brakes SUZUKI GRAND VITARA 2001 2.G Service Owner's Manual

YH4
GRAND
VITARA
5-18 BRAKES
09950-78220
Flare nut wrench (10 mm)09900-20205
Micrometer (0 ± 25 mm)09956-02310
Fluid pressure gauge09956-02210
Brake circuit plug
09952-36310 / 09952-46510
Pressure gauge attachment
SPECIAL TOOLS

YH4
GRAND
VITARA
5A
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-1
SECTION 5A
BRAKES PIPE/HOSE/MASTER CYLINDER
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 DESCRIPTION5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster Assembly5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSPV (Load Sensing Proportioning Valve) Assembly 5A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Hose / Pipe5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Brake Hose / Pipe5A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Reservoir5A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly5A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Booster5A-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSPV (Load Sensing Proportioning Valve) Assembly 5A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

YH4
GRAND
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.

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-5
[A]: Vehicle with ABS for right hand steering vehicle
[B]: Vehicle with ABS for left hand steering vehicle
1. E-ring
2. Flexible hose
3. Hose washer
4. Hose bolt
5. Brake caliper
6. 2 way joint
NOTE:
Insert E-ring till its end surface is flush
with or lower than bracket end surface.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
(c): 10 N.m (1.0 kg-m, 7.5 lb-ft)
(b): 21 N.m (2.1 kg-m, 15.5 lb-ft)
A: View A
B: View B
C: View Ca: Clamp a
b: Clamp b
c: Clamp c
d: Clamp d
C
t: Top side
f: Front side
[A]
[B]

YH4
GRAND
VITARA
5A-6 BRAKES PIPE / HOSE / MASTER CYLINDER
NOTE:
Insert E-ring till its end surface is flush
with or lower than bracket end surface.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
[C]: Vehicle without ABS for right hand steering vehicle
[D]: Vehicle without ABS for left hand steering vehicle
1. E-ring
2. Flexible hose
3. Hose washer
4. Hose bolt
5. Brake caliper
6. 4way joint
[C]
[D]
D: View D a: Clamp a
b: Clamp b
c: Clamp c
d: Clamp dt: Top side
f: Front side

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-8 BRAKES PIPE / HOSE / MASTER CYLINDER
1. Reservoir
2. Master cylinder
1. Reservoir
2. Connector pin
3. Grommets
MASTER CYLINDER RESERVOIR
REMOVAL
1) Disconnect reservoir lead wire at coupler.
2) Clean outside of reservoir.
3) Take out fluid with syringe or such.
4) Remove reservoir connector pin by using special tool.
Special Tool
(A): 09922-85811
5) Remove reservoir.
NOTE:
Do not allow brake fluid to get on painted surfaces.

YH4
GRAND
VITARA
1. Reservoir
2. Pin
1. Reservoir
2. Cap
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-9
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
1) When using new grommets, lubricate them with the same fluid
as the one to fill reservoir with. Then press-fit grommets to mas-
ter cylinder. Grommets must be seated in place.
2) Install reservoir and drive in reservoir pin.
NOTE:
Drive in reservoir pin till both of its ends at the right and left
or reservoir becomes the same length.
3) Connect reservoir lead wire.
4) Fill reservoir with specified fluid.
5) Upon completion of installation, check for fluid leakage.