Suzuki Grand Vitara JB419. Manual - part 82

Propeller Shaft:  3D-2

Repair Instructions

Propeller Shaft Removal and Installation

S5JB0B3406002

Removal

1) Hoist vehicle.
2) Give match marks (1) on joint flange and propeller 

shaft as shown in the figure.

3) Remove rear propeller shaft.
4) Drain transfer oil when removed front propeller shaft 

from transfer, if necessary.

Installation
Reverse removal procedure to install propeller shaft 
noting the following points.
• Clean and inspect sliding portion of propeller shaft 

end (where oil seal contacts) before installation and if 
even small dent or scratch exists, correct end clean it 
again.
Then apply grease inside splines of propeller shaft.

“B”:  Grease 99000–25010 (SUZUKI Super Grease 
A)

• Install propeller shaft aligning match marks. 

Otherwise, vibration may occur during driving.

• Use the following specification to torque universal joint 

flange nuts and bolts. For front propeller shaft flange 
bolt (front differential side), apply thread lock cement 
to thread part of bolts if reused.

• Fill transfer oil, if removed front propeller shaft 

referring to “Transfer Oil Change in Section 3C in 
related manual”, if necessary.

“A”:  Thread lock cement 99000–32110 (Thread 
Lock Cement Super 1322)

Tightening torque
Front propeller shaft flange bolt (a):  30 N·m (3.0 
kgf-m, 22.0 lb-ft)
Rear propeller shaft flange nut (b):  85 N·m (8.5 
kgf-m, 61.5 lb-ft)

[A]: Front propeller shaft
[B]: Rear propeller shaft

I5JB0A340002-02

IYSQ01521009-01

[A]: Front propeller shaft
[B]: Rear propeller shaft

I5JB0A340004-01

3D-3 Propeller Shaft: 

Specifications

Tightening Torque Specifications

S5JB0B3407001

NOTE
The specified tightening torque is also described in the following.
“Propeller Shaft Construction”

 

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

Special Tools and Equipment

Recommended Service Material

S5JB0B3408001

NOTE
Required service material is also described in the following.
“Propeller Shaft Construction”

 

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Front propeller shaft flange bolt

30

3.0 

22.0

)

Rear propeller shaft flange nut

85

8.5 

61.5

)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Super Grease A

P/No.: 99000–25010

)

Thread lock cement

Thread Lock Cement Super 1322

P/No.: 99000–32110

)

Table of Contents 4- i

4

Section 4

CONTENTS

Brakes

Precautions ................................................. 4-*

Precautions.............................................................. 4-*

Precautions for Brakes........................................... 4-*

Brake Control System and Diagnosis ....4A-*

General Description ............................................. 4A-*

Brakes Construction.............................................4A-*
Front Brake Hose / Pipe Construction..................4A-*
Rear Brake Hose / Pipe Construction ..................4A-*
Master Cylinder Assembly Construction ..............4A-*
Booster Assembly Construction ...........................4A-*

Diagnostic Information and Procedures............ 4A-*

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

Repair Instructions .............................................. 4A-*

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-*

Rear Brake Hose / Pipe Removal and 

Installation..........................................................4A-*

Master Cylinder Components...............................4A-*
Master Cylinder Reservoir Removal and 

Installation..........................................................4A-*

Master Cylinder Assembly Removal and 

Installation..........................................................4A-*

Master Cylinder Assembly Inspection ..................4A-*
Brake Booster Components.................................4A-*
Brake Booster Removal and Installation ..............4A-*
Booster Push Rod Clevis Adjustment ..................4A-*

Specifications....................................................... 4A-*

Tightening Torque Specifications.........................4A-*

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

Recommended Service Material..........................4A-*
Special Tool .........................................................4A-*

Front Brakes .............................................4B-*

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

Front Disc Brake Caliper Assembly 

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

Repair Instructions .............................................. 4B-*

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

Installation ......................................................... 4B-*

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

Installation ......................................................... 4B-*

Front Disc Brake Caliper Disassembly and 

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

Front Disc Brake Caliper Inspection.................... 4B-*
Front Brake Disc Removal and Installation ......... 4B-*
Front Brake Disc Inspection ................................ 4B-*

Specifications....................................................... 4B-*

Tightening Torque Specifications........................ 4B-*

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

Recommended Service Material ......................... 4B-*

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-*

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 Check and Adjustment ................ 4D-*
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
ABS 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 Lamp Check ...............................4E-10

EBD Warning Lamp (Brake Warning Lamp) 

Check................................................................ 4E-*

DTC Check........................................................4E-10
DTC Table.........................................................4E-11

DTC Clearance ................................................... 4E-*

Scan Tool Data .................................................4E-11
ABS Warning Lamp Does Not Come ON at 

Ignition Switch ON ..........................................4E-12

ABS Warning Lamp Comes ON Steady............4E-14
EBD Warning Lamp (Brake Warning Lamp) 

Comes ON Steady ..........................................4E-15

Serial Data Link Circuit Check ............................ 4E-*

DTC C1015: G Sensor Circuit Failure (For 

4WD Vehicle) ..................................................4E-16

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-17

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-20

DTC C1057: ABS (EPS

®) Control Module 

Power Supply Circuit Failure...........................4E-22

DTC C1061: Pump Motor and/or Motor Driver 

Circuit Failure ..................................................4E-24

DTC C1063: Solenoid Valve Power Supply 

Driver Circuit Failure .......................................4E-25

DTC C1071: ABS (ESP

®) Control Module 

Internal Defect.................................................4E-27

DTC U1073: Control Module Communication 

Bus Off ............................................................4E-28

DTC U1100: Lost Communication with ECM 

(Reception Error).............................................4E-30

Repair Instructions ............................................4E-31

Hydraulic Unit Operation Check........................4E-31
ABS (ESP

®) Hydraulic Unit / Control Module 

Assembly On-Vehicle Inspection ....................4E-32

ABS (ESP

®) Hydraulic Unit / Control Module 

Assembly Removal and Installation ................4E-32

Front Wheel Speed Sensor On-Vehicle 

Inspection.......................................................... 4E-*

Front Wheel Speed Sensor Removal and 

Installation ......................................................... 4E-*

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

Inspection.......................................................... 4E-*

Rear Wheel Speed Sensor Removal and 

Installation ......................................................... 4E-*

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

Installation ......................................................... 4E-*

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

Installation ......................................................... 4E-*

Specifications .....................................................4E-34

Tightening Torque Specifications......................4E-34

Special Tools and Equipment ...........................4E-35

Special Tool ......................................................4E-35

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