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-

ESP

® 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

ABS (ESP

®) hydraulic unit / control module

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

ABS (ESP

®) 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

ESP

® 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

ESP

® 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

DTC C1027: ESP

® 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

® Control

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

DTC C1057: ESP

® (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

DTC C1071: ESP

® (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

ESP

® Hydraulic Unit / Control Module

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

ESP

® 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

ESP

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

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