ABS SUZUKI GRAND VITARA 1999 2.G Service Owner's Guide

YH4
GRAND
VITARA
1. Flexible hose
2. E-ring
3. Brake pipe
4. Cross member1. LSPV stay
1. Hose
2. Axle housing
1. Propeller shaft
2. Differential carrier
REAR SUSPENSION 3E-17
7) Using special tools (B) & (C) indicated below, draw out axle
shafts. For vehicle equipped with ABS, remove wheel speed
sensor from axle housing before drawing out axle shaft.
NOTE:
Use care not to pull brake back plate along with shaft.
Special Tool
(C): 09943-35512
(B): 09942-15510
8) For vehicle without ABS, remove LSPV stay from axle housing.
9) Remove brake back plate from rear axle housing.
10) Disconnect brake pipe from flexible hose and remove E-ring
(front side).
11) Remove brake pipe clamps and pipes from axle housing and
disconnect breather hose from axle housing.
12) Disconnect propeller shaft and remove propeller shaft from
transmission.

YH4
GRAND
VITARA
3E-18 REAR SUSPENSION
1. Axle housing
2. Jack
1. Differential carrier
assembly
2. Differential carrier nut
1. Lower rod
2. Lower rod rear
mount nut
3. Shock absorber
1. Lower mount
bolt
13) For jobs hereafter, support rear axle housing by using floor jack
under axle housing.
14) Remove differential carrier assembly.
15) Loosen rear mount nut of upper rod but don't remove bolt.
16) Loosen rear mount nut of lower rod but don't remove bolt.
17) Remove rear axle side lateral rod mount bolt.
18) Remove shock absorber lower mount bolt.
19) Lower floor jack until tension of suspension coil spring be-
comes a little loose and remove rear mount bolt of upper , lower
and lateral rod.
20) Lower rear axle housing gradually.
21) Remove axle housing.

YH4
GRAND
VITARA
1. Lower rod
2. Body center
1. Rear axle housing
2. Spring seat
3. Coil spring
4. Stepped part
1. Axle housing ªAº 1. Body center
1
2
1
REAR SUSPENSION 3E-19
INSTALLATION
Install removed parts in reverse order of removal, noting the follow-
ing.
1) Place rear axle housing on floor jack. Then install upper / lower
rod rear mounting bolts (right & left) in proper direction as shown
(refer to UPPER ROD INSTALLATION for upper rod bolts). At
this time, mount nuts but don't tighten them.
2) Install coil spring (right & left) on spring seat of axle housing and
raise axle housing.
NOTE:
When seating coil spring, mate spring end with stepped
part of rear axle spring seat as shown.
3) Install lateral rod to rear axle housing.
4) Install lower part of shock absorber to right and left sides of axle
housing and install bolts in proper direction as shown in figure.
At this time, mount nuts but don't tighten them.
5) Clean mating surfaces of axle housing and differential carrier
and apply sealant to housing side.
ªAº: Sealant 99000-31110
6) Install differential carrier assembly to axle housing and tighten
carrier nuts to specified torque.
Tightening Torque
(a): 55 N
.m (5.5 kg-m, 40.0 lb-ft)

YH4
GRAND
VITARA
1. Axle housingªAº
(c)
1. Axle housing
3E-20 REAR SUSPENSION
7) For vehicle with ABS, connect wheel speed sensor coupler and
install harness.
8) Install propeller shaft and torque nuts to specification.
Tightening Torque
(b): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
9) Remove floor jack from axle housing and connect breather
hose onto axle housing and clamp it securely.
10) Connect brake pipes onto axle housing and clamp them se-
curely.
For clamping positions, refer to SECTION 5A of this manual.
11) Connect brake flexible hose to bracket on axle housing and se-
cure it with E-ring.
12) Install LSPV stay to axle housing, tighten LSPV stay bolt to
specified torque.
And adjust LSPV referring to ªLSPV ASSEMBLY INSPEC-
TION AND ADJUSTMENTº in SECTION 5A.
Tightening Torque
(c): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
13) Connect brake pipe to brake flexible hose and tighten brake
pipe flare nut to specified torque.
Tightening Torque
(d): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
14) Clean mating surface of axle housing (right & left) and brake
back plate, then apply sealant as shown.
ªAº: Sealant 99000-31110
15) Apply grease to axle shaft inner oil seal lip as shown.
ªAº: Grease 99000-25010

YH4
GRAND
VITARA
3. Container 1. Plug cap
2. Vinyl tube
1. Bearing retainer
(e)
(f)
(g)
REAR SUSPENSION 3E-21
16) Apply sealant to mating surface of bearing retainer with brake
back plate.
NOTE:
Make sure to remove old sealant before applying it anew.
ªBº: Sealant 99000-31110
17) Install rear axle shaft to rear axle housing and tighten bearing
retainer nuts to specified torque.
NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing.
Tightening Torque
(e): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
18) For vehicle with ABS, tighten wheel speed sensor bolt to speci-
fied torque.
Tightening Torque
(f): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
19) Connect brake pipes to wheel cylinders (right & left) and tighten
brake pipe flare nuts to specified torque.
Tightening Torque
(g): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
20) Install brake drum (right & left). For details, refer to SECTION
5C ªBRAKE DRUM INSTALLATIONº.
21) Refill differential gear housing with new specified gear oil. Re-
fer to ªON-VEHICLE SERVICEº in SECTION 7F for refill.
22) Fill reservoir with brake fluid and bleed brake system.(For
bleeding operation, see SECTION 5.)

YH4
GRAND
VITARA
3E-22 REAR SUSPENSION
23) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(h): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
24) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load three to ten times so as to obtain proper drum-
to-shoe clearance.
Adjust parking brake cable (for adjustment, see SECTION 5C
of this manual.)
25) Tighten parking brake lever cover screws.
26) Lower hoist.
27) Tighten right and left lower / upper rod nuts lateral rod mount
bolt and shock absorber nuts to specified torque.
NOTE:
When tightening these nuts, be sure that vehicle is off
hoist and in non loaded condition.
Tightening Torque
(i): 90 N
.m (9.0 kg-m, 65.0 lb-ft)
(j): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
28) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
29) Perform brake test (foot brake and parking brake).
30) Check each installed part for oil leakage.

YH4
GRAND
VITARA
REAR SUSPENSION 3E-23
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mKg-mlb-ft
Shock absorber lock nut292.921.0
Shock absorber nut292.921.0
Shock absorber lower nut858.561.5
Lower rod bolt and nut
Upper rod bolt and nut909.065.0
Lateral rod bolt
Differential carrier nut555.540.0
Propeller shaft nut505.036.5
Brake pipe flare nut161.611.5
Bearing retainer nut232.317.0
Differentiation gear oilFiller plug505.036.5g
filler & drain plugDrain plug272.716.0
Wheel nut10010.072.5
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
Brake fluidDOT 3Brake reservoir tank
Sealant
SUZUKI BOND NO. 1215
(99000-31110)
Joint seam of axle and brake back
plate

Joint seam of bearing retainer and
brake back plate

Joint seam of differential carrier and
axle housing

Drain plug

Mating surface of oil seal and axle
housing
Gear oilFor gear oil information, refer to
SECTION 7F of this manualDifferential gear
(Refer axle housing.)

YH4
GRAND
VITARA
5
BRAKES 5-1
GENERAL DESCRIPTION5- 2 . . . . . . . . . . . . . .
DIAGNOSIS5- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Road Testing Brakes 5- 3. . . . . . . . . . . . . . . . . .
Brake Fluid Leaks 5- 3. . . . . . . . . . . . . . . . . . . .
Substandard or Contaminated
Brake Fluid 5- 3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 5- 4. . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5- 7 . . . . . . . . . . . .
Bleeding Brakes 5- 7. . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Free Height Check 5- 9. . . . . . . .
Brake Light Switch Adjustment 5- 9. . . . . . . . .
Excessive Pedal Travel Check 5- 9. . . . . . . . .
Brake Pedal Play Check 5-10. . . . . . . . . . . . . . .
Brake Fluid Level Check 5-10. . . . . . . . . . . . . . . Brake Hose and Pipe Check 5-10. . . . . . . . . . .
Master Cylinder Check 5-10. . . . . . . . . . . . . . . .
Brake Disc Check 5-11. . . . . . . . . . . . . . . . . . . .
Brake Pad Check 5-11. . . . . . . . . . . . . . . . . . . . .
Brake Shoe Check 5-11. . . . . . . . . . . . . . . . . . . .
Parking Brake Check and
Adjustment 5-12. . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Brake Hydraulic System 5-13. . . . . . .
Fluid Pressure Test 5-13. . . . . . . . . . . . . . . . . . .
Booster Operation Check 5-15. . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS5-17 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5-17 . . . . . . . .
SPECIAL TOOLS5-18 . . . . . . . . . . . . . . . . . . . . . .
SECTION 5
BRAKES
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:

When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E or 5E1 first.

All brake fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and / or could result in major repair expense. They must be replaced with one of same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to as-
sure proper retention of all parts. There is to be no welding as it may result in extensive damage and
weakening of the metal.
DIAGNOSIS5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PIPE / HOSE / MASTER CYLINDER5A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE5B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING AND REAR BRAKE5C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS

YH4
GRAND
VITARA
[FOR VEHICLE WITHOUT ABS]
[FOR VEHICLE WITH ABS]
1. Master cylinder
2-1. 4-way joint
2-2. 2-way joint
3. LSPV (Load Sensing Proportioning Valve)
4. Rear axle housing
5. ABS actuator (H.U.)
F.R.:Front side
5-2 BRAKES
GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons
(two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make
two independent circuits. One connects front brakes (right and left) and the other connects rear brakes (right and
left).
The load sensing proportioning valve (LSPV) is included in these circuits between the master cylinder and the rear
brake for the vehicle without ABS.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading / trailing
shoes) for the rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and me-
chanical linkage system. The same brake shoes are used for both parking and foot brakes.

YH4
GRAND
VITARA
5-4 BRAKES
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Not enough brak-
ing force
Brake oil leakage from brake lines.

Brake disc or pads stained with oil.

Overheated brakes.

Poor contact of shoes on brake drum.

Brake shoes linings stained with oil or wet
with water.

Badly worn brake shoe linings.

Defective wheel cylinders.

Malfunctioning caliper assembly.

Air in system.

Maladjusted sensor spring length of LSPV.

Broken sensor spring of LSPV.

Defective collar of LSPV.

Malfunctioning ABS (Antilock brake system),
if equipped.Locate leaking point and repair.
Clean or replace.
Determine cause and repair.
Repair for proper contact.
Replace.
Replace.
Repair or replace.
Repair or replace.
Bleed system.
Check or adjust.
Replace.
Replace.
Check system and replace as
necessary.
Brake pull
(Brakes not work-
ing in unison)
Pad or shoe linings are wet with water or
stained with oil in some brakes.

Drum-to-shoe clearance out of adjustment in
some brakes.
(Malfunctioning auto adjusting mechanism)

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Malfunctioning wheel cylinders.

Disturbed front end alignment.

Unmatched tires on same axle.

Restricted brake pipes or hoses.

Malfunctioning caliper assembly.

Loose suspension parts.

Loose calipers.Replace.
Check for inoperative auto adjusting
mechanism.
Replace.
Inflate equally.
Repair or replace.
Adjust as prescribed.
Tires with approximately the same
amount of tread should be used on the
same axle.
Check for soft hoses and damaged
lines.
Replace with new hoses and new
brake pipes.
Check for stuck or sluggish pistons
and proper lubrication of caliper slide
bush.
Caliper should slide.
Check all suspension mountings.
Check and torque bolts to specifica-
tions.
Noise (High pitched
squeak without
brake applied)
Front lining worn out.Replace linings.
Rear brake locked
prematurely
Maladjusted sensor spring length of LSPV.

Malfunction LSPV assembly.Check or adjust.
Replace assembly.
Brake locked
(For vehicles
equipped with
ABS)
Malfunctioning ABS, if equipped.Check system and replace as
necessary.