sec 8 SUZUKI GRAND VITARA 2004 2.G Service Workshop Manual

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-31
1. Diagnosis
connector
(6 pins connector)
2. Diag. switch
terminal
3. Ground
4. Service wire
Brake
pedal
Ignition
sw.
Motor
Solenoid
Rear3.0 sec.
3.0
ON-VEHICLE SERVICE
PRECAUTION
When connector are connected to ABS hydraulic unit / control mod-
ule assembly, do not disconnect connectors of sensors and turn
ignition switch ON. Then DTC will be set in ABS control module.
ABS HYDRAULIC UNIT OPERATION CHECK
1) Check that basic brake system other than ABS is in good condi-
tion.
2) Check that battery voltage is 11V or higher.
3) With ªABSº warning lamp, check that no abnormality is de-
tected in ABS. Refer to ªDIAGNOSTIC TROUBLE CODE
(DTC) CHECKº in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake dragging
occurs. If it does, correct.
7) With diag. switch terminal of diagnosis connector connected to
ground by using service wire, turn ignition switch ON and check
if ªABSº warning lamp indicates DTC 12.
8) Turn ignition switch OFF.
9) Perform following checks with help of another person.
Brake pedal should be depressed and then ignition switch
turned ON by one person and wheel should be turned by
another person's hand. At this time, check that:

Operation sound of solenoid is heard and wheel turns only
about 0.5 sec. (Brake force is depressurized).

Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF
ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace hydrau-
lic unit / control module assembly.
11) Turn ignition switch OFF and remove service wire from diagno-
sis connector.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-33
1. ABS hydraulic unit /
control module
assembly
2. Nut
1. To left-front
2. To right-front
3. To rear
4. From master cylinder4) Remove three nuts and take out ABS hydraulic unit / control
module assembly from bracket.
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.
INSTALLATION
1) Install hydraulic unit by reversing removal procedure.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
(b): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
(c): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
2) Bleed air from brake system. Refer to ªBLEEDING BRAKESº in
Section 5.
3) Check each installed part for fluid leakage and perform hydraulic
unit operation check.

YH4
GRAND
VITARA
5E1-34 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
1. Left front wheel speed sensor
2. Left front strut
3. Sensor rotor
1. Wheel speed sensor connector
1. Peak-to-peak voltage
FRONT WHEEL SPEED SENSOR
OUTPUT VOLTAGE INSPECTION
1) Turn ignition switch OFF.
2) Hoist vehicle a little.
3) Disconnect connector of wheel speed sensor.
4) Connect voltmeter between connector terminals.
5) While turning wheel at a speed of approximately 2 / 3 to 1 full
rotation per second, check AC voltage of sensor.
Output AC voltage at 2 / 3 to
one rotation per second (35 ± 53 Hz): 106 mV or more
If measured voltage is not as specified, check sensor, rotor and
their installation conditions.
Reference
When using oscilloscope for this check, check if peak-to-peak volt-
age meets specification and waveform is complete.
Peak-to-peak voltage
at 2 / 3 to one rotation per second (35 ± 53 Hz): 150 mV or more

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-35
FORWARD
1. Front wheel speed
sensor connector
2. Headlight assembly
1. Front wheel speed sensor
2. Bolt
REMOVAL
1) Disconnect negative cable at battery.
2) Hoist vehicle and remove wheel.
3) Disconnect front wheel speed sensor connector.
4) Remove harness clamp bolts and remove front wheel speed
sensor from knuckle.
CAUTION:

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 installa-
tion hole.
SENSOR INSPECTION

Check sensor for damage.

Check sensor for resistance.
Resistance between terminals: 1.2 ± 1.6 k
at 20C (68F)
Resistance between terminal and sensor body: 1 M
or more
If any faulty is found, replace.
SENSOR ROTOR INSPECTION

Check rotor for being missing, damaged or deformed.

Turn drive shaft and check if rotor rotation is free from eccentricity
and looseness.

Check that no foreign material is attached.
If any faulty is found, repair or replace. Refer to WHEEL HUB RE-
MOVAL and INSTALLATION in Section 3D.

YH4
GRAND
VITARA
5E1-36 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
1. Front wheel speed sensor
2. Bolt
INSTALLATION
1) Check that no foreign material is attached to sensor and rotor.
2) Install it by reversing removal procedure.
CAUTION:

Do not pull wire harness or twist more than necessary
when installing front wheel speed sensor.

Fit harness grommet to inner fender securely.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Check that there is no clearance between sensor and knuckle.
FRONT SENSOR ROTOR
REMOVAL
Remove front sensor rotor referring to WHEEL HUB REMOVAL in
Section 3D.
INSTALLATION
CAUTION:
Don't reuse front sensor rotor removed from front wheel
hub because of it for being deformed.
Install new front sensor rotor referring to WHEEL HUB INSTALLA-
TION in Section 3D.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-37
1. Rear wheel speed sensor
2. Sensor rotor
3. Rear axle housing
1. Rear wheel speed
sensor harness
2. Connector
1. Sensor bolt
2. Clamps
REAR WHEEL SPEED SENSOR
OUTPUT VOLTAGE INSPECTION
Check in the same procedure as that used of front wheel speed
sensor check.
Output AC voltage at 2 / 3 to
one rotation per second (25 ± 38 Hz): 106 mV or more
Reference
When using oscilloscope,
peak-to-peak voltage at 2 / 3 to
one rotation per second (25 ± 38 Hz): 150 mV or more
REMOVAL
1) Disconnect negative cable at battery.
2) Hoist vehicle.
3) Disconnect rear wheel speed sensor connector and detach wire
harness from vehicle body and rear axle.
4) Remove harness clamps and remove rear wheel speed sensor
from rear axle.
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 installa-
tion hole.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-39
1. Rear axle
2. Retainer ring
3. Sensor rotor
4. Vinyl envelope
ªAº Grind with grinderªAº
1. Sensor rotor 4
31
2
2 1
3
REAR SENSOR ROTOR
REMOVAL
1) Remove rear axle shaft. Refer to REAR AXLE SHAFT RE-
MOVAL in Section 3E.
2) In order to remove sensor rotor from retainer ring, grind with a
grinder one part of the sensor rotor as illustrated till it becomes
thin.
CAUTION:

Cover vinyl sheet or the like over wheel bearing so that
fine grains from grinding will not enter there.

Be careful not to go so far as to grind the retainer ring.
3) Break with a chisel the thin ground sensor rotor, and it can be re-
moved.
INSTALLATION
1) Press-fit sensor rotor as shown.
NOTE:
Use care not to cause any damage to outside of retainer
ring.
2) Install rear axle shaft. Refer to REAR AXLE SHAFT INSTALLA-
TION in Section 3E.

YH4
GRAND
VITARA
5E1-40 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
1. Parking brake
lever ass'y
2. G sensor
3. Bolt ª1º
4. Bolt ª2º
[A] Horizontal
[B] Upright with
arrow upward
[C] Upright with
arrow downward
A: Forward
G SENSOR (FOR 4WD MODEL ONLY)
REMOVAL
1) Turn ignition switch OFF and disconnect battery negative cable.
2) Remove rear center console box.
3) Remove parking brake lever bolts ª1º and G sensor with bracket
from floor.
NOTE:
Loosen only bolt ª2º.
4) Remove sensor with bracket from floor.
5) Disconnect connector from sensor.
CAUTION:

Do not separate sensor and bracket. It will lead to erro-
neous assembly.

Sensor must not be dropped or shocked. It will affect its
original performance.
INSPECTION
1) Check sensor bracket for bend.
2) Connect positive cable of 12 volt battery to ªAº terminal of sensor
and ground cable to ªCº terminal. Then using voltmeter, check
voltage between ªBº terminal and ªCº terminal.
When placed horizontally: 2 ± 3 V
When placed upright with arrow upward: 3 ± 4 V
When placed upright with arrow downward: 1 ± 2 V
If measured voltage is not as specified, replace sensor with
bracket.
INSTALLATION
1) Connect connector to sensor securely.
2) Install sensor with bracket and parking lever assy onto floor so
that arrow mark directs vehicle forward.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Install rear console box.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-41
(d)
TRANSFER 4WD SWITCH
For removal, inspection and installation of this switch, refer to
SWITCHES in Section 7A.
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake pipe flare nut: (a)161.611.5
ABS hydraulic unit nut: (b)212.115.5
ABS hydraulic unit bracket bolt: (c)101.07.5
Wheel speed sensor bolt(Front): (d)232.317.0Wheel s eed sensor bolt(Rear): (e)212.115.5
Parking lever assy mounting bolt: (f)232.317.0

YH4
GRAND
VITARA
7A
MANUAL TRANSMISSION (TYPE 1) 7A-1
TYPE 1
GENERAL DESCRIPTION7A- 1 . . . . . . . . . . . . . .
DIAGNOSIS7A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE7A- 3 . . . . . . . . . . . . . . . .
Gear Oil 7A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Control Levers 7A- 4. . . . . . . . . . . . . . . . . . .
Switches 7A- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Rear Mounting 7A- 8. . . . . . . . . . . . . . . .
Dismounting of Trans. Unit 7A- 9. . . . . . . . . . . . .
Remounting of Trans. Unit 7A-12. . . . . . . . . . . . . Extension Case (2WD MODEL) 7A-13. . . . . . . .
Extension Case Oil Seal
(2WD MODEL) 7A-13. . . . . . . . . . . . . . . . . . . . . .
UNIT REPAIR7A-14 . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS7A-14 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS7A-14 . . . . . .
SPECIAL TOOL7A-14 . . . . . . . . . . . . . . . . . . . . . . .
As the aluminum case is sealed with liquid type gas-
ket, it is necessary to use genuine sealant or its equiv-
alent on its mating surfaces when reassembling it.
Also, the case fastening bolts must be tightened to
specified torque by means of the torque wrench and
tightening over or below the specified torque should
be avoided.
The description under ON-VEHICLE SERVICE in this
section covers a part of the TYPE 2 manual transmis-
sion and the transfer. The transfer is next to the trans-
mission as well, but their gear boxes are independent
and each of them has its own drain and level / filler
plugs for the oil change or the level check.
For the repair procedure of the transfer unit, refer to
Section 7D.
SECTION 7A
MANUAL TRANSMISSION
(TYPE 1)
CONTENTS
GENERAL DESCRIPTION
The manual transmission consists of the input shaft,
main shaft, countershaft and reverse gear which are
installed in the aluminum case. Its gears are of for-
ward five speeds in synchro mesh and reverse one
speed in constant mesh system.
The main shaft gears are held by the needle bearings
and on them the synchronizer rings and synchronizer
sleeve & hubs are assembled.
The gear shift lever case is located at the upper be-
hind the transmission case and has a cam which pre-
vents direct gear shift from the 5th speed gear to the
reverse gear.