cylinder SUZUKI GRAND VITARA 2000 2.G Service Service Manual

YH4
GRAND
VITARA
1. LSPV
2. Brake pipe
1. LSPV assembly
2. LSPV spring
3. LSPV stay
4. Bolt
5. Stepper bole
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-17
LSPV (Load Sensing Proportioning Valve)
ASSEMBLY (if equipped)
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Hoist vehicle.
3) Disconnect brake pipes from LSPV.
4) Remove LSPV assembly with spring from vehicle body.
5) Remove spring from lever.
CAUTION:

LSPV assembly must not be disassembled.
Replace with new one if defective.

Stopper bolt should not be loosened or tightened. (if
equipped)
INSTALLATION
CAUTION:
Refer to above CAUTION.
Install by reversing removal procedure, noting the following.
1) Apply multi-purpose grease ªAº to upper and lower joint of coil
spring.

YH4
GRAND
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.

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-19
09922-85811
Connector pin remover09950-96010
Booster piston rod gauge09952-16010
Booster piston rod adjuster
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake flexible hose bolt (Brake caliper / 2 (4) way joint)232.317.0
Master cylinder attaching nut131.39.5
Booster nut131.39.5
Clevis nut252.518
2-way (or 4-way) joint mounting bolt101.07.5
Brake pipe flare nut161.611.5
Front caliperM88.00.86.0
Brake bleederplug
Front cali erM108.50.856.5Brake bleeder lugWheel cylinder7.50.755.5
LSPV8.00.86.0
LSPV mounting bolt
LSPV stay bolt232.317.0
LSPV spring nut
Wheel nut10010.072.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Brake fluid
Indicated on reservoir
cap or described in owner's
manual of vehicle
To fill master cylinder reservoir.

To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when
they are disassembled.
SPECIAL TOOLS

YH4
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.

YH4
GRAND
VITARA
5B-4 FRONT BRAKE
1. Wheel nut
2. Washer
(or spacer)
ªAº: Apply grease
Brake Disc
Before this inspection, brake pads must be removed.
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and disc is not defective unless they are serious.
But when there are deep scratches or scratches all over disc sur-
face, replace it. When only one side is scratched, polish and correct
that side.
Disc thickness ªaº
Standard: 22 mm (0.866 in.) For SUMITOMO ELECTRIC. . . . .
brake caliper
17 mm (0.670 in.) For TOKICO brake caliper. . . . .
Service limit: 20 mm (0.787 in.) For SUMITOMO ELECTRIC. .
brake caliper
15 mm (0.590 in.) For TOKICO brake caliper. .
Use wheel nuts and suitable plain washers to hold the disc securely
against the hub, then mount a dial indicator as shown and measure
the runout at 25 mm (0.98 in.) from the outer edge of the disc.
Limit on disc deflection: 0.15 mm (0.006 in.)
NOTE:
Check front wheel bearing for looseness before measure-
ment.
Cylinder Slide Guide Pin / Pin Bolt
Check guide pin for smooth movement as shown.
If it is found faulty, correct or replace. Apply rubber grease to guide
pin outer surface. Rubber grease should be the on whose viscosity
is less affected by such low temperature a ±40
C (±40
F).
Dust Boot
Check boot for breakage, crack and damage. If defective, replace.

YH4
GRAND
VITARA
1. Caliper
2. Flexible hose
3. Hose mounting bolt
4. Wire hook
5. Container
1. Cloth
5B-6 FRONT BRAKE
FRONT DISC BRAKE CALIPER
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove brake flexible hose mounting bolt from caliper. As this
will allow fluid to flow out of hose, have a container ready before-
hand.
3) Remove caliper pin bolts.
4) Remove caliper.
DISASSEMBLY
Before disassembly, clean all around caliper with brake fluid.
1) Remove anti noise shim (if equipped) and blow compressed air
into cylinder through bolt hole where flexible hose was fitted.
With this air pressure, piston can be pushed out of cylinder.
WARNING:
Do not apply too highly compressed air which will cause
piston to jump out of cylinder. It should be taken out grad-
ually with moderately compressed air. Do not place your
fingers in front of piston when using compressed air.

YH4
GRAND
VITARA
FRONT BRAKE 5B-7
2) Remove piston seal using a thin blade like a thickness gauge,
etc.
CAUTION:
Be careful not to damage inside (bore side) of cylinder.
INSPECTION
Cylinder Boot
Check boots for breakage, crack and damage. If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate unsmooth re-
turn of the piston. In such a case, replace rubber seal.
ASSEMBLY
Reassemble front brake in reverse order of disassembly, noting the
following points.
CAUTION:

Wash each part cleanly before installation in the same
fluid as the one used in master cylinder reservoir.

Never use other fluid or thinner.

Before installing piston and piston seal to cylinder, apply
fluid to them.

After reassembling brake lines, bleed air from them.
Piston Seal
Piston seal is used to seal piston and cylinder and to adjust clear-
ance between pad and disc. Replace with a new one at every over-
haul. Fit piston seal into groove in cylinder taking care not to twist
it.

YH4
GRAND
VITARA
1. Boot
2. Piston
5B-8 FRONT BRAKE
Piston and Boot
1) Before inserting piston into cylinder, install boot onto piston as
shown.
2) Fit boot as it is in above figure into boot groove in cylinder with
fingers.
Check to make sure that boot is fitted into boot groove in cylinder
completely in its circumference.
3) Insert piston into cylinder by hand and fit boot in boot groove in
piston.
4) To confirm that boot is fitted in its groove in cylinder properly, pull
piston out of cylinder a little but do not take it all out.
5) Insert piston into cylinder by hand.
6) Install anti noise shim, if equipped.

YH4
GRAND
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.

YH4
GRAND
VITARA
FRONT BRAKE 5B-11
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake caliper bleeder plug
(For SUMITOMO ELECTRIC brake caliper)8.00.806.0
Brake caliper bleeder plug
(For TOKICO brake caliper)8.50.856.5
Caliper pin bolt (For TOKICO brake caliper)272.720.0
Caliper pin bolt (M10)
(For SUMITOMO ELECTRIC brake caliper)505.036.5
Caliper pin bolt (M12)
(For SUMITOMO ELECTRIC brake caliper)858.561.5
Flexible hose bolt232.317.0
Brake carrier bolt858.561.5
Wheel nut10010.072.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Brake fluid
Indicated on reservoir
cap or described in owner's
manual of vehicle
To fill master cylinder reservoir.

To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when
they are disassembled.