1999 SUZUKI GRAND VITARA tightening torque

YH4
GRAND
VITARA
PARKING AND REAR BRAKE 5C-17
09943-35512
Brake drum remover
(Front wheel hub remover)09942-15510
Sliding hammer
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Wheel cylinder bleeder plug7.50.755.5
Parking brake lever bolt232.317.0
Wheel cylinder bolt (For non sealed type)8.50.856.5
Wheel cylinder bolt (For gasket sealed type)111.112.0
Brake pipe flare nut161.612.0
Brake back plate nut232.317.0
Wheel nut10010.072.5
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Brake fluid
Indicated on reservoir
cap or described in owner's
manual of vehicle
To fill master cylinder reservoir.

To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when
they are disassembled.
Water tight
sealantSEALING COMPOUND 366E
99000-31090
To apply to mating surfaces of brake back
plate and rear wheel cylinder.
SealantSUZUKI BOND NO. 1215
99000-31110

To apply to mating surfaces of brake back
plate and rear axle housing.

To apply mating surfaces of brake back
plate and rear wheel bearing retainer.
SPECIAL TOOLS

YH4
GRAND
VITARA
Diagnostic Trouble Code (DTC) Table 5E1-14. . .
System Circuit 5E1-15. . . . . . . . . . . . . . . . . . . . . . .
Table ± A ªABSº Warning Lamp Circuit
Check ± Lamp does not come ªONº
at ignition switch on 5E1-16. . . . . . . . . . . . . . . . . .
Table ± B ªABSº Warning Lamp Circuit
Check ± Lamp comes ªONº steady 5E1-17. . . .
Table ± C ªABSº Warning Lamp Circuit
Check ± The lamp flashes continuously
while ignition switch is on5E1-18 . . . . . . . . . . . . . .
Table ± D Code (DTC) is not Outputted
even with Diag. Switch Terminal
Connected to Ground 5E1-19. . . . . . . . . . . . . . . .
Table ± E EBD Warning Lamp (Brake
Warning Lamp) Check-lamp Comes
ªONº Steady 5E1-20. . . . . . . . . . . . . . . . . . . . . . . .
DTC 15 ± G Sensor Circuit 5E1-21. . . . . . . . . . . .
DTC 21, 22, 25, 26, 31, 32, 35 or 36
± Wheel Speed Sensor Circuit 5E1-23. . . . . . . .
DTC 41, 45 or 56 ± Solenoid Circuit 5E1-26. . . . .
DTC 57 ± Solenoid and Pump Motor
Power Source Circuit 5E1-27. . . . . . . . . . . . . . . .
DTC 61 ± ABS Pump Motor Circuit 5E1-28. . . . . .
DTC 63 ± ABS Fail-Safe Relay Circuit 5E1-29. . .
DTC 71 ± ABS Control Module 5E1-30. . . . . . . . .
ON-VEHICLE SERVICE5E1-31 . . . . . . . . . . . . . . . .
Precaution 5E1-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
ABS Hydraulic Unit Operation Check 5E1-31. . . .
ABS Hydraulic Unit / Control Module
Assembly 5E1-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic unit inspection 5E1-32. . . . . . . . . . . . . Removal 5E1-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-33. . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Speed Sensor 5E1-34. . . . . . . . . . . .
Output voltage inspection 5E1-34. . . . . . . . . . . .
Removal 5E1-35. . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor inspection 5E1-35. . . . . . . . . . . . . . . . . .
Sensor rotor inspection 5E1-35. . . . . . . . . . . . . .
Installation 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . .
Front Sensor Rotor 5E1-36. . . . . . . . . . . . . . . . . . .
Removal 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-36. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Wheel Speed Sensor 5E1-37. . . . . . . . . . . .
Output voltage inspection 5E1-37. . . . . . . . . . . .
Removal 5E1-37. . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor inspection 5E1-38. . . . . . . . . . . . . . . . . .
Sensor rotor inspection 5E1-38. . . . . . . . . . . . . .
Installation 5E1-38. . . . . . . . . . . . . . . . . . . . . . . . .
Rear Sensor Rotor 5E1-39. . . . . . . . . . . . . . . . . . . .
Removal 5E1-39. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-39. . . . . . . . . . . . . . . . . . . . . . . . .
G Sensor 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5E1-40. . . . . . . . . . . . . . . . . . . . . . . . .
Transfer 4WD Switch 5E1-41. . . . . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS5E1-41 . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5E1-42 . . . . . . . . . . . . . . . . . . . . . .
5E1-2 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
GENERAL DESCRIPTION
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 is a 4-wheel type
which controls the fluid pressure applied to the wheel cylinder of each of the four brakes to prevent each wheel
from getting locked.
The component parts of this ABS includes 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.

In this ABS, ABS hydraulic unit (actuator assembly), ABS control module, pump motor relay and fail-safe relay
are combined as one component.

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 of 4 wheels.

Fail-safe (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.

ªABSº warning lamp which lights to inform abnormality when system fails to operate properly.

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 sensor
independently of change of load due to load capacity and so on. And if the EBD system fails to operate properly,
the brake warning lamp lights to inform abnormality.

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
5E1-36 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
5E1-38 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
1. Clamps
2. Sensor bolt
SENSOR INSPECTION

Check sensor (pole piece) for damage or bent.

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 serration (teeth) for being missing, damaged or de-
formed.

Turn wheel 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.
INSTALLATION
1) Check that no foreign material is attached to sensor and rotor.
2) Install it by reversing removal procedure.
Tightening Torque
(a): 21 N
.m (2.1 kg-m, 15.0 lb-ft)
CAUTION:
Do not pull wire harness or twist more than necessary
when installing rear wheel speed sensor.
3) Check that there is no clearance between sensor and knuckle.

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.