SU-
ZUKI scan tool to data link connector.
Special Tool
(A): 09931-76011 (SUZUKI scan tool)
(B): Mass storage cartridge
(C): 16 / 14 pin DLC cable
2) Turn ignition switch ON.
3) Read DTC according to instructions displayed on SUZUKI scan
tool and print it or write it down. Refer to SUZUKI scan tool opera-
tor's manual for further details.
4) After completing the check, turn ignition switch off and discon-
nect SUZUKI scan tool from DLC.
DIAGNOSTIC TROUBLE CODE (DTC)
CLEARANCE
WARNING:
When performing a driving test, select a safe place where
there is neither any traffic nor any traffic accident possibil-
ity and be very careful during testing to avoid occurrence of
an accident.
After repair or replace malfunction part(s), clear all DTC's by per-
forming the following procedure.
1) Turn ignition switch OFF.
2) Using service wire, connect diag. switch terminal of diag. con-
nector to diag. ground terminal.
3) With connection described in above step 2) maintained, turn
ignition switch ON.
4) Repeat on / off operation of service wire at diag. ground terminal
at least 5 times within 10 seconds.
NOTE:
Service wire ON time must be for 0.1 second and more.
5) Turn ignition switch OFF and disconnect service wire from diag.
connector.
6) Perform DRIVING TEST and DTC CHECK and confirm that nor-
mal DTC (DTC 12) is displayed; not malfunction DTC.
NOTE:
It is also possible to clear DTC by using SUZUKI scan tool.
Refer to Cartridge Manual for procedure to clear DTC.

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5E1-16 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
-1. Main fuse
-2. Ignition switch
-3. Circuit fuse for IG
-4. ªABSº warning lamp
-5. ABS hydraulic unit / control
module assembly
5-1. Fail-safe relay
5-2. To solenoid valves and
pump motor relay
(ABS hydraulic unit)
-6. Diagnosis connector
(Black connector)
6-1. Diag. switch terminal
6-2. Diag. ground terminal
-7. Combination meter
7-1. ABS lamp driver module
-8. ABS hydraulic unit/
control module connector
of harness
-9. EBD warning lamp
(Brake warning lamp)
-10. Parking brake switch
-11. Brake fluid level switch
TABLE ± A ªABSº WARNING LAMP CIRCUIT CHECK ± LAMP DOES NOT
COME ªONº AT IGNITION SWITCH ON
CIRCUIT DESCRIPTION
Operation (ON / OFF) of the ªABSº warning lamp is controlled by the ABS control module and ABS lamp driver mod-
ule.
If the Antilock brake system is in good condition, the ABS control module turns the ªABSº warning lamp ON at the
ignition switch ON, keeps it ON for 2 seconds only and then turns it OFF. If an abnormality in the system is detected,
the lamp is turned ON by ABS control module. Also, it is turned ON by ABS lamp driver module when the connector
of the ABS control module was disconnected.
INSPECTION
STEPACTIONYESNO
11) Turn ignition switch ON.
Do other warning lamp come ON?Go to step 2.Go to step 4.
21) Disconnect ABS hydraulic unit / control module
connector.
Does ABS warning lamp light with ignition switch ON?Replace ABS
hydraulic unit / control
module assembly.Go to step 3.
31) Remove combination meter.
Is bulb of ABS warning lamp in good condition?ªBl / Oº circuit shorted
to ground. If OK,
replace ABS
warning circuit (lamp
driver module).Replace bulb.
4Is IG fuse in good condition?Open in ªB / Wº wire to
combination meter or
poor connection.Repair and
replace.

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ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-17
1. ABS hydraulic
unit / control
module connector
TABLE ± B ªABSº WARNING LAMP CIRCUIT CHECK ± LAMP COMES ªONº
STEADY
Refer to TABLE ± A for System Circuit Diagram and Circuit Description.
INSPECTION
STEPACTIONYESNO
1Perform diagnostic trouble code check. Is there any DTC
(including code No.12, NO CODES on SUZUKI scan
tool) exists?Go to step 2.Go to step 3.
2Is malfunction DTC (other than code No.12) exists at step
1?Go to step 7 of ABS
diagnostic flow table
in this section.Go to step 3.
31) Disconnect ABS hydraulic unit / control module
connector. (See Fig. 1)
2) Check for proper connection to ABS hydraulic
unit / control module connector at terminals ªA17º,
ªA25º and ªA10º.
3) If OK, turn ignition switch ªONº and measure
voltage at terminal ªA25º of connector.
Is it 10 ± 14 V?Go to step 4.ªB / Wº circuit open.
41) With ABS control module connector disconnected,
turn ignition switch ON and light ABS warning lamp.
2) Connect terminal ªA17º of disconnected connector to
ground using service wire.
Does ªABS warning lampº turn off?Go to step 5.ªBl / Oº circuit open.
If wire and
connection are OK,
replace ABS lamp
driver module.
51) Measure resistance from connector terminal ªA10º
to body ground.
Is continuity indicated?Substitute a
known-good ABS
hydraulic unit /
control module
assembly and
recheck.ªBº circuit open.
Fig. 1

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5E1-20 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
TABLE ± E EBD WARNING LAMP (BRAKE WARNING LAMP) CHECK-LAMP
COMES ªONº STEADY
CIRCUIT DESCRIPTION
EBD warning lamp (brake warning lamp) is controlled by parking brake switch, brake fluid level switch and ABS
control module / hydraulic unit assembly through lamp driver module in combination meter. Refer to ªTABLE-Aº for
circuit diagram.
STEP
ACTIONYESNO
11) Make sure that:

Parking brake is completely released.Go to step 2.Release parking
brake completely

Brake fluid level is upper than the minimum level.
Are the check results OK?and / or replenish
brake fluid.
2Does ªABSº warning lamp come on?Perform ªTABLE Bº
previously
outlined.Go to step 3.
31) Disconnect ABS hydraulic unit / control module
connector.
2) Check for proper connection to ABS hydraulic unit /
control module connector at terminals ªA26º.
3) If OK, apply chocks to wheels and select gear in neutral
position (P range for A / T).
4) Keep brake pedal depressed and start engine.
Release parking brake.
5) Connect terminal ªA26º of disconnected connector to
ground using service wire.
Does EBD warning lamp (brake warning lamp) turn off?Substitute a
known-good ABS
hydraulic unit /
control module
assembly and
recheck.ªBrº circuit open.
If wire and
connection are
OK, replace
combination
meter.