Suzuki Esteem, Swift 1994-02

Hydraulic Control Module

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Removal & Installation




WARNING
To help avoid personal injury, due to a retained load on the hydraulic modulator/motor pack assembly, the gear tension relief function of the SUZUKI scan tool must be performed prior to removal of the hydraulic modulator.

  1. Using the SUZUKI scan tool, perform the gear tension relief sequence.
  2.  
  3. Remove battery from vehicle.
  4.  
  5. Drain brake fluid in reservoir, master cylinder and ABS actuator assembly (hydraulic modulator/motor pack assembly).
  6.  
  7. Disconnect solenoid connectors (1).
    NOTE
    Place a shop towel beneath the hydraulic modulator brake pipes to prevent brake fluid from contaminating motor pack or electrical connectors.

  8.  
  9. Disconnect brake pipes (1) from ABS actuator with special tool 09950-78220.
    NOTE
    Do not allow brake fluid to get on painted surface, motor and electrical connectors.

  10.  
  11. Remove ABS actuator assembly (1) from vehicle.
  12.  
  13. Disconnect motor pack harness connector.

    Click image to see an enlarged view

    Fig. Motor pack (1), hydraulic modulator (2), ABS solenoid (3) and under cover (4)-Swift

  14.  

To install:

  1. Install ABS actuator assembly in reverse order of removal procedure, noting the following points.
  2.  
  3. Torque all fasteners to the following specifications:

    ABS actuator assembly mounting bolts: 8 ft. lbs. (10 Nm)
     
    Brake pipe flare nuts: 12 ft. lbs. (16 Nm)
     

  4.  
  5. After installing, bleed air from brake system.
  6.  



Click image to see an enlarged view

Fig. ABS hydraulic unit/control module assembly (1) and assembly mounting nuts (2)-Esteem

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative cable from battery.
  4.  
  5. Using special tool 09950-78220, disconnect brake pipes from ABS hydraulic unit/control module assembly.
    CAUTION
    Put bleeder plug cap onto pipe to prevent fluid from spilling. Do not allow brake fluid to get on painted surfaces.

  6.  
  7. Disconnect ABS hydraulic unit/control module assembly connector.
  8.  
  9. Remove three nuts and take out ABS hydraulic unit/control module assembly from bracket.
    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.

  10.  

To install:

Click image to see an enlarged view

Fig. To right front (1), left rear (2), right rear (3), left front (4), master cylinder-secondary (5) and master cylinder-primary (6)-Esteem

  1. Install hydraulic unit by reversing removal procedure.
  2.  
  3. Torque all fasteners to the following specifications:

    Brake pipe flare nut a: 12 ft. lbs. (16 Nm)
     
    Hydraulic unit nut b: 8 ft. lbs. (11 Nm)
     
    Hydraulic unit bracket bolt c: 17 ft. lbs. (23 Nm)
     

  4.  
  5. Bleed air from brake system.
  6.  
  7. Check each installed part for fluid leakage and perform hydraulic unit operation check.
    NOTE
    For new ABS hydraulic unit/control module assembly, if ABS Hydraulic Unit Operation Check procedure has not been performed, -ABS- warning lamp may flash when ignition switch is turned to ON position. Accordingly perform ABS Hydraulic Unit Operation Check to stop flashing of -ABS- warning lamp.

  8.  
  9. Perform hydraulic unit operation check as follows:


    1. Check that basic brake system other than ABS is in good condition.
    2.  
    3. Check that battery voltage is 11V or higher.
    4.  
    5. With -ABS- warning lamp, check that no abnormality is detected in ABS. Turn the ignition switch to ON and check that -ABS- warning lamp lights for about 2 seconds and then goes OFF.
    6.  
    7. Lift up vehicle.
    8.  
    9. Set transmission to neutral and release parking brake.
    10.  
    11. Turn each wheel gradually by hand to check if brake dragging occurs. If it does, correct.

      Click image to see an enlarged view

      Fig. Diag. switch terminal (2) of DIAG-2 connector (1) connected to ground (3) using service wire-Esteem

    12.  
    13. With diag. switch terminal (2) of DIAG-2 connector (1) connected to ground (3) by using service wire, turn ignition switch to ON and check if -ABS- warning lamp indicates DTC 12.
    14.  

  10.  
  11. Turn ignition switch to OFF.
  12.  
  13. Perform the following checks with help of another person. Brake pedal (1) should be depressed and then ignition switch turned to ON position 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.
     

    1. If all 4-wheels cannot be checked during one ignition cycle (OFF - ON), repeat the previous two steps till all 4 wheels are checked. If a faulty condition is found in this step and the step before, replace hydraulic unit.
    2.  
    3. Turn ignition switch to OFF position and remove service wire from DIAG-2 connector.
    4.  

  14.  

 
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