2003 SUZUKI GRAND VITARA Parking and rear brake

YH4
GRAND
VITARA
PARKING AND REAR BRAKE 5C-15
1. Rear axle shaft
2. Wheel bearing
3. Brake back plate1. Rear axle shaft
1. Rear axle
housing ªAº
INSTALLATION
1) Apply sealant to mating surface of bearing retainer with brake
back plate.
ªAº: Sealant 99000-31110
NOTE:
Make sure to remove old sealant before applying it anew.
2) Install brake back plate to rear axle shaft.
3) Apply sealant to joint seam of rear axle housing and brake back
plate.
ªAº: Sealant 99000-31110
NOTE:
Make sure to remove old sealant before applying it anew.
4) Install rear axle shaft to rear axle housing.
5) Tighten brake back plate nuts to specified torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
5C-16 PARKING AND REAR BRAKE
1. Brake back plate
2. Cable cap
3. Parking brake cable
6) Install wheel cylinder, and tighten wheel cylinder bolts and
brake pipe flare nut (or nuts) to specified torque. (Refer to steps
1) to 4) of WHEEL CYLINDER INSTALLATION of this section.)
7) Install parking brake cable to brake back plate.
8) Install brake shoes, referring to steps 1) to 4) of BRAKE SHOE
INSTALLATION.
9) Install brake drum. Refer to steps 1) to 2) of BRAKE DRUM
INSTALLATION in this section.
10) Refill differential housing with new specified gear oil. Refer to
ªMAINTENANCE SERVICEº in Section 7E for refill.
11) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to BLEEDING BRAKES in Section 5.)
12) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
13) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load three to ten times so as to obtain proper drum-
to-shoe clearance.
Adjust parking brake cable. (For adjustment, refer to PARKING
BRAKE CHECK AND ADJUSTMENT in Section 5.)
14) Tighten rear center console box screws.
15) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
16) Check each installed part for oil leakage.

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
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-15
1. Battery
2. Main fuses
3. Ignition switch
4. Circuit fuses
5. ABS hydraulic unit / control module
5-1. Terminal arrangement for ABS hydraulic unit /
control module assembly
5-2. ABS fail-safe relay (Solenoid valve relay)
5-3. ABS pump motor relay
5-4. Pump motor
5-5. Solenoid valves
6. ªABSº warning lamp
7. Right-rear wheel speed sensor
8. Left-rear wheel speed sensor
9. Right-front wheel speed sensor
10. Left-front wheel speed sensor
11. Data link connector
12. Diagnosis connector
13. Stop lamp
14. Stop lamp switch
15. PCM (ECM+TCM) or ECM
16. G sensor (For 4WD model only)
17. 4WD switch (For 4WD model only)
18. 4WD indicator lamp (For 4WD model only)
19. 4WD controller (If equipped)
20. EBD warning lamp (Brake warning lamp)
21. Combination meter
22. Parking brake switch
23. Brake fluid lever switch
24. Warning lamp driver moduleWire colorB : Black
B / Bl : Black / Blue
B / O : Black / Orange
B / W : Black / White
Bl : Blue
Bl /B : Blue / Black
Bl / O : Blue / Orange
Br : Brown
G : Green
G / B : Green / Black
G / W : Green / White
Lg : Lightgreen
Lg / B : Lightgreen / Black
O / B : Orange / Black
O / G : Orange / Green
O / W : Orange / White
P : Pink
P / B : Pink / Black
V / G : Violet / Green
W / BI : White / Blue
W / G : White / Green
W / Y : White / Yellow
Y : Yellow
Y / B : Yellow / Black
SYSTEM CIRCUIT
TERMINALCIRCUIT
A1Right-rear wheel speed sensor (+)
A2Right-front wheel speed sensor (±)
A3Right-front wheel speed sensor (+)
A4G sensor ground (For 4WD model only)
A5ÐÐÐ
A6ÐÐÐ
A7Idle up signal
A8Diagnosis switch terminal
A9Stop lamp switch
A10Ground (For ABS control module)
A11ABS fail-safe relay
A12Right-rear wheel speed sensor (±)
A13Left-front wheel speed sensor (±)
A14G sensor signal (For 4WD model only)
A15ÐÐÐ
A16ÐÐÐ
A17ªABSº warning lamp
A18Left-rear wheel speed sensor (+)
A19Left-rear wheel speed sensor (±)
A20Left-front wheel speed sensor (+)
A21ÐÐÐ
A22Data link connector
A23ÐÐÐ
A244WD switch (For 4WD model only)
A25Ignition switch
A26ªEBDº warning lamp
A27ABS pump motor relay
A28Ground (For ABS pump motor)

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-23
1. Ignition switch
2. ABS hydraulic unit /
control module assembly
3. Left-front wheel speed
sensor
4. Right-front wheel speed
sensor
5. Left-rear wheel speed
sensor
6. Right-rear wheel speed
sensor
7. ABS hydraulic unit /
control connector of harness
DTC 21 (DTC C1021), 22 (DTC C1022) ± RIGHT-FRONT WHEEL SPEED SENSOR
CIRCUIT
DTC 25 (DTC C1025), 26 (DTC C1026) ± LEFT-FRONT WHEEL SPEED SENSOR
CIRCUIT
DTC 31 (DTC C1031), 32 (DTC C1032) ± RIGHT-REAR WHEEL SPEED SENSOR
CIRCUIT
DTC 35 (DTC C1035), 36 (DTC C1036) ± LEFT-REAR WHEEL SPEED SENSOR
CIRCUIT
DESCRIPTION
The ABS control module monitors the voltage at the positive (+) terminal of each sensor while the ignition switch
is ON. When the voltage is not within the specified range, an applicable DTC will be set. Also, when no sensor signal
is inputted at starting or while running, an applicable DTC will be set.
NOTE:
When the vehicle was operated in any of the following ways, one of these DTC's may be set even when
the sensor is in good condition. If such possibility is suspected, repair the trouble (dragging of brake, etc.)
of the vehicle, clear DTC once and then after performing the driving test as described in Step 2 of ªABS
DIAG. FLOW TABLEº, check whether or not any abnormality exists.
± The vehicle was driven with parking brake pulled.
± The vehicle was driven with brake dragging.
± Wheel spin occurred while driving.
± Wheel(s) was turned while the vehicle was jacked up.
± The vehicle was stuck.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-31
1. Diagnosis
connector
(6 pins connector)
2. Diag. switch
terminal
3. Ground
4. Service wire
Brake
pedal
Ignition
sw.
Motor
Solenoid
Rear3.0 sec.
3.0
ON-VEHICLE SERVICE
PRECAUTION
When connector are connected to ABS hydraulic unit / control mod-
ule assembly, do not disconnect connectors of sensors and turn
ignition switch ON. Then DTC will be set in ABS control module.
ABS HYDRAULIC UNIT OPERATION CHECK
1) Check that basic brake system other than ABS is in good condi-
tion.
2) Check that battery voltage is 11V or higher.
3) With ªABSº warning lamp, check that no abnormality is de-
tected in ABS. Refer to ªDIAGNOSTIC TROUBLE CODE
(DTC) CHECKº in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake dragging
occurs. If it does, correct.
7) With diag. switch terminal of diagnosis connector connected to
ground by using service wire, turn ignition switch ON and check
if ªABSº warning lamp indicates DTC 12.
8) Turn ignition switch OFF.
9) Perform following checks with help of another person.
Brake pedal should be depressed and then ignition switch
turned ON by one person and wheel should be turned by
another person's hand. At this time, check that:

Operation sound of solenoid is heard and wheel turns only
about 0.5 sec. (Brake force is depressurized).

Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF
ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace hydrau-
lic unit / control module assembly.
11) Turn ignition switch OFF and remove service wire from diagno-
sis connector.

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