system SUZUKI GRAND VITARA 2000 2.G Service Workshop Manual

YH4
GRAND
VITARA
[A]: With ABS
[B]: Without ABS
1. Piston stopper circlip
2. Piston stopper
3. Cylinder cup
4. Plate
5. Primary piston
6. Piston cup
7. Primary piston return spring
8. Primary spring retainer
9. Secondary piston pressure cup
10. Secondary piston
11. Return spring secondary seat
12. Secondary piston return spring
13. Secondary piston stopper bolt
14. Master cylinder body
ªAº: Primary piston
ªBº: Secondary piston
[B] [A]
5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER
GENERAL DESCRIPTION
MASTER CYLINDER ASSEMBLY
The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (ªaº
in the figure below) and secondary (ªbº) chambers. The hydraulic pressure produced in the primary chamber (ªaº)
acts on the front (for vehicle without ABS, rear) wheel brakes.
Also, the hydraulic pressure produced in the secondary chamber (ªbº) acts on the rear (for vehicle without ABS,
front) wheel brakes.
NOTE:
Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with
clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rub-
ber components may result. If any hydraulic component is removed or brake line disconnected, bleed the
brake system.
The torque values specified are for dry, unlubricated fasteners.
BOOSTER ASSEMBLY
The booster is located between the master cylinder and the brake pedal. It is so designed that the force created
when the brake pedal is depressed is mechanically increased combined with the engine vacuum.
The booster has two diaphragms of
ù7.5 in. (191 mm) effective diameter.
CAUTION:

Never disassemble brake booster assembly. If it is found faulty, replace it with new assembly.

The torque values specified are for dry, unlubricated fasteners. If any hydraulic component is re-
moved or brake line disconnected, bleed the brake system.

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VITARA
1. LSPV
2. LSPV lever
3. Spring
4. LSPV stay
5. Brake flare nut
[A]: Type A
[B]: Type B
1. Plunger
2. Lip seal
3. LSPV lever
4. Sensor spring
5. From master cylinder
primary chamber
(Rear wheel brake)
6. From master cylinder
secondary chamber
(Front wheel brake)
7. To rear wheel brake
8. Pin
9. Bolt hole
[A] [B]
44
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3
LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped)
As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear
wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the
vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Also, it releases the above described control over the hydraulic pressure applied to the rear wheel brake, should
any failure occur in the hydraulic circuit of the front wheel brake so that the hydraulic pressure produced in the mas-
ter cylinder is applied to the rear wheel brake directly to operate it.
CONSTITUTION
The LSPV components are grouped into three sections as follows.
ªAº: Sensor section
The main parts in this section are a lever and a spring which senses variation in the vehicle height as affected
by the loaded condition and converts it into the load.
ªBº: Hydraulic pressure control section
Included in this section are a stepped plunger and valve mechanism to execute proportional control.
ªCº: Fail-safe section
The main parts in this section are a chamber which draws in the hydraulic pressure from the front wheel brake
system and a fail-safe piston which releases the valve mechanism in the control section connected to the rear
wheel brake, should any failure occur in the front wheel brake system.

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BRAKES PIPE / HOSE / MASTER CYLINDER 5A-7
1. Rear axle
2. Shock absorber
3. Clamp
1. Brake pipe (to rear)
2. Brake pipe
(to LSPV, for vehicle without ABS)
3. 4-way (2-way) joint
4. Chassis frame
REAR BRAKE HOSE / PIPE
REMOVAL
1) Raise and suitably support vehicle. Remove tire and wheel.
2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.
INSTALLATION
1) Reverse removal procedure for brake hose or pipe installation procedure.

Be sure to obtain more than 3 mm (0.118 in.) clearance between axle housing and brake pipe.

Install clamps properly referring to figure below and tighten bolts.

When installing hose, make sure that it has no twist or kink.
2) Fill and maintain brake fluid level in reservoir. Bleed brake system.
3) Perform brake test and check each installed part for fluid leakage.

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GRAND
VITARA
1. Pin
2. Reservoir
3. Master cylinder
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-13
5) Apply thin coat of brake fluid to all around new grommets (2pcs.)
and install them to cylinder body, then install reservoir.
6) Set a new pin in reservoir hole and drive it in. At this time, make
end of pin and end face margin of reservoir equal.
INSTALLATION
NOTE:

See NOTE at the beginning of this section.

Adjust clearance between booster piston rod and primary
piston with special tool, referring to CLEARANCE BETWEEN
BOOSTER PISTON AND MASTER CYLINDER PISTON AD-
JUSTMENT in this section.
1) Install master cylinder to brake booster.
2) Tighten master cylinder attaching nuts to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
3) Connect brake pipes to master cylinder.

For vehicle with ABS
a) Connect brake pipes between master cylinder and ABS hy-
draulic unit.
b) For LH steering vehicle, connect ABS control module con-
nector.
c) For RH steering vehicle, install ABS hydraulic unit bracket
bolts and tighten it to specified torque.
Tightening Torque
(b): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
4) Tighten flare nuts to specification.
Tightening Torque
(c): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
5) Connect reservoir lead wire.
6) Fill reservoir with specified brake fluid.
7) Check brake pedal play and bleed air from system.
8) Perform brake test and check each installed part for fluid leak-
age.

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VITARA
5A-18 BRAKES PIPE / HOSE / MASTER CYLINDER
1. LSPV spring bolt
2. LSPV bolt
3. Brake pipe flare nut
4. Air bleeding plug
1. LSPV lever
2. Stopper bolt (if equipped)
3. Coil spring ªAº: Don't turn(a)
2) Torque each bolt and nut to specification as indicated respec-
tively in figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft) (brake flare nut)
(c): 7.5 N
.m (0.75 kg-m, 9.0 lb-ft) (bleeder plug)
3) Upon completion of installation, fill reservoir tank with specified
fluid and bleed air from brake system.
NOTE:
Make sure to bleed air from LSPV bleeder without failure.
4) After bleeding air, check that LSPV is installed properly, referring
to following INSPECTION & ADJUSTMENT.
INSPECTION & ADJUSTMENT
Confirm the following before inspection and adjustment.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.

Vehicle is free from any other load.
With vehicle in above conditions;
1) Place it on level floor.
2) Push up (for 5 door model) or push down (for 3 door model)
LSPV lever with finger till it stops and measure length ªLº of coil
spring as it is pulled.
3) Spring length ªLº should be the value specified below.
Spring length (between spring end and spring bolt)
ªLº: 103 mm (4.06 in.) (5 door model). . . . .
ªLº: 157 mm (6.18 in.) (3 door model). . . . .
4) If it isn't, adjust it to specification by changing stay positions as
shown in figure. After adjustment, tighten bolt to specified
torque.
For details, refer to left figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
NOTE:
Check to make sure that LSPV body and brake pipe joints
are free from fluid leakage. Replace defective parts, if any.

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VITARA
5B
FRONT BRAKE 5B-1
SECTION 5B
FRONT BRAKE
NOTE:
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 assure
proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening
of the metal.
CONTENTS
GENERAL DESCRIPTION5B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Pad5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper5B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Disc5B-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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GRAND
VITARA
[A]: TOKICO produced
[B]: SUMITOMO ELECTRIC produced1. Caliper pin bolt
2. Boot
3. Disc brake caliper
(Disc brake cylinder)
4. Piston seal
5. Disc brake piston
6. Cylinder boot
7. Disc brake inner pad
8. Disc brake outer pad
9. Brake caliper carrier
10. Pad spring
11. Bleeder plug
12. Bleeder plug cap
13. Caliper pin
14. Anti noise shim
15. Inner shim
Tightening torque
(a): 8.5 N.m (0.85 kg-m, 6.5 lb-ft)
(b): 8.0 N.m (0.80 kg-m, 6.0 lb-ft) [A]
[B]
5B-2 FRONT BRAKE
GENERAL DESCRIPTION
DISC BRAKE CALIPER ASSEMBLY
This caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying
force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston
and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in
a clamping action on the disc. This clamping action forces the pads (linings against the disc, creating friction to
stop the vehicle.
NOTE:

Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo-
nents may result. If any component is removed or line disconnected, bleed the brake system.
Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners.

For identification of the brake caliper type, see maker name or mark on brake caliper as shown.

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VITARA
1. Caliper pin bolts
1. Flexible hose bolt
FRONT BRAKE 5B-9
Caliper
Before installing caliper (cylinder body) to carrier, check to ensure
that guide pin (pin bolt) inserted in each caliper carrier hole can be
moved smoothly in thrust direction.
NOTE:
Where temperature gets as low as ±30
C in cold weather, use
rubber grease whose viscosity varies very little even at ±40
C
(±40
F).
INSTALLATION
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts to specifications.
Tightening Torque
(a), (b): 27 N
.m (2.7 kg-m, 20.0 lb-ft) For TOKICO brake. .
caliper
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft) For SUMITOMO. . . . .
(b): 85 N.m (8.5 kg-m, 61.5 lb-ft) ELECTRIC brake
85 N.m (8.5 kg-m, 61.5 lb-ft)caliper
NOTE:
Make sure that boots are fit into groove securely.
3) Install brake flexible hose as shown and torque hose mounting
bolt to specification.
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Torque wheel nuts to specification.
Tightening Torque
(c): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
5) After completing installation, fill reservoir with brake fluid and
bleed brake system. Perform brake test and check each
installed part for oil leakage.

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GRAND
VITARA
5C
PARKING AND REAR BRAKE 5C-1
SECTION 5C
PARKING AND REAR BRAKE
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:
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 assure
proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening
of the metal.
CONTENTS
GENERAL DESCRIPTION5C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brake Assembly5C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Cable5C- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Drum5C- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shoe5C- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder5C-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Back Plate5C-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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VITARA
1. Brake back plate
2. Brake shoe
3. Shoe return upper spring
4. Adjuster
5. Shoe return lower spring
6. Adjuster lever
7. Adjuster spring
8. Shoe hold down spring
9. Shoe hold down pin
10. Wheel cylinder
11. Link
12. Brake strut
(a)
Tightening torque
(a): 7.5 N.m (0.75 kg-m, 5.5 lb-ft)
5C-2 PARKING AND REAR BRAKE
GENERAL DESCRIPTION
DRUM BRAKE ASSEMBLY
The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main-
tained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is
depressed and when parking brake is applied on level road.
It also uses duo servo operation when parking brake is applied on gradient road and load is applied in longitudinal
direction of vehicle.
NOTE:
Replace all components included in repair kits to service this drum brake. Lubricate parts as specified.
WARNING:
If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque
values specified are for dry, unlubricated fasteners.