Disc brake SUZUKI GRAND VITARA 2004 2.G Service Service Manual

YH4
GRAND
VITARA
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)

YH4
GRAND
VITARA
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

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
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

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-19
-1. ªABSº warning lamp
-2. ABS hydraulic unit / control
module assembly
-3. Diagnosis connector
3-1. Diag. switch terminal
3-2. Diag. ground terminal
-4. ABS hydraulic unit/
control module connector
of harness
1. ABS hydraulic
unit / control
module connector
TABLE ± D CODE (DTC) IS NOT OUTPUTTED EVEN WITH DIAG. SWITCH
TERMINAL CONNECTED TO GROUND
CIRCUIT DESCRIPTION
When the diag. switch terminal is connected to the ground with the ignition switch turned ON, the ABS control mod-
ule outputs a diagnostic trouble code by flashing ªABSº warning lamp.
INSPECTION
STEPACTIONYESNO
1Is it shorted diag. switch terminal and ground terminal by
service wire properly?Go to step 2.Connect service
wire securely.
21) Disconnect service wire.
2) Disconnect ABS hydraulic unit / control module
connector. (See Fig. 1)
3) Measure resistance between diag. switch terminal
and connector terminal ªA8º.
Is it infinite (
)?ªPº circuit open.Go to step 3.
31) Measure resistance between ground terminal of
monitor connector and body ground.
Is continuity indicated?Go to step 4.ªBº circuit open or
poor connection.
41) Check for proper connection to ABS hydraulic
unit / control module at terminal ªA8º and ªA10º.
2) If OK, then check ªABSº warning lamp circuit
referring to ªTABLE A, B and Cº.
Is it in good condition?Substitute a
known-good ABS
hydraulic unit /
control module
assembly and
recheck.Repair ªABSº
warning lamp
circuit.
Fig. 1

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
5E1-22 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
1. ABS hydraulic
unit / control
module connector
INSPECTION
STEPACTIONYESNO
1Is G sensor installed floor securely?Go to step 2.Tighten sensor or
bracket screw
securely. If not,
using new screw.
21) Ignition switch OFF.
2) Remove G sensor with bracket.
3) Check for proper connection to G sensor.
4) If OK then check G sensor referring to item
INSPECTION of G sensor.
Is it in good condition?Go to step 3.Replace G sensor.
31) Disconnect connectors from ABS hydraulic unit /
control module assembly (See Fig. 1) and G sensor.
2) Check for proper connection to ABS control module
at terminals ªA14º and ªA4º.
3) If OK, then turn ignition switch ON and measure
voltage between ªB / Wº terminal of sensor
connector and body ground.
Is it 10 ± 14 V?Go to step 4.ªB / Wº circuit open.
4Measure voltage between ªO / Wº terminal of sensor
connector and body ground.
Is it 0 V?Go to step 5.ªO / Wº circuit
shorted to power
circuit.
51) Ignition switch OFF.
2) Check that ªO / Wº circuit is free from open
or short to ground and ªO / Gº circuit.
Is it in good condition? (See Fig. 2)ªO / Gº circuit open.
If circuit is OK, substi-
tute a known-good
ABS hydraulic
unit / control module
assembly.ªO / Wº circuit open
or shorted to
ground or ªO / Gº
circuit.
Fig. 1 Fig. 2

YH4
GRAND
VITARA
5E1-24 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
INSPECTION
STEPACTIONYESNO
11) Disconnect the applicable sensor connector with
ignition switch OFF.
2) Measure resistance between sensor terminals.
Resistance of wheel speed sensor:
1.2 ± 1.6 k
(at 20C, 68F)
3) Measure resistance between each terminal and
body ground.
Insulation resistance: 1M
or higher
Were measured resistance values in step 2) and 3)
as specified? (See Fig. 1)Go to step 2.Replace sensor.
21) Ignition switch OFF.
2) Disconnect connector from ABS hydraulic
unit / control module assembly. (See Fig. 2)
3) Check for proper connection to ABS hydraulic unit /
control module assembly at each sensor terminal.
4) If OK then, turn ignition switch ON and measure
voltage between sensor positive terminal of module
connector and body ground.
Is it 0 V?Go to step 3.Sensor positive
circuit shorted to
power.
31) Ignition switch OFF.
2) Connect connector to sensor.
3) Measure resistance between sensor terminals at
module connector.
4) Measure resistance between sensor positive
terminal and negative terminal of module connector,
between positive terminal and body ground.
Are measured resistance values within each specified
range described in above step 1?Go to step 4.Circuit open or
shorted to
ground.
41) Remove wheel speed sensor.
2) Check sensor for damage or foreign material being
attached.
Is it in good condition? (See Fig. 3)Go to step 5.Clean or replace
sensor.
5Check visually through wheel speed sensor
installation hole for following.

Rotor neither missing or damaged.

No foreign material being attached.

Rotor not being eccentric.

Wheel bearing free from excessive play.
Are they in good condition? (See Fig. 4)Go to step 6.Clean, repair or
replace.
61) Install sensor to knuckle or axle housing.
2) Tighten sensor bolt to specified torque and check
that there is not any clearance between sensor and
knuckle or axle housing. (See Fig. 5)
Replace sensor if any.
Referring to item OUTPUT VOLTAGE INSPECTION of
FRONT WHEEL SPEED SENSOR, check output voltage
or waveform of sensor. Is proper output voltage or
waveform obtained?Substitute a
known-good ABS
hydraulic unit /
control module
assembly and
recheck.Replace sensor
and recheck.