1999 SUZUKI GRAND VITARA acc

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GRAND
VITARA
1. Stop light switch
BRAKES 5-9
BRAKE PEDAL FREE HEIGHT CHECK
Remove foot rest and displace carpet and dash silencer(s) so as to
measure brake pedal free height between pedal face and asphalt
sheet installed on dash panel.
Brake pedal free height ªaº from asphalt sheet:
208 ± 218 mm (8.19 ± 8.58 in.)
If the measurement is not within the specification, check the posi-
tion of booster push rod clevis and / or stop light switch according
to the instruction shown in this section.
The free height varies depending on installation position of booster
push rod clevis and stop light switch.
BRAKE LIGHT SWITCH ADJUSTMENT
Adjustment should be made as follows when installing switch. Pull
up brake pedal toward you and while holding it there, adjust switch
position so that clearance between end of thread and brake pedal
return cushion (shown as ªbº in figure).
Then tighten lock nut to specified torque.
Clearance ªbº: 1.5 ± 2.0 mm (0.06 ± 0.08 in.)
Tightening Torque
(b): 7.5 N
.m (0.75 kg-m, 5.5 lb-ft)
EXCESSIVE PEDAL TRAVEL CHECK
1) Remove foot rest and displace carpet and dash silencer(s).
2) Start engine.
3) Depress brake pedal a few times.
4) With brake pedal depressed with approximately 30 kg (66 lbs)
load, measure pedal to asphalt sheet clearance ªcº.
Clearance ªcº: over 115 mm (4.53 in.)
5) If clearance ªcº is less than specification, the most possible
cause is either rear brake shoes are worn out beyond limit or air
is in lines.
Should clearance ªcº remain less than specification even after
replacement of brake shoes and bleeding of system, other pos-
sible but infrequent cause is malfunction of rear brake shoe ad-
justers or booster push rod length out of adjustment.

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VITARA
1. Pad rim
2. Lining
3. Disc
1. Rubber plug
2. Brake shoe
3. Brake shoe rim
BRAKES 5-11
BRAKE DISC CHECK
Refer to FRONT DISC BRAKE PAD of Section 5B for inspection
point and procedure.
BRAKE PAD CHECK
Inspect pad linings periodically according to maintenance schedule
whenever wheels are removed (for tire rotation or other reason).
Take a look through hole of caliper and check lining thickness of in-
side pad.
Thickness ªeº
Standard: 10.0 mm (0.39 in.)
Service Limit: 2.0 mm (0.08 in.)
If one of brake pad is worn to service limit, all linings must be re-
placed at the same time.
BRAKE SHOE CHECK
Inspection should be carried out on following points after brake ped-
al travel ªcº (pedal to asphalt sheet clearance) check as described
on previous page of this section, even when it is more than 115 mm
(4.53 in.).
Amount of brake shoe wear can be checked as follows.
1) Hoist vehicle.
2) Remove rubber plug from brake back plate.
3) Through hole of back plate, visually check for thickness of brake
shoe lining. If lining thickness ªfº is found less than below speci-
fied wear limit, replace with new brake shoes.
Thickness ªfº
Service Limit: 1.0 mm (0.04 in.)

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VITARA
1. LSPV
2. LSPV lever
3. Spring
4. LSPV stay
5. Brake flare nut
[A]: Type A
[B]: Type B
1. Plunger
2. Lip seal
3. LSPV lever
4. Sensor spring
5. From master cylinder
primary chamber
(Rear wheel brake)
6. From master cylinder
secondary chamber
(Front wheel brake)
7. To rear wheel brake
8. Pin
9. Bolt hole
[A] [B]
44
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3
LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped)
As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear
wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the
vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Also, it releases the above described control over the hydraulic pressure applied to the rear wheel brake, should
any failure occur in the hydraulic circuit of the front wheel brake so that the hydraulic pressure produced in the mas-
ter cylinder is applied to the rear wheel brake directly to operate it.
CONSTITUTION
The LSPV components are grouped into three sections as follows.
ªAº: Sensor section
The main parts in this section are a lever and a spring which senses variation in the vehicle height as affected
by the loaded condition and converts it into the load.
ªBº: Hydraulic pressure control section
Included in this section are a stepped plunger and valve mechanism to execute proportional control.
ªCº: Fail-safe section
The main parts in this section are a chamber which draws in the hydraulic pressure from the front wheel brake
system and a fail-safe piston which releases the valve mechanism in the control section connected to the rear
wheel brake, should any failure occur in the front wheel brake system.

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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.

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ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-7
DIAGNOSIS
To ensure that the trouble diagnosis is done accurately and smooth-
ly, observe ªPrecautions in Diagnosing Troublesº and follow ªABS
Diagnostic Flow Tableº.
PRECAUTION IN DIAGNOSING TROUBLES

If the vehicle was operated in any of the following ways, ªABSº
warning light may light momentarily but this does not indicate any-
thing abnormal in ABS.
± The vehicle was driven with parking brake pulled.
± The vehicle was driven with brake dragging.
± The vehicle was stuck in mud, sand, etc.
± Wheel spin occurred while driving.
± Wheel(s) was rotated while the vehicle was jacked up.

Be sure to read ªPrecautions for Electronic Circuit Serviceº in
ªGENERAL INFORMATIONº section before inspection and ob-
serve what is written there.

Be sure to use the trouble diagnosis procedure as described in
the flow table. Failure to follow the flow table may result in incor-
rect diagnosis. (Some other diag. trouble code may be stored by
mistake in the memory of ABS control module during inspection.)

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VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-9
1-1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown below will facilitate collecting information to the
point required for proper analysis and diagnosis.
CUSTOMER QUESTIONNAIRE (EXAMPLE)
Customer's name:Model:VIN:
Date of issue:Date Reg.Date of problem:Mileage:
Problem Symptoms

ªABSº warning light abnormal: fails to turn on/fails to go off /
flashes

Abnormal noise while vehicle is running: from motor, from valve,
other__________________

Wheel is locked at braking:

Pump motor does not stop (running):

Braking does not work:

Other:
Frequency of occurrence
Continuous/Intermittent ( times a day, a month) /
other______________
Conditions for Occurrence
of Problem

Vehicle at stop & ignition switch ON:

When starting: at initial start only / at every start / Other______________

Vehicle speed: while accelerating / while decelerating / at stop /
while turning / while running at constant speed /
other________________

Road surface condition: Paved road / rough road / snow-covered
road / other_________________

Chain equipment:
Environmental Condition
Weather: fair / cloudy / rain / snow / other___________________

Temperature: F (C)
Diagnostic Trouble Code

First check: Normal code/malfunction code ( )

Second check after
test drive: Normal code / malfunction code ( )

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5E1-10 ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL)
1-2. PROBLEM SYMPTOM CONFIRMATION
Check if what the customer claimed in CUSTOMER QUESTIONNAIRE is actually found in the vehicle and
if that symptom is found, whether it is identified as a failure. (This step should be shared with the customer
if possible.) When ªABSº warning lamp is not operated correctly, proceed to ªDiagnostic Flow Table-A, B or
Cº.
1-3. DIAGNOSTIC TROUBLE CODE (DTC) CHECK, RECORD AND CLEARANCE
Perform ªDiagnostic Trouble Code Checkº as shown below, record it and then clear it referring to ªDiagnostic
Trouble Code Clearanceº in this section.
If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again when
the ignition switch is turned ON, attempt to diagnose the trouble based on the DTC recorded in this step may
mislead the diagnosis or make diagnosing difficult. Proceed to Step 2 to check ABS control module for proper
self-diagnosis function.
If the malfunction DTC which was once displayed and then cleared can be detected (indicated) again when
ignition switch is turned ON, proceed to Step 3.
2. DRIVING TEST
Test drive the vehicle at 40 km / h for more than a minute and check if any trouble symptom (such as abnormal
lighting of ªABSº warning lamp) exists.
If the malfunction DTC is confirmed again at ignition switch ON, driving test as described in above is not neces-
sary. Proceed to Step 3.
3. DIAGNOSTIC TROUBLE CODE CHECK
Recheck diagnostic trouble code referring to item ªDTC CHECKº as shown below.
4. DIAGNOSTIC TROUBLE CODE FLOW CHART
According to Diagnostic flow table for the diagnostic trouble code confirmed in Step 3, locate the cause of the
trouble, namely in a sensor, switch, wire harness, connector, actuator, ABS control module or other part and
repair or replace faulty parts.
5. ªDIAGNOSISº IN ªBRAKEº SECTION
Check the parts or system suspected as a possible cause referring to ªDiagnosisº in ªBRAKESº section and
based on symptoms appearing on the vehicle (symptoms obtained through Steps 1-1, 1-2 and 2 and repair or
replace faulty parts, if any.
6. CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to IN-
TERMITTENT TROUBLE in ªGENERAL INFORMATIONº section and related circuit of trouble code recorded
in Step 1-3.
7. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the ABS is free from any abnormal conditions. If what has been
repaired is related to the malfunction DTC, clear the DTC once and perform test driving and confirm that a nor-
mal code is indicated.

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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.