SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
VITARA
1. Parking brake lever cover
2. Brake cable locking nut
1. Brake drum
2. 8 mm bolts
PARKING AND REAR BRAKE 5C-7
BRAKE DRUM
REMOVAL
1) Hoist vehicle and pull up parking brake lever.
2) Remove wheel.
3) Release parking brake lever.
4) Remove rear center console box screws and with rear part of
rear center console box lifted a little, loosen parking brake cable
locking nut.
5) Remove brake drum by using 8 mm bolts (2 pcs.).
INSPECTION
Brake Drum
Inspect drum for cleanliness. Check wear of its braking surface by
measuring its inside diameter.
Inside diameter ªaº
Standard: 220 mm (8.66 in.)
Service Limit: 222 mm (8.74 in.)
Whenever brake drums are removed, they should be thoroughly
cleaned and inspected for cracks, scores, deep grooves.

YH4
GRAND
VITARA
1. Pawl lever
2. Adjuster
3. Brake shoes
5C-8 PARKING AND REAR BRAKE
Cracked, Scored, or Grooved Drum
A cracked, drum is unsafe for further service and must be replaced.
Do not attempt to weld a cracked drum.
Smooth up any slight scores. Heavy or extensive scoring will cause
excessive brake lining wear and it will probably be necessary to re-
surface drum braking surface.
If brake linings are slightly worn and drum is grooved, drum should
be polished with fine emery cloth but should no be turned.
NOTE:
When drum is removed, visually inspect wheel cylinder for
brake fluid leakage. Correct leaky point, if any.
Brake Shoe
Where lining is worn out beyond service limit, replace shoe.
Thickness ªaº
Standard: 6.5 mm (0.24 in.)
Service limit: 3.0 mm (0.12 in.)
If one of brake linings is to service limit, all linings must be replaced
at the same time.
CAUTION:
Never polish lining with sandpaper. If lining is polished with
sandpaper, hard particles of sandpaper will be deposited in
lining and may damage drum. When it is required to correct
lining, replace it with a new one.
INSTALLATION
NOTE:
See NOTE at the beginning of the section.
1) Before installing brake drum, check outer diameter of brake
shoes. If it is not within value as specified below, adjust it to spec-
ification by turning adjuster.
Outer diameter of brake shoes
ªaº: 219.4 ± 219.7 mm (8.638 ± 8.650 in.)

YH4
GRAND
VITARA
6. Shoe hold down
springs
7. Strut spring
8. Lower shoe return
spring 1. Upper shoe return spring
2. Adjuster
3. Pawl lever
4. Adjuster spring
5. Shoe hold down pins
1. Brake back plate
2. Cable cap
3. Brake cable
PARKING AND REAR BRAKE 5C-9
2) Install brake drum after making sure that inside of brake drum
and brake shoes are free from dirt and oil.
3) 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, refer to PARKING
BRAKE CHECK AND ADJUSTMENT in Section 5.)
4) Tighten rear center console box screws.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
6) Check to ensure that brake drum is free from dragging and prop-
er braking is obtained. Then remove vehicle from hoist and per-
form brake test (foot brake and parking brake).
BRAKE SHOE
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
WARNING:
Use special care when installing brake shoe return
spring. Failure in its proper installation may allow it to
springback and cause personal injury.
2) Remove shoe hold down springs by turning shoe hold down
pins.
3) Remove upper return spring, struts, adjuster, adjuster lever and
springs.
4) Remove brake shoes and lower shoe return spring.
5) Remove brake shoes and disconnect parking brake cable from
parking brake shoe lever.

YH4
GRAND
VITARA
5C-10 PARKING AND REAR BRAKE
1. Retainer
2. Parking brake shoe lever
3. Brake shoe
6) Remove parking brake shoe lever from brake shoe.
INSPECTION
Parking Shoe Lever
Inspect brake shoe lever for free movement against brake shoe
web. If defective, correct or replace.
Strut, Adjuster
Check thread or ratchet of strut and adjuster for wear, sticking and
corrosion.
Springs
Inspect for damage or weakening.
Inspect each part with arrow for rust. If found defective, replace.
Brake Shoe
Refer to BRAKE DRUM INSPECTION.

YH4
GRAND
VITARA
6. Shoe hold down
springs
7. Strut spring
8. Lower shoe return
spring 1. Upper shoe return spring
2. Adjuster
3. Pawl lever
4. Adjuster spring
5. Shoe hold down pins1. Lower return spring
2. Lower strut
PARKING AND REAR BRAKE 5C-11
INSTALLATION
1) Assemble parts as shown in reverse order of removal.
2) Install shoe hold down springs by pushing them down in place
and turning hold down pins.
3) Install adjuster and upper shoe return spring.
4) Install adjuster lever, adjuster spring and strut spring.
5) For procedure hereafter, refer to steps 1) to 6) of BRAKE DRUM
INSTALLATION.

YH4
GRAND
VITARA
1. Wheel cylinder
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts1. Bleeder plug cap
5C-12 PARKING AND REAR BRAKE
WHEEL CYLINDER
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Loosen brake pipe flare nut (or nuts) but only within the extent
that fluid does not leak.
4) Remove wheel cylinder mounting bolts. Disconnect brake pipe
(or pipes) from wheel cylinder and put wheel cylinder bleeder
plug cap onto pipe to prevent fluid from spilling.
INSPECTION
Inspect wheel cylinder disassembled parts for wear, cracks, corro-
sion or damage.
NOTE:
Clean wheel cylinder components with brake fluid.
INSTALLATION (For non sealed type)
1) Take off bleeder plug cap from brake pipe and connect pipe (or
pipes) to wheel cylinder just enough to prevent fluid from leak-
ing.
2) Tighten wheel cylinder to brake back plate to specified torque.
Tightening Torque
(a): 8.5 N
.m (0.85 kg-m, 6.5 lb-ft)
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)

YH4
GRAND
VITARA
2
1. Wheel cylinder
2. Gasket
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts
PARKING AND REAR BRAKE 5C-13
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to steps 1) to 5) of BRAKE SHOE
INSTALLATION.
NOTE:
Be sure to bleed brake system. (for bleeding operation, re-
fer to BLEEDING BRAKES in Section 5.)
INSTALLATION (For gasket sealed type)
1) Install gasket to joint seam of wheel cylinder and brake back
plate. Then take off bleeder plug cap from brake pipe and con-
nect pipe (or pipes) to wheel cylinder just enough to prevent fluid
from leaking.
NOTE:
Be sure to check gasket for deterioration or any damage be-
fore installation and replace if found defective.
2) Tighten wheel cylinder to brake back plate to specified torque.
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to BRAKE SHOE INSTALLA-
TION.
NOTE:
Be sure to bleed brake system. Refer to ªCHECK AND AD-
JUSTMENTº in BRAKES section.

YH4
GRAND
VITARA
5C-14 PARKING AND REAR BRAKE
1
2
3
1. Brake back plate
2. Cable cap
3. Brake cable
1. Wheel bearing retainer nut
1. Rear axle shaft
2. Wheel bearing
3. Brake back plate(A)
BRAKE BACK PLATE
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Perform steps 3) and 4) of WHEEL CYLINDER REMOVAL.
4) Remove cable from brake back plate by squeezing parking
brake cable cap.
5) Drain rear differential gear oil.
6) Remove wheel bearing retainer nuts from rear axle housing.
7) Using special tools, draw out rear axle shaft with brake back
plate.
Special Tool
(A): 09943-35512
(B): 09942-15510
8) Remove brake back plate from rear axle shaft.

YH4
GRAND
VITARA
PARKING AND REAR BRAKE 5C-15
1. Rear axle shaft
2. Wheel bearing
3. Brake back plate1. Rear axle shaft
1. Rear axle
housing ªAº
INSTALLATION
1) Apply sealant to mating surface of bearing retainer with brake
back plate.
ªAº: Sealant 99000-31110
NOTE:
Make sure to remove old sealant before applying it anew.
2) Install brake back plate to rear axle shaft.
3) Apply sealant to joint seam of rear axle housing and brake back
plate.
ªAº: Sealant 99000-31110
NOTE:
Make sure to remove old sealant before applying it anew.
4) Install rear axle shaft to rear axle housing.
5) Tighten brake back plate nuts to specified torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

YH4
GRAND
VITARA
5C-16 PARKING AND REAR BRAKE
1. Brake back plate
2. Cable cap
3. Parking brake cable
6) Install wheel cylinder, and tighten wheel cylinder bolts and
brake pipe flare nut (or nuts) to specified torque. (Refer to steps
1) to 4) of WHEEL CYLINDER INSTALLATION of this section.)
7) Install parking brake cable to brake back plate.
8) Install brake shoes, referring to steps 1) to 4) of BRAKE SHOE
INSTALLATION.
9) Install brake drum. Refer to steps 1) to 2) of BRAKE DRUM
INSTALLATION in this section.
10) Refill differential housing with new specified gear oil. Refer to
ªMAINTENANCE SERVICEº in Section 7E for refill.
11) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to BLEEDING BRAKES in Section 5.)
12) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
13) 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, refer to PARKING
BRAKE CHECK AND ADJUSTMENT in Section 5.)
14) Tighten rear center console box screws.
15) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
16) Check each installed part for oil leakage.