Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 286

4E-36 ABS: 

Repair Instructions

Hydraulic Unit Operation Check

S6JB0A4506001

1) Check that basic brake system other than ABS or 

ESP

® is in good condition.

2) Check that battery voltage is 11 V or higher.
3) Lift up vehicle.
4) Set transmission to neutral and release parking 

brake.

5) Turn each wheel gradually by hand to check if brake 

dragging occurs. If it does, correct.

6) Connect SUZUKI scan tool to data link connector 

(DLC) (1) with ignition switch OFF.

Special tool
(A):  SUZUKI scan tool

7) Turn ignition switch to ON position and select menu 

press / depress in “HYDRAULIC CONTROL TEST” 
under “miscellaneous test” (“MISC. TEST”) mode of 
SUZUKI scan tool. Refer to SUZUKI scan tool 
operator’s manual for further details.

NOTE
“Press” in the menu is functionable only 
vehicle with ESP

®.

 

8) Perform the following checks with help of another 

person.
• Depressurization check

Step on brake pedal (1) and then select testing 
wheel by SUZUKI scan tool and the wheel (2) 
should be turned by another person’s hand. At this 
time, check whether the wheel rotates freely due 
to brake depressurization.

• Pressurization check

Step off brake pedal (1) and then select testing 
wheel by SUZUKI scan tool and the wheel (2) 
should be turned by another person’s hand. At this 
time, check whether the wheel locks due to brake 
pressurization.

NOTE
Pressurization / Depressurization by SUZUKI 
scan tool is available for 0.5 second.

 

9) Check for all 4-wheels condition respectively. If a 

faulty condition is found, replace hydraulic unit / 
control module assembly.

10) After completing the check, turn ignition switch to 

OFF position and disconnect SUZUKI scan tool from 
DLC.

ABS (ESP

®) Hydraulic Unit / Control Module 

Assembly On-Vehicle Inspection

S6JB0A4506002

CAUTION

!

 

Never disassemble ABS (ESP

®) hydraulic 

unit / control module assembly, loosen blind 
plug or remove motor. Performing any of 
these prohibited services will affect original 
performance of ABS (ESP

®) hydraulic unit / 

control module assembly.

 

Check hydraulic unit for fluid leakage.
If any, repair or replace.

(A)

1

I5JB0A450008-01

I4RH01450021-01

ABS: 4E-37

ABS (ESP

®) Hydraulic Unit / Control Module Assembly Removal and Installation

S6JB0A4506003

CAUTION

!

 

Never disassemble ABS (ESP

®) hydraulic unit / control module assembly, loosen blind plug or remove 

motor. Performing any of these prohibited services will affect original performance of ABS (ESP

®) 

hydraulic unit / control module assembly.

 

5

2

(c)

(d)

3

(a)

(c)

(d)

(a)

4

1

(b)

(a)

[A]

[

B]

6

7

6

6

8

8

9

10

I5JB0B450006-01

[A]: ESP

® model

5. ABS control module connector

: 16 N

⋅m (1.6 kgf-m, 11.5 lb-ft)

[B]: Non-ESP

® model

6. Brake pipe flare nut for M10

: 19 N

⋅m (1.9 kgf-m, 14.0 lb-ft)

1. ABS hydraulic unit / control module assembly

7. Brake pipe flare nut for M12

: 9 N

⋅m (0.9 kgf-m, 6.5 lb-ft)

2. ESP

® hydraulic unit / control module assembly

8. ABS (ESP

®) hydraulic unit / control module 

assembly bolt

: 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

3. Bracket

9. ABS (ESP

®) hydraulic unit / control module 

assembly bracket bolt

4. ESP

® control module connector

10. ABS (ESP

®) hydraulic unit / control module 

assembly bracket nut

4E-38 ABS: 

NOTE

• For ESP

® model, be sure to perform “Sensor Calibration in Section 4F” before performing hydraulic 

unit operation check when ESP

® hydraulic unit / control module is replaced.

• When ignition switch is turned to ON position after replacing ESP

® hydraulic unit / control module, 

DTC C1075, C1076, C1078 and C1077 are stored in ESP

® control module and the following lights 

light up or flash. However, these are in normal operation. These DTCs are cleared and lights are 
turned off if the following operations are performed in order.
1) “Sensor Calibration in Section 4F”.
2) “Hydraulic Unit Operation Check”.
3) Ignition switch OFF and ON.

 

Removal

1) Disconnect negative (–) cable from battery.
2) Remove ECM referring to “Engine Control Module 

(ECM) Removal and Installation: For Petrol Engine 
Model in Section 1C”.

3) Disconnect ABS (ESP

®) control module connector 

as shown in figure.

4) Using special tool, loosen flare nuts (1) and 

disconnect brake pipes (2) from ABS (ESP

®) 

hydraulic unit / control module assembly (3).

Special tool
(A):  09950–78220

NOTE
Put bleeder plug cap or the like onto pipe to 
prevent fluid from spilling. Do not allow brake 
fluid to get on painted surfaces.

 

5) Disconnect harness clamps (4) from bracket (5).

1. ABS warning light

4. SLIP indicator light

2. EBD warning light (brake warning light)

5. ESP

® OFF light

3. ESP

® warning light

3

2

1

4

5

I6JB01460002-02

[A]: ESP

® model

1. ESP

® control module connector

[B]: Non-ESP

® model

2. ABS control module connector

C: Pull up to disconnect

3. Lock

D: Pull down to disconnect

3

1

[A]

[B]

C

D

3

2

I6JB01450016-02

3

2

4

5

1

(A)

I5JB0A450023-01

ABS: 4E-39

6) Remove ABS (ESP

®) hydraulic unit / control module 

with bracket from vehicle by removing bracket bolt 
and two bracket nuts.

7) Remove bolt and pull out ABS (ESP

®) hydraulic unit 

/ control module assembly (1) from bracket (3) using 
flat end rod or the like (2).

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 / control module assembly by 

reversing removal procedure.

Tightening torque
Brake pipe flare nut for M10 (a):  16 N·m (1.6 kgf-
m, 11.5 lb-ft)
Brake pipe flare nut for M12 (b):  19 N·m (1.9 kgf-
m, 14.0 lb-ft)
ABS (ESP

®) hydraulic unit / control module 

assembly bolt (c):  9 N·m (0.9 kgf-m, 6.5 lb-ft)
ABS (ESP

®) hydraulic unit / control module 

assembly bracket bolt (d):  25 N·m (2.5 kgf-m, 
18.0 lb-ft)
ABS (ESP

®) hydraulic unit / control module 

assembly bracket nut (e):  25 N·m (2.5 kgf-m, 
18.0 lb-ft)

2) Connect ABS (ESP

®) control module connector and 

lock it as shown in figure.

3) Connect harness clamp to bracket.
4) Install ECM referring to “Engine Control Module 

(ECM) Removal and Installation: For Petrol Engine 
Model in Section 1C”.

5) Connect negative (–) cable at battery.
6) Bleed air from brake system referring to “Air 

Bleeding of Brake System in Section 4A”.

7) Check each installed part for fluid leakage.
8) For ESP

® model, perform “Sensor Calibration in 

Section 4F”.

9) Perform “Hydraulic Unit Operation Check”.

10) Turn ignition switch to OFF position once and then 

ON position. In this state, make sure that warning / 
indicator lights are turn off.

11) Check DTC(s) are not stored in hydraulic unit / 

control module.

2

1

3

I5JB0A450024-01

[A]: ESP

® model

1. ESP

® control module connector

[B]: Non-ESP

® model

2. ABS control module connector

C: Pull down until lock to connect

3. Lock

D: Pull up until lock to connect

C

D

[A]

[B]

1

3

3

2

I6JB01450018-03