Index Suzuki Suzuki Grand Vitara JB627 - service and repair manual

Content .. 167 168 169 170 ..

Suzuki Grand Vitara JB627. Service manual - part 169

3D-7 Propeller Shaft:

Table of Contents 4- i

4

Section 4

CONTENTS

Brakes

Precautions .................................................4-1

Precautions............................................................. 4-1

Precautions for Brakes.......................................... 4-1

Brake Control System and Diagnosis ... 4A-1

General Description .............................................4A-1

Brakes Construction............................................ 4A-1
Front Brake Hose / Pipe Construction................. 4A-2
Rear Brake Hose / Pipe Construction ................. 4A-3
Master Cylinder Assembly Construction ............. 4A-4
Booster Assembly Construction .......................... 4A-4

Diagnostic Information and Procedures............4A-5

Brake Diagnosis Note ......................................... 4A-5
Brakes Symptom Diagnosis................................ 4A-5

Repair Instructions ..............................................4A-7

Excessive Pedal Travel Check............................ 4A-7
Brake Pedal Play Check ..................................... 4A-8
Brake Fluid Level Check ..................................... 4A-8
Air Bleeding of Brake System ............................. 4A-8
Brake Pedal Free Height Adjustment.................. 4A-9
Brake Light Switch Adjustment .........................4A-10
Brake Flexible Hose and Pipe Check................4A-10
Master Cylinder Check......................................4A-10
Flushing Brake Hydraulic System ..................... 4A-10
Booster Operation Check.................................. 4A-11
Front Brake Hose / Pipe Removal and

Installation.......................................................4A-12

Rear Brake Hose / Pipe Removal and

Installation.......................................................4A-12

Master Cylinder Components............................4A-13
Master Cylinder Reservoir Removal and

Installation.......................................................4A-14

Master Cylinder Assembly Removal and

Installation.......................................................4A-15

Master Cylinder Assembly Inspection ...............4A-16
Brake Booster Components.............................. 4A-17
Brake Booster Removal and Installation ........... 4A-18
Booster Push Rod Clevis Adjustment ...............4A-18

Specifications.....................................................4A-19

Tightening Torque Specifications......................4A-19

Special Tools and Equipment ...........................4A-19

Recommended Service Material....................... 4A-19
Special Tool ......................................................4A-19

Front Brakes ............................................ 4B-1

General Description .............................................4B-1

Front Disc Brake Caliper Assembly

Construction ......................................................4B-1

Repair Instructions ..............................................4B-2

Front Disc Brake Components ............................4B-2
Front Disc Brake Pad On-Vehicle Check ............4B-3
Front Disc Brake Pad Removal and

Installation .........................................................4B-3

Front Brake Disc and Pad Inspection..................4B-4
Front Disc Brake Caliper Removal and

Installation .........................................................4B-5

Front Disc Brake Caliper Disassembly and

Assembly...........................................................4B-6

Front Disc Brake Caliper Inspection....................4B-7
Front Brake Disc Removal and Installation .........4B-8
Front Brake Disc Inspection ................................4B-8

Specifications.......................................................4B-9

Tightening Torque Specifications........................4B-9

Special Tools and Equipment .............................4B-9

Recommended Service Material .........................4B-9

Rear Brakes.............................................. 4C-1

General Description .............................................4C-1

Rear Drum Brake Assembly Construction ..........4C-1

Repair Instructions ..............................................4C-1

Rear Drum Brake Assembly Components ..........4C-1
Rear Brake Drum Removal and Installation........4C-2
Rear Brake Drum and Shoe Inspection ..............4C-2
Rear Brake Shoe On-Vehicle Check...................4C-3
Rear Brake Shoe Removal and Installation ........4C-3
Rear Brake Shoe Inspection ...............................4C-5
Wheel Cylinder Removal and Installation ...........4C-5
Wheel Cylinder Inspection ..................................4C-6
Rear Brake Back Plate Removal and

Installation .........................................................4C-6

Specifications.......................................................4C-6

Tightening Torque Specifications........................4C-6

Special Tools and Equipment .............................4C-6

Recommended Service Material .........................4C-6

Parking Brake .......................................... 4D-1

Component Location ...........................................4D-1

Parking Brake Cable Location.............................4D-1

Repair Instructions ..............................................4D-2

4-ii Table of Contents

Parking Brake Check and Adjustment ................4D-2
Parking Brake Lever Removal and Installation ....4D-3
Parking Brake Cable Removal and

Installation.........................................................4D-4

Specifications.......................................................4D-4

Tightening Torque Specifications........................4D-4

ABS............................................................4E-1

Precautions...........................................................4E-1

Precautions in Diagnosing Troubles ...................4E-1
Precautions in On-Vehicle Service......................4E-1
Precautions in Hydraulic Unit Operation

Check................................................................4E-1

General Description .............................................4E-2

ABS Description ..................................................4E-2
ABS (ESP

®) hydraulic unit / control module

Assembly Description .......................................4E-2

CAN Communication System Description...........4E-3

Schematic and Routing Diagram........................4E-4

ABS Schematic ...................................................4E-4
ABS Wiring Circuit Diagram ................................4E-5

Component Location ...........................................4E-7

ABS Components Location .................................4E-7

Diagnostic Information and Procedures............4E-8

ABS Check..........................................................4E-8
ABS Warning Light Check.................................4E-10
EBD Warning Light (Brake Warning Light)

Check..............................................................4E-10

DTC Check........................................................4E-11
DTC Table.........................................................4E-11
DTC Clearance .................................................4E-12
Scan Tool Data .................................................4E-12
ABS Warning Light Does Not Come ON at

Ignition Switch ON ..........................................4E-13

ABS Warning Light Comes ON Steady.............4E-15
EBD Warning Light (Brake Warning Light)

Comes ON Steady ..........................................4E-16

Serial Data Link Circuit Check ..........................4E-17
DTC C1015: G Sensor Circuit Failure (Non-

® Model) ..................................................4E-19

DTC C1021, C1022 / C1025, C1026 / C1031,

C1032 / C1035, C1036: Right-Front / Left-
Front / Right-Rear / Left-Rear Wheel Speed
Sensor Circuit or Encoder Failure ...................4E-20

DTC C1041 / C1042 / C1043 / C1044 / C1045

/ C1046 / C1051 / C1052 / C1053 / C1054 /
C1055 / C1056: Inlet Solenoid Circuit
Failure, Outlet Solenoid Circuit Failure,
Master Cylinder Cut Solenoid Circuit Failure,
Low Pressure Solenoid Circuit Failure ............4E-23

DTC C1057: ABS (ESP

®) Control Module

Power Supply Circuit Failure...........................4E-24

DTC C1061: ABS Pump Motor and/or Motor

Driver Circuit Failure .......................................4E-26

DTC C1063: Solenoid Valve Power Supply

Driver Circuit Failure .......................................4E-27

DTC C1071: ABS (ESP

®) control module

Internal Detect.................................................4E-28

DTC U1073: Control Module Communication

Bus Off ............................................................4E-30

DTC U1100: Lost Communication with ECM

(Reception Error).............................................4E-32

Repair Instructions ............................................4E-33

Hydraulic Unit Operation Check........................4E-33
ABS (ESP

®) hydraulic unit / control module

Assembly Components ...................................4E-34

®) hydraulic unit / control module

Assembly On-Vehicle Inspection ....................4E-35

®) hydraulic unit / control module

Assembly Removal and Installation ................4E-35

Front Wheel Speed Sensor On-Vehicle

Inspection........................................................4E-38

Front Wheel Speed Sensor Removal and

Installation .......................................................4E-39

Front Wheel Speed Sensor Inspection .............4E-40
Rear Wheel Speed Sensor On-Vehicle

Inspection........................................................4E-40

Rear Wheel Speed Sensor Removal and

Installation .......................................................4E-40

Rear Wheel Speed Sensor Inspection ..............4E-41
Front Wheel Encoder On-Vehicle Inspection ....4E-41
Front Wheel Encoder Removal and

Installation .......................................................4E-41

Rear Wheel Encoder On-Vehicle Inspection.....4E-41
Rear Wheel Encoder Removal and

Installation .......................................................4E-41

Specifications .....................................................4E-42

Tightening Torque Specifications......................4E-42

Special Tools and Equipment ...........................4E-42

Special Tool ......................................................4E-42

Electronic Stability Program ...................4F-1

Precautions........................................................... 4F-1

Precautions in Diagnosing Troubles ................... 4F-1
Precautions in On-Vehicle Service...................... 4F-1
Precautions in Hydraulic Unit Operation

Check ................................................................ 4F-1

Precautions in Sensor Calibration....................... 4F-2
Precautions in Speedometer Test or Other

Tests ................................................................. 4F-2

General Description ............................................. 4F-2

Electronic Stability Program Description ............. 4F-2
ESP

® Hydraulic Unit / Control Module

Assembly Description........................................ 4F-3

Warning Light, Indicator Light Description .......... 4F-3
CAN Communication System Description........... 4F-4
CAN Communication System For Electronic

Stability Program Description............................ 4F-5

Schematic and Routing Diagram ........................ 4F-6

Electronic Stability Program Schematic .............. 4F-6
Electronic Stability Program Wiring Circuit

Diagram............................................................. 4F-7

Component Location ........................................... 4F-9

Electronic Stability Program Component

Location............................................................. 4F-9

Diagnostic Information and Procedures .......... 4F-10

Electronic Stability Program Check................... 4F-10

Table of Contents 4-iii

® Warning Light Check.............................. 4F-12

ABS Warning Light Check ................................ 4F-12
EBD Warning Light (Brake Warning Light)

Check.............................................................. 4F-12

DTC Check ....................................................... 4F-13
DTC Table......................................................... 4F-13
DTC Clearance ................................................. 4F-16
Fail-Safe Table.................................................. 4F-16
Scan Tool Data ................................................. 4F-18
ESP

® Warning Light Does Not Come ON at

Ignition Switch ON .......................................... 4F-19

® Warning Light Comes ON Steady.......... 4F-20

Serial Data Link Circuit Check .......................... 4F-22
DTC C1015 / C1017 / C1023: Longitudinal G

Sensor / Lateral G Sensor / Yaw Rate
Sensor in Yaw Rate / G Sensor Assembly
Failure ............................................................. 4F-23

DTC C1016: Brake Light Switch Circuit

Failure ............................................................. 4F-24

DTC C1018: Brake Fluid Level Switch Failure .. 4F-25
DTC 1020: Master Cylinder Pressure Sensor

Power Supply Failure...................................... 4F-26

DTC C1021, C1022 / C1025, C1026 / C1031,

C1032 / C1035, C1036: Right-Front / Left-
Front / Right-Rear / Left-Rear Wheel Speed
Sensor Circuit or Encoder Failure................... 4F-27

DTC C1024: Steering Angle Sensor Circuit

Failure ............................................................. 4F-27

® OFF Switch Circuit

Failure ............................................................. 4F-27

DTC C1028: Master Cylinder Pressure

Sensor Circuit Failure ..................................... 4F-28

DTC C1034: Yaw Rate / G Sensor Assembly

Power Supply Failure...................................... 4F-29

DTC C1037: Steering Angle Sensor Power

Supply Failure ................................................. 4F-30

DTC C1038: Steering Angle Sensor Detect

Rolling Counter Failure from ESP

Module ............................................................ 4F-31

DTC C1039: Yaw Rate / G Sensor Assembly

Internal Failure ................................................ 4F-32

DTC C1040: Stability Control System

Function Failure .............................................. 4F-32

DTC C1041 / C1042 / C1043 / C1044 / C1045

/ C1046 / C1051 / C1052 / C1053 / C1054 /
C1055 / C1056: Inlet Solenoid Circuit
Failure, Outlet Solenoid Circuit Failure,
Master Cylinder Cut Solenoid Circuit Failure,
Low Pressure Solenoid Circuit Failure............ 4F-33

® (ABS) control module

power supply circuit failure.............................. 4F-33

DTC C1061: Pump Motor and/or Motor Driver

Circuit Failure.................................................. 4F-33

DTC C1063: Solenoid Valve Power Supply

Driver Circuit Failure ....................................... 4F-33

® (ABS) Control Module

Internal Defect................................................. 4F-33

DTC C1073: Lost Communication With Yaw

Rate / G Sensor Assembly.............................. 4F-33

DTC C1075 / 1076 / 1077 / 1078: Steering

Angle Sensor / Master Cylinder Pressure
Sensor / Longitudinal G Sensor / Lateral G
Sensor in Yaw Rate / G Sensor Assembly
Calibration Incomplete .................................... 4F-34

DTC C1090: ECM Detect Rolling Counter

Failure from ESP

® Control Module................. 4F-35

DTC C1091 / 1092 / 1093: ECM / TCM / 4WD

Control Module Data in CAN Line Failure ....... 4F-36

DTC U1073: Control Module Communication

Bus Off ............................................................ 4F-36

DTC U1100: Lost Communication with ECM

(Reception Error)............................................. 4F-36

DTC U1101: Lost Communication with TCM

(Reception Error)............................................. 4F-37

DTC U1126: Lost Communication with

Steering Angle Sensor (Reception Error)........ 4F-39

DTC U1139: Lost Communication with 4WD

Control Module (Reception Error) ................... 4F-40

DTC U1140: Lost Communication with BCM

(Reception Error)............................................. 4F-42

Repair Instructions ............................................ 4F-44

Hydraulic Unit Operation Check........................ 4F-44
Sensor Calibration............................................. 4F-44
ESP

® Hydraulic Unit / Control Module

Assembly Components ................................... 4F-45

® Hydraulic Unit / Control Module

Assembly On-Vehicle Inspection .................... 4F-45

® Hydraulic Unit / Control Module

Assembly Removal and Installation ................ 4F-45

Front Wheel Speed Sensor On-Vehicle

Inspection........................................................ 4F-45

Front Wheel Speed Sensor Removal and

Installation ....................................................... 4F-45

Front Wheel Speed Sensor Inspection ............. 4F-45
Rear Wheel Speed Sensor On-Vehicle

Inspection........................................................ 4F-45

Rear Wheel Speed Sensor Removal and

Installation ....................................................... 4F-45

Rear Wheel Speed Sensor Inspection .............. 4F-45
Front Wheel Encoder On-Vehicle Inspection .... 4F-45
Front Wheel Encoder Removal and

Installation ....................................................... 4F-45

Rear Wheel Encoder On-Vehicle Inspection..... 4F-45
Rear Wheel Encoder Removal and

Installation ....................................................... 4F-45

Master Cylinder Pressure Sensor On-Vehicle

Inspection........................................................ 4F-45

Yaw Rate / G Sensor Assembly On-Vehicle

Inspection........................................................ 4F-46

Yaw Rate / G Sensor Assembly Removal and

Installation ....................................................... 4F-48

Yaw Rate / G Sensor Inspection ....................... 4F-49
Steering Angle Sensor On-Vehicle Inspection .. 4F-49
Steering Angle Sensor Removal and

Installation ....................................................... 4F-50

Steering Angle Sensor Inspection..................... 4F-50
ESP

® OFF Switch Removal and Installation .... 4F-50

® OFF Switch Inspection ........................... 4F-50

Specifications..................................................... 4F-51

Content .. 167 168 169 170 ..