rear brake SUZUKI SWIFT 2000 1.G RG413 Service Service Manual

5-32 BRAKES
5) Remove brake back plate (1) by removing bolts (2).
INSTALLATION
1) Apply water tight sealant to mating surfaces of brake back
plate and rear axle.
“A” : Sealant 99000-31090
2) Install brake back plate and tighten back plate bolts to speci-
fied torque.
Tightening torque
Brake back plate bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
3) Apply water tight sealant where plate and cable contact, and
run parking brake cable (1) through brake back plate (2) and
secure it with clip (3).
“A” : Sealant 99000-31090
4) Install wheel cylinder, and tighten wheel cylinder bolts and
brake pipe flare nut to specified torque. (Refer to “WHEEL
CYLINDER”.)
5) For procedure hereafter referring to “WHEEL CYLINDER”.
A: Forward

BRAKES 5-33
BRAKE BACK PLATE (FOR 4WD VEHICLE)
REMOVAL AND INSTALLATION
Refer to “REAR AXLE SHAFT AND WHEEL BEARING (4WD VEHICLE)” in Section 3E.
MASTER CYLINDER
MASTER CYLINDER RESERVOIR
REMOVAL
1) Remove master cylinder.
2) Pull out retainer (1) and remove reservoir (2).
1. Reservoir tank 9. Sleeve Tightening torque
2. Retainer 10. Primary piston
: Apply brake fluid to contact surface of cup.Do not reuse.
3. Grommet
: Apply brake fluid.11. Primary cup
: Confirm installing direction.
4. Master cylinder body 12. Washer
5. Secondary return spring 13. Cap
6. Secondary cup
: Confirm installing direction Size of cup : 6=11>14>8 .14. Cap cup
: Confirm installing direction.
7. Secondary piston
: Apply brake fluid to contact surface of cup.15. Master cylinder gasket
8. Sleeve cup
: Confirm installing direction.
2
1

5-44 BRAKES
REAR BRAKE HOSE/PIPE
REMOVAL
1) Raise and support vehicle properly. Remove tire and wheel.
2) Clean dirt and foreign material from both flexible hose end and pipe end fittings.
3) Remove brake flexible hose or pipe.
INSTALLATION
Reverse brake flexible hose installation procedure, nothing the followings.
Fill and maintain brake fluid level in reservoir.
Bleed brake system. Refer to “AIR BLEEDING OF BRAKE SYSTEM”.
Perform brake test and check each installed part for fluid leakage.
Never reuse protector nut once removed. Be sure to use a new one.
Install clamps properly referring to figure below and tighten bolts.
When installing hose, make sure that it has no twist or kink.

BRAKES 5-45
T : Top side 1. 4 way joint [A] : with ABS
F : Front side 2. LSPV assembly [B] : without ABS
R : Right side 3. P valve [C] : with LSPV
L : Left side 4. Rear brake hose Tightening torque
B : View B a-g: Clamp

BRAKES 5-47
T : Top side 3. Inner cable end a : View A f : View F
F : Front side 4. Spring b : View B Tightening torque
R : Rear side 5. Adjusting nut c : View C
1. Cable
: Apply water tight sealant (99000-31090)6. Clip d : View D
2. Parking brake shoe lever 7. Parking brake lever e : View E

5-48 BRAKES
LSPV (LOAD SENSING PROPORTIONING VALVE) ASSEMBLY (IF EQUIPPED)
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Hoist vehicle.
3) Disconnect brake pipes from LSPV assembly.
Special tool
09950-78230 (10 x 11 mm)
4) Remove nut (2) and detach spring end from rear axle (3).
5) Remove LSPV assembly (1) with spring (4) from vehicle
body.
1. LSPV assembly 3. Adjust nut Tightening torque
2. Spring 4. Brake pipe
CAUTION:
Never disassemble LSPV assembly. Disassembly will
spoil its original performance. Replace with new one if
detective.
3
21
25 N·m(2.5 kg-m)
4 16 N·m(1.6 kg-m)
25 N·m(2.5 kg-m)
3
24
1

5-50 BRAKES
REQUIRED SERVICE MATERIAL
SPECIAL TOOL
MaterialRecommended SUZUKI product
(Part Number)Use
Brake fluid DOT 3 or SAE J1703To fill master cylinder reservoir.
To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when they
are disassembled.
Water tight sealant SEALING COMPOUND 366E
(99000-31090)To apply to mating surfaces of brake back
plate and rear axle (2WD vehicle) or rear
axle housing (4WD vehicle).
To apply to mating surfaces of brake back
plate and parking brake cable.
Lithium grease SUZUKI SUPER GREASE A
(99000-25010)To apply to slide pin of brake caliper carrier.
09900-06106 09900-20606 09900-20701 09942-15510
Snap ring remover Dial gauge Dial gauge chuck Sliding hammer
09943-17912 09951-18220 09952-16020 09952-46010
Brake drum remover
(Front wheel hub
remover)Secondary cup installer
setBooster piston rod
adjusterMaster cylinder attach-
ment

5E-2 ANTILOCK BRAKE SYSTEM (ABS)
DTC C1015 (DTC 15) – G SENSOR
CIRCUIT .................................................... 5E-22
DTC C1021 (DTC 21), DTC C1022
(DTC 22) – RIGHT-FRONT WHEEL
SPEED SENSOR CIRCUIT OR SENSOR
RING .......................................................... 5E-24
DTC C1025 (DTC 25), DTC C1026
(DTC 26) – LEFT-FRONT WHEEL
SPEED SENSOR CIRCUIT OR SENSOR
RING .......................................................... 5E-24
DTC C1031 (DTC 31), DTC C1032
(DTC 32) – RIGHT-REAR WHEEL
SPEED SENSOR CIRCUIT OR SENSOR
RING .......................................................... 5E-24
DTC C1035 (DTC 35), DTC C1036
(DTC 36) – LEFT-REAR WHEEL SPEED
SENSOR CIRCUIT OR SENSOR RING.... 5E-24
DTC C1041 (DTC 41) – RIGHT-FRONT
INLET SOLENOID CIRCUIT...................... 5E-26
DTC C1045 (DTC 45) – LEFT-FRONT
INLET SOLENOID CIRCUIT...................... 5E-26
DTC C1051 (DTC 51) – RIGHT-REAR
INLET SOLENOID CIRCUIT...................... 5E-26
DTC C1055 (DTC 55) – LEFT-REAR
INLET SOLENOID CIRCUIT...................... 5E-26
DTC C1042 (DTC 42) – RIGHT-FRONT
OUTLET SOLENOID CIRCUIT.................. 5E-26
DTC C1046 (DTC 46) – LEFT-FRONT
OUTLET SOLENOID CIRCUIT.................. 5E-26
DTC C1052 (DTC 52) – RIGHT-REAR
OUTLET SOLENOID CIRCUIT.................. 5E-26DTC C1056 (DTC 56) – LEFT-REAR
OUTLET SOLENOID CIRCUIT ................. 5E-26
DTC C1057 (DTC 57) – POWER
SOURCE CIRCUIT .................................... 5E-27
DTC C1061 (DTC 61) – ABS PUMP
MOTOR CIRCUIT ...................................... 5E-28
DTC C1063 (DTC 63) – ABS FAIL-SAFE
RELAY CIRCUIT ....................................... 5E-29
DTC C1071 (DTC 71) – ABS CONTROL
MODULE ................................................... 5E-30
ON-VEHICLE SERVICE................................ 5E-31
PRECAUTIONS ......................................... 5E-31
ABS HYDRAULIC UNIT OPERATION
CHECK (USING SUZUKI SCAN TOOL) ... 5E-31
ABS HYDRAULIC UNIT OPERATION
CHECK (NOT USING SUZUKI SCAN
TOOL) ........................................................ 5E-31
ABS HYDRAULIC UNIT/CONTROL
MODULE ASSEMBLY ............................... 5E-33
FRONT WHEEL SPEED SENSOR ........... 5E-35
FRONT WHEEL SPEED SENSOR
RING .......................................................... 5E-37
REAR WHEEL SPEED SENSOR.............. 5E-38
REAR WHEEL SPEED SENSOR
RING (FOR 2WD VEHICLE) ..................... 5E-41
REAR WHEEL SPEED SENSOR
RING(FOR 4WD VEHICLE) ...................... 5E-42
G SENSOR (FOR 4WD VEHICLE
ONLY) ........................................................ 5E-43
SPECIAL TOOL ............................................ 5E-44

GENERAL DESCRIPTION
COMPONENTS/PARTS LOCATION AND BRAKE HOSE/PIPE ROUTING
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 has also the following function.
While braking is applied, but before ABS control becomes effective, braking force is distributed between the front
and rear so as to prevent the rear wheels from being locked too early for better stability of the vehicle.

ANTILOCK BRAKE SYSTEM (ABS) 5E-3
The main component parts of this ABS include the 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.
ABS warning lamp which lights to inform abnormality when system fails to operate properly.
ABS hydraulic unit/control module assembly is incorporated ABS control module, ABS hydraulic unit (actua-
tor assembly), fail-safe relay and pump motor relay.
–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 4 wheels.
–Fail-safe relay (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.
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 sen-
sor independently of change of load due to load capacity and so on. And if the EBD system fails to operate prop-
erly, the brake warning lamp lights to inform abnormality.
[A] : RH steering vehicle shown 4. Stop lamp switch
1. ABS hydraulic unit/control module assembly 5. ABS warning lamp
2. G sensor (For 4WD vehicle only) 6. EBD warning lamp (Brake warning lamp)
3. Wheel speed sensors
156
2 4
33
[A]
NOTE:
As for the difference of RH steering vehicle and LH steering vehicle, the location of the combination
meter and the brake master cylinder assembly only changes.

5E-4 ANTILOCK BRAKE SYSTEM (ABS)
SYSTEM SCHEMATIC
1. ABS hydraulic unit/control module assembly 7.“ABS” warning lamp 13. Wheel speed sensor (Right-front)
2. ABS control module 8.“EBD” warning lamp (Brake warning lamp) 14. Wheel speed sensor (Left-front)
3. ABS hydraulic unit 9. Lamp driver module 15. Wheel speed sensor (Right-rear)
4. Fail safe relay 10. ECM 16. Wheel speed sensor (Left-rear)
5. Pump motor relay 11. Data link connector 17. G sensor (For 4WD vehicle only)
6. Stop lamp switch 12. Monitor coupler
INPUT OUTPUT
ABS control
module Wheel speed sensor (LF)
Wheel speed sensor (LR)
Wheel speed sensor (RF)
Wheel speed sensor (RR)
Stop lamp switch
Diag. switch terminal
Battery Voltage
G sensor (for 4WD vehicle only)
Pump motor
relay
Fail-safe
relay
Hydraulic unit
Pump motor
LF inlet solenoid
LF outlet solenoid
LR inlet solenoid
LR outlet solenoid
RF inlet solenoid
RF outlet solenoid
RR inlet solenoid
RR outlet solenoid
“ABS” warning lamp
ECM
EBD warning lamp
(Brake warning lamp)
Data link connector
ABS hydraulic unit/control
module assembly