Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual — part 47

3C-83 Transfer: Non-Shift Type (Transfer without Shift Actuator)

Specifications

Tightening Torque Specifications

S5JB0E3327001

NOTE
The specified tightening torque is also described in the following.
“Transfer Assembly Components: Non-Shift Type (Transfer without Shift Actuator)”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A in related
manual”.

Special Tools and Equipment

Recommended Service Material

S5JB0E3328001

NOTE
Required service material is also described in the following.
“Transfer Assembly Components: Non-Shift Type (Transfer without Shift Actuator)”

Special Tool

S5JB0E3328002

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Input gear plate bolt

23

2.3

17.0

)

Rear case bolt

23

2.3

17.0

)

/ )

Strainer bolt

10

1.0

7.5

)

Oil pump cover bolt

23

2.3

17.0

)

Differential lock shift lever case bolt

23

2.3

17.0

)

Differential lock shift lever case dowel bolt

23

2.3

17.0

)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Super Grease A

P/No.: 99000–25010

)

/ ) / )

Sealant

SUZUKI Bond No.1217G

P/No.: 99000–31260

)

/ ) / ) / )

Thread lock cement

Thread Lock Cement Super 1322

P/No.: 99000–32110

)

09912–34510

09913–70123

Case separator

Bearing installing tool

)

)

/ )

09913–76010

09913–85210

Bearing installer

Bearing installer

)

/ ) / ) / )

)

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-*
Master Cylinder Assembly Construction . . . ..4A-*
Booster Assembly Construction . . . . . . ...4A-*

Diagnostic Information and Procedures. . . 4A-3

Brake Diagnosis Note . . . . . . . . . . ..4A-*

Brakes Symptom Diagnosis. . . . . . . . 4A-3

Repair Instructions . . . . . . . . . . . ..4A-5

Excessive Pedal Travel Check. . . . . . . .4A-*
Brake Pedal Play Check . . . . . . . . . ..4A-*
Brake Fluid Level Check . . . . . . . . . ..4A-*
Air Bleeding of Brake System . . . . . . . ..4A-*
Brake Pedal Free Height Adjustment. . . . ...4A-*
Brake Light Switch Adjustment . . . . . . . 4A-*
Brake Flexible Hose and Pipe Check. . . . ...4A-*
Master Cylinder Check. . . . . . . . . . .4A-*
Flushing Brake Hydraulic System . . . . . . 4A-*
Booster Operation Check. . . . . . . . . .4A-*

Front Brake Hose / Pipe Removal and

Installation. . . . . . . . . . . . . . . 4A-5

Rear Brake Hose / Pipe Removal and

Installation. . . . . . . . . . . . . . . 4A-5

Master Cylinder Components. . . . . . . ...4A-*

Master Cylinder Reservoir Removal and

Installation. . . . . . . . . . . . . . . 4A-5

Master Cylinder Assembly Removal and

Installation. . . . . . . . . . . . . . . 4A-6

Master Cylinder Assembly Inspection . . . . . 4A-8
Brake Booster Components. . . . . . . . 4A-9
Brake Booster Removal and Installation . . ... 4A-10

Booster Push Rod Clevis Adjustment . . . . ..4A-*

Specifications. . . . . . . . . . . . . .4A-11

Tightening Torque Specifications. . . . . ..4A-11

Special Tools and Equipment . . . . . . ...4A-11

Special Tool . . . . . . . . . . . . . ..4A-11

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

General Description . . . . . . . . . . . . 4B-*

Front Disc Brake Caliper Assembly

Construction . . . . . . . . . . . . . .. 4B-*

Repair Instructions . . . . . . . . . . . ..4B-1

Front Disc Brake Components . . . . . . . 4B-*
Front Disc Brake Pad On-Vehicle Check . . . 4B-*

Front Disc Brake Pad Removal and

Installation . . . . . . . . . . . . . . .4B-1

Front Brake Disc and Pad Inspection. . . . .. 4B-*

Front Disc Brake Caliper Removal and

Installation . . . . . . . . . . . . . . .4B-2

Front Disc Brake Caliper Disassembly and

Assembly. . . . . . . . . . . . . . ... 4B-*

Front Disc Brake Caliper Inspection. . . . . 4B-*

Front Brake Disc Removal and Installation . . .4B-2

Front Brake Disc Inspection . . . . . . . . 4B-*

Specifications. . . . . . . . . . . . . ...4B-3

Tightening Torque Specifications. . . . . . 4B-3

Rear Brakes. . . . . . . . . . . ...4C-*

General Description . . . . . . . . . . . . 4C-*

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

Repair Instructions . . . . . . . . . . . .. 4C-*

Rear Drum Brake Assembly Components . . .. 4C-*
Rear Brake Drum Removal and Installation. . 4C-*
Rear Brake Drum and Shoe Inspection . . . .. 4C-*
Rear Brake Shoe On-Vehicle Check. . . . ... 4C-*
Rear Brake Shoe Removal and Installation . . 4C-*
Rear Brake Shoe Inspection . . . . . . . ... 4C-*
Wheel Cylinder Removal and Installation . . ... 4C-*
Wheel Cylinder Inspection . . . . . . . . .. 4C-*
Rear Brake Back Plate Removal and

Installation . . . . . . . . . . . . . . . 4C-*

Specifications. . . . . . . . . . . . . ... 4C-*

Tightening Torque Specifications. . . . . . 4C-*

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

Recommended Service Material . . . . . . . 4C-*

Parking Brake . . . . . . . . . . ...4D-*

Component Location . . . . . . . . . . ... 4D-*

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

Repair Instructions . . . . . . . . . . . .. 4D-*

Parking Brake Check and Adjustment . . . . 4D-*

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.

4-ii Table of Contents

Parking Brake Lever Removal and Installation . 4D-*
Parking Brake Cable Removal and

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

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

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

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
Self-Diagnosis 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 Lamp Check . . . . . . . ...4E-10
EBD Warning Lamp (Brake Warning Lamp)

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

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

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

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

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

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

4WD vehicle). . . . . . . . . . . . ...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: Pump Motor and/or Motor Driver

Circuit. . . . . . . . . . . . . . . ..4E-26

DTC C1063: Solenoid Valve Power Supply

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

DTC C1071: ABS (ESP

®) Control Module

Internal Defect. . . . . . . . . . . . .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 On-Vehicle Inspection . . . . . 4E-33

ABS (ESP

®) Hydraulic Unit / Control Module

Assembly Removal and Installation . . . . 4E-34

Front Wheel Speed Sensor On-Vehicle

Inspection. . . . . . . . . . . . . . 4E-36

Front Wheel Speed Sensor Removal and

Installation . . . . . . . . . . . . . ...4E-37

Front Wheel Speed Sensor Inspection . . . .4E-38
Rear Wheel Speed Sensor On-Vehicle

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

Rear Wheel Speed Sensor Removal and

Installation . . . . . . . . . . . . . ...4E-38

Rear Wheel Speed Sensor Inspection . . . ..4E-39
Front Wheel Encoder On-Vehicle Inspection . 4E-39
Front Wheel Encoder Removal and

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

Rear Wheel Encoder On-Vehicle Inspection. .4E-39
Rear Wheel Encoder Removal and

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

Specifications . . . . . . . . . . . . . .4E-40

Tightening Torque Specifications. . . . . ..4E-40

Special Tools and Equipment . . . . . . ...4E-40

Special Tool . . . . . . . . . . . . . ..4E-40

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-2

Warning Lamp, Indicator Lamp 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
ESP

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

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

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

Table of Contents 4-iii

DTC Check . . . . . . . . . . . . . ... 4F-13
DTC Table. . . . . . . . . . . . . . . 4F-13
DTC Clearance . . . . . . . . . . . . . 4F-17
Fail-Safe Table. . . . . . . . . . . . .. 4F-17
Scan Tool Data . . . . . . . . . . . . . 4F-20
ESP

® Warning Lamp Does Not Come ON at

Ignition Switch ON . . . . . . . . . . .. 4F-21

ESP

® Warning Lamp Comes ON Steady. . . 4F-22

Serial Data Link Circuit Check . . . . . . .. 4F-23
DTC C1015 / C1017 / C1023: Longitudinal G

Sensor / Lateral G Sensor / Yaw Rate
Sensor in Yaw Rate / G Sensor Assembly
Failure . . . . . . . . . . . . . . . . 4F-25

DTC C1016: Stop Lamp Switch Circuit Failure .. 4F-25
DTC C1018: Brake Fluid Level Switch Failure .. 4F-27
DTC 1020: Master Cylinder Pressure Sensor

Power Supply Failure. . . . . . . . . .. 4F-28

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-28

DTC C1024: Steering Angle Sensor Circuit

Failure . . . . . . . . . . . . . . . . 4F-29

DTC C1027: ESP

® OFF Switch Circuit

Failure . . . . . . . . . . . . . . . . 4F-29

DTC C1028: Master Cylinder Pressure

Sensor Circuit Failure . . . . . . . . . . 4F-30

DTC C1034: Yaw Rate / G Sensor Assembly

Power Supply Failure. . . . . . . . . .. 4F-31

DTC C1037: Steering Angle Sensor Power

Supply Failure . . . . . . . . . . . . . 4F-32

DTC C1038: Steering Angle Sensor Detect

Rolling Counter Failure from ESP

® Control

Module . . . . . . . . . . . . . . . 4F-33

DTC C1039: Yaw Rate / G Sensor Assembly

Internal Failure . . . . . . . . . . . . 4F-34

DTC C1040: Stability Control System

Function Failure . . . . . . . . . . . .. 4F-34

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-35

DTC C1050: Back Switch Failure. . . . . .. 4F-35
DTC C1057: ESP

® (ABS) control module

power supply circuit failure. . . . . . . .. 4F-36

DTC C1061: Pump Motor and/or Motor Driver

Circuit Failure. . . . . . . . . . . . .. 4F-36

DTC C1063: Solenoid Valve Power Supply

Driver Circuit Failure . . . . . . . . . ... 4F-36

DTC C1071: ESP

® (ABS) Control Module

Internal Defect. . . . . . . . . . . . . 4F-36

DTC C1073: Lost Communication With Yaw

Rate / G Sensor Assembly. . . . . . . .. 4F-36

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-37

DTC C1090: ECM Detect Rolling Counter

Failure from ESP

® Control Module. . . . . 4F-38

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

Control Module Data in CAN Line Failure . ... 4F-39

DTC U1073: Control Module Communication

Bus Off . . . . . . . . . . . . . . . 4F-39

DTC U1100: Lost Communication with ECM

(Reception Error). . . . . . . . . . . . 4F-39

DTC U1101: Lost Communication with TCM

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

DTC U1126: Lost Communication with

Steering Angle Sensor (Reception Error). . 4F-42

DTC U1139: Lost Communication with 4WD

Control Module (Reception Error) . . . . ... 4F-43

DTC U1140: Lost Communication with BCM

(Reception Error). . . . . . . . . . . . 4F-44

Repair Instructions . . . . . . . . . . . 4F-45

Hydraulic Unit Operation Check. . . . . . 4F-45
Sensor Calibration. . . . . . . . . . . . 4F-45
ESP

® Hydraulic Unit / Control Module

Assembly On-Vehicle Inspection . . . . . 4F-46

ESP

® Hydraulic Unit / Control Module

Assembly Removal and Installation . . . . 4F-46

Front Wheel Speed Sensor On-Vehicle

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

Front Wheel Speed Sensor Removal and

Installation . . . . . . . . . . . . . ... 4F-46

Front Wheel Speed Sensor Inspection . . . . 4F-46
Rear Wheel Speed Sensor On-Vehicle

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

Rear Wheel Speed Sensor Removal and

Installation . . . . . . . . . . . . . ... 4F-46

Rear Wheel Speed Sensor Inspection . . . .. 4F-46
Front Wheel Encoder On-Vehicle Inspection . 4F-46
Front Wheel Encoder Removal and

Installation . . . . . . . . . . . . . ... 4F-46

Rear Wheel Encoder On-Vehicle Inspection. . 4F-47
Rear Wheel Encoder Removal and

Installation . . . . . . . . . . . . . ... 4F-47

Master Cylinder Pressure Sensor On-Vehicle

Inspection. . . . . . . . . . . . . . 4F-47

Yaw Rate / G Sensor Assembly On-Vehicle

Inspection. . . . . . . . . . . . . . 4F-48

Yaw Rate / G Sensor Assembly Removal and

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

Yaw Rate / G Sensor Inspection . . . . . ... 4F-50
Steering Angle Sensor On-Vehicle Inspection .. 4F-51
Steering Angle Sensor Removal and

Installation . . . . . . . . . . . . . ... 4F-51

Steering Angle Sensor Inspection. . . . . . 4F-51
ESP

® OFF Switch Removal and Installation . 4F-51

ESP

® OFF Switch Inspection . . . . . . ... 4F-52

Specifications. . . . . . . . . . . . . . 4F-52

Tightening Torque Specifications. . . . . .. 4F-52

Special Tools and Equipment . . . . . . ... 4F-52

Special Tool . . . . . . . . . . . . . .. 4F-52