Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

ABS Hydraulic Unit

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REMOVAL & INSTALLATION



See Figure 1


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.


CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the ABS hydraulic unit mounting

  1. Use a special wrench (such as Suzuki tool 09950-78210) to loosen the brake fluid lines from the hydraulic unit, then plug the brake lines to prevent fluid loss or fluid contamination.
  2.  
  3. Detach the wiring harness connectors from the unit.
  4.  
  5. Remove the three retaining nuts, then lift the unit from the mounting bracket.
  6.  


WARNING
Do not subject the unit to sudden impacts, do not allow dust to enter the unit, and do not set the hydraulic unit on its side or upside down. Handling it in these ways will result in unit damage.

To install:
  1. Position the unit in the mounting bracket, then install the retaining nuts. Tighten the nuts to 186 inch lbs. (21 Nm).
  2.  
  3. Reattch the brake fluid lines to the hydraulic unit, ensuring that the lines are attached to their original ports on the unit. Tighten the brake line fittings to 141 inch lbs. (16 Nm).
  4.  
  5. Reattach the wiring harness connectors to the unit.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Bleed the hydraulic brake system, as described earlier in this section. (This ABS system is bled in the same manner as the same vehicle not equipped with the ABS system.)
  10.  

 
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