Led SUZUKI GRAND VITARA 2000 2.G Service Repair Manual

YH4
GRAND
VITARA
1. Air bleeder plug
2. Weight
3. Attachment2
ªLº
BRAKES 5-13
FLUSHING BRAKE HYDRAULIC SYSTEM
It is recommended that entire hydraulic system be thoroughly
flushed with clean brake fluid whenever new parts are installed in
hydraulic system.
Periodical change of brake fluid is also recommended.
FLUID PRESSURE TEST(if equipped with
LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.
1) Stop vehicle on level floor and place approximately about
200 kg (441 lbs) weight on rear housing so that rear axle weight
800 kg (1764 lb).
Rear axle weight ªLº: 800 kg (1764 lb)
2) Install special tool to front and rear brake.
NOTE:
Special tool should be connected to breather of front (driv-
er's side brake) and rear brakes.
Special Tool
Front brake
(A): 09956-02310
(B): 09952-46510 (Attachment for vehicle with SUMITOMO
ELECTRIC brake caliper)
(C): 55473-82030 (Air bleeder plug supplied as a spare part)
Rear brake
(A): 09956-02310
(B): 09952-36310 (Attachment for thread diameter 7 mm of
bleeder plug) or
09952-46510 (Attachment for thread diameter 8 mm of
bleeder plug)
(C): 55473-82030 (Air bleeder plug supplied as a spare part)
NOTE:

Special tool (B) is used instead of thread diameter 10 mm
attachment of special tool (A).
So remove the attachment from (A) and install (B) as
shown in figure.

For vehicle with TOKICO brake caliper, use the attach-
ment included in special tool (A).

For identification of brake caliper type, refer to GENERAL
DESCRIPTION in SECTION 5B.

YH4
GRAND
VITARA
BRAKES 5-17
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake pipe 2-way (or 4-way) joint bolt232.317.0
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
LSPV7.50.755.5
LSPV mounting bolt
LSPV stay bolt232.317.0
LSPV spring nut
Wheel nut10010.072.5
Stop light switch lock nut7.50.755.5
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.

YH4
GRAND
VITARA
5A-4 BRAKES PIPE / HOSE / MASTER CYLINDER
DIAGNOSIS
Refer to Section 5 (BRAKES)
CHECK AND ADJUSTMENT
Refer to Section 5 (BRAKES)
ON-VEHICLE SERVICE
FRONT BRAKE HOSE / PIPE
REMOVAL
1) Raise and suitably support vehicle. Remove tire and wheel.
This operation is not necessary when removing pipes connecting master cylinder and flexible hose.
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 and pipe installation procedure.
For installation, make sure that steering wheel is in straightforward position and hose has no twist or kink. Check
to make sure that hose doesn't contact any part of suspension, both in extreme right and extreme left turn condi-
tions. If it does at any point, remove and correct. Fill and maintain brake fluid level in reservoir. Bleed brake sys-
tem.
2) Perform brake test and check installed part for fluid leakage.

YH4
GRAND
VITARA
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.

YH4
GRAND
VITARA
5A-12 BRAKES PIPE / HOSE / MASTER CYLINDER
Vehicle not equipped with ABSVehicle equipped with ABS
1. Rod
2. Circlip
INSPECTION
Inspect all disassembled parts for wear or damage, and replace
parts if necessary.
NOTE:

Wash disassembled parts with brake fluid.

Do not reuse piston cups.
Inspect master cylinder bore for scoring or corrosion. It is best to re-
place corroded cylinder.
Corrosion can be identified as pits or excessive roughness.
NOTE:
Polishing bore or master cylinder with cast aluminum body
with anything abrasive is prohibited, as damage to cylinder
bore may occur.
Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from
cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot
be kept from cylinder bore surfaces.
ASSEMBLY
NOTE:

See NOTE at the beginning of this section.

Before assembling, wash each part in fluid recommended to
use for that vehicle.
1) Install secondary piston assembly into cylinder.
2) Install primary piston assembly in cylinder.
3) Depress, and install circlip.
4) Install piston stopper bolt with pistons pushed in all the way and
tighten it to specified torque (For vehicle without ABS).
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)

YH4
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.

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
1. Caliper
2. Caliper pin bolts
3. Disc
1. Caliper
2. Wire hook
3. Pad
FRONT BRAKE 5B-3
DIAGNOSIS
Refer to Section 5 (BRAKES).
CHECK AND ADJUSTMENT
Refer to Section 5 (BRAKES).
ON-VEHICLE SERVICE
FRONT DISC BRAKE PAD
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper pin bolts.
3) Remove E-ring from strut and then remove caliper from caliper
carrier.
NOTE:
Hang removed caliper with a wire hook or the like so as to
prevent brake hose from bending and twisting excessively
or being pulled. Don't operate brake pedal with pads re-
moved.
4) Remove pads.
INSPECTION
Brake Pad
Check pad lining for wear. When wear exceeds limit, replace with
new one.
CAUTION:
Never polish pad lining with sandpaper. If lining is polished
with sandpaper, hard particles of sandpaper will be depos-
ited in lining and may damage disc. When pad lining re-
quires correction, replace it with a new one.
Pad thickness (lining + rim) ªaº
Standard: 15.0 mm (0.590 in.) For SUMITOMO ELECTRIC. . .
brake calliper
15.5 mm (0.610 in.) For TOKICO brake caliper. . .
Service limit: 7.0 mm (0.275 in.) For SUMITOMO ELECTRIC. .
brake caliper
7.5 mm (0.295 in.) For TOKICO brake caliper. .
NOTE:
When pads are removed, visually inspect caliper for brake
fluid leak. Correct leaky point, if any.