drum brakes SUZUKI GRAND VITARA 2002 2.G Service Workshop Manual

YH4
GRAND
VITARA
3-4 STEERING, SUSPENSION, WHEELS AND TIRES
ConditionPossible CauseCorrection
Wander or Poor
Steering Stability
Mismatched or uneven tires.

Loose ball joints and tie rod
ends.

Faulty shock absorbers / struts or
mounting.

Loose stabilizer bar.

Broken or sagging springs.

Rack and pinion not properly adjusted.
(if equipped with manual steering
gear case)

Disturbed front end alignment.Replace tire or inflate tires to
proper pressure.
Replace suspension control arm or
tie rod end.
Replace absorber / strut or repair
mounting.
Tighten or replace stabilizer bar or
bushes.
Replace spring.
Check or adjust rack and pinion
torque.
Check and adjust front end alignment.
Erratic Steering when
Braking
Worn wheel bearings.

Broken or sagging springs.

Leaking wheel cylinder or caliper.

Warped discs.

Badly worn brake linings.

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Defective wheel cylinders.

Disturbed front end alignment.Replace wheel bearing.
Replace spring.
Repair or replace wheel cylinder or
caliper.
Replace brake disc.
Replace brake shoe lining.
Replace brake drum.
Inflate tires to proper pressure.
Replace or repair wheel cylinder.
Check front end alignment.
Low or Uneven Trim
Height
Right-to-left trim height
(H) difference should be
within 15 mm (0.6 in.)
with curb weight.
*Same with rear side.
Broken or sagging springs.

Overloaded.

Incorrect springs.Replace spring.
Check loading.
Replace spring.
Ride Too Soft
Faulty shock absorber or struts.Replace shock absorber or strut.
Suspension Bottoms
Overloaded.

Faulty shocks or struts.

Incorrect broken or sagging springs.Check loading.
Replace shock absorber or strut.
Replace spring.

YH4
GRAND
VITARA
[FOR VEHICLE WITHOUT ABS]
[FOR VEHICLE WITH ABS]
1. Master cylinder
2-1. 4-way joint
2-2. 2-way joint
3. LSPV (Load Sensing Proportioning Valve)
4. Rear axle housing
5. ABS actuator (H.U.)
F.R.:Front side
5-2 BRAKES
GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons
(two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make
two independent circuits. One connects front brakes (right and left) and the other connects rear brakes (right and
left).
The load sensing proportioning valve (LSPV) is included in these circuits between the master cylinder and the rear
brake for the vehicle without ABS.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading / trailing
shoes) for the rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and me-
chanical linkage system. The same brake shoes are used for both parking and foot brakes.

YH4
GRAND
VITARA
BRAKES 5-3
SUBSTANDARD OR
CONTAMINATED BRAKE FLUID
Improper brake fluid, mineral oil or water in the fluid
may cause the brake fluid to boil or the rubber compo-
nents in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the
drum brake wheels.
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol
out of the system. Replace all rubber parts in the sys-
tem, including hoses. Also, when working on the
brake mechanisms, check for fluid on the linings. If ex-
cessive fluid is found, replace the linings.
If master cylinder piston seals are satisfactory, check
for leakage or excessive heat conditions. If condition
is not found, drain fluid, flush with brake fluid, refill and
bleed system.
The system must be flushed if there is any doubt as
to the grade of fluid in the system or if fluid has been
used which contained parts that have been subjected
to contaminated fluid.
DIAGNOSIS
ROAD TESTING BRAKES
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both
light and heavy pedal forces at various speeds to de-
termine if the vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the
other without brake application. If it does, check the
tire pressure, front end alignment and front suspen-
sion attachments for looseness. See diagnosis chart
for other causes.
BRAKE FLUID LEAKS
Check the master cylinder fluid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low level indicates a leak in the
system. In such a case, check the entire brake system
for leakage. If even a slight evidence of leakage is
noted, the cause should be corrected or defective
parts should be replaced.
If fluid level is lower than the minimum level of reser-
voir, refilling is necessary. Fill reservoir with specified
brake fluid.
Brake fluid: Refer to reservoir tank cap.
CAUTION:
Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
tank cap, do not use or mix different type of
fluid when refilling; otherwise serious damage
will occur.
Do not use old or used brake fluid, or any fluid
from a unsealed container.

YH4
GRAND
VITARA
5-4 BRAKES
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Not enough brak-
ing force
Brake oil leakage from brake lines.

Brake disc or pads stained with oil.

Overheated brakes.

Poor contact of shoes on brake drum.

Brake shoes linings stained with oil or wet
with water.

Badly worn brake shoe linings.

Defective wheel cylinders.

Malfunctioning caliper assembly.

Air in system.

Maladjusted sensor spring length of LSPV.

Broken sensor spring of LSPV.

Defective collar of LSPV.

Malfunctioning ABS (Antilock brake system),
if equipped.Locate leaking point and repair.
Clean or replace.
Determine cause and repair.
Repair for proper contact.
Replace.
Replace.
Repair or replace.
Repair or replace.
Bleed system.
Check or adjust.
Replace.
Replace.
Check system and replace as
necessary.
Brake pull
(Brakes not work-
ing in unison)
Pad or shoe linings are wet with water or
stained with oil in some brakes.

Drum-to-shoe clearance out of adjustment in
some brakes.
(Malfunctioning auto adjusting mechanism)

Drum is out of round in some brakes.

Wheel tires are inflated unequally.

Malfunctioning wheel cylinders.

Disturbed front end alignment.

Unmatched tires on same axle.

Restricted brake pipes or hoses.

Malfunctioning caliper assembly.

Loose suspension parts.

Loose calipers.Replace.
Check for inoperative auto adjusting
mechanism.
Replace.
Inflate equally.
Repair or replace.
Adjust as prescribed.
Tires with approximately the same
amount of tread should be used on the
same axle.
Check for soft hoses and damaged
lines.
Replace with new hoses and new
brake pipes.
Check for stuck or sluggish pistons
and proper lubrication of caliper slide
bush.
Caliper should slide.
Check all suspension mountings.
Check and torque bolts to specifica-
tions.
Noise (High pitched
squeak without
brake applied)
Front lining worn out.Replace linings.
Rear brake locked
prematurely
Maladjusted sensor spring length of LSPV.

Malfunction LSPV assembly.Check or adjust.
Replace assembly.
Brake locked
(For vehicles
equipped with
ABS)
Malfunctioning ABS, if equipped.Check system and replace as
necessary.

YH4
GRAND
VITARA
BRAKES 5-5
ConditionPossible CauseCorrection
Excessive pedal
travel (Pedal
stroke too large)
Partial brake system failure.

Insufficient fluid in master cylinder
reservoirs.

Air in system. (pedal soft / spongy)

Rear brake system not adjusted.
(malfunctioning auto adjusting mechanism)

Bent brake shoes.

Worn rear brake shoes.Check brake systems and repair as
necessary.
Fill reservoirs with approved brake
fluid.
Check for leaks and air in brake
systems.
Check warning light. Bleed system if
required.
Bleed system.
Repair auto adjusting mechanism.
Adjust rear brakes.
Replace brake shoes.
Replace brake shoes.
Dragging brakes
(A very light drag
is present in all
disc brakes
immediately
after pedal is
released)
Master cylinder pistons not returning
correctly.

Restricted brake pipes or hoses.

Incorrect parking brake adjustment on rear
brakes.

Weakened or broken return springs in the
brake.

Sluggish parking-brake cables or linkage.

Wheel cylinder or caliper piston sticking.

Malfunctioning ABS, if equipped with ABS.Replace master cylinder.
Check for soft hoses or damaged
pipes and replace with new hoses
and / or new brake pipes.
Check and adjust to correct specifi-
cations.
Replace.
Repair or replace.
Repair as necessary.
Check system and replace as
necessary.
Pedal pulsation
(Pedal pulsates
when depressed
for braking)
Damaged or loose wheel bearings.

Distorted steering knuckle or rear axle
shafts.

Excessive disc lateral runout.

Parallelism not within specifications.

Rear drums out of round.Replace wheel hub component.
Replace knuckle or rear axle shaft.
Check per instructions. If not within
specifications, replace or machine
the disc.
Check per instructions. If not within
specifications, replace or machine
the disc.
Check runout.
Repair or replace drum as
necessary.
Braking noise
Glazed shoe linings, or foreign matters
stuck to linings.

Worn or distorted shoe linings.

Loose front wheel bearings.

Distorted backing plates or loose mounting
bolts.Repair or replace shoe lining.
Replace shoe lining (or pad).
Replace wheel hub component.
Replace or retighten securing bolts.

YH4
GRAND
VITARA
1. Parking brake lever
2. Brake cable
3. Self locking nut
5-12 BRAKES
PARKING BRAKE CHECK AND
ADJUSTMENT
CHECK
Hold center of parking brake lever grip and pull it up with 20 kg
(40 lbs) force.
With parking brake lever pulled up as shown, count ratchet
notches.
There should be 5 to 7 notches.
Also, check if both right and left rear wheels are locked firmly.
To count number of notches easily, listen to click sounds that ratchet
makes while pulling parking brake lever without pressing its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable by referring
to adjustment procedure described on the following as to obtain
specified parking brake stroke.
NOTE:
Check tooth tip of each notch for damage or wear. If any dam-
age or wear is found, replace parking brake lever.
ADJUSTMENT
NOTE:
Make sure for following conditions before cable adjustment.

No air is trapped in brake system.

Brake pedal travel is proper.

Brake pedal has been depressed a few times with about
30 kg (66 lbs) load.

Parking brake lever has been pulled up a few times with
about 20 kg (44 lbs) force.

Rear brake shoes are not worn beyond limit, and self adjust-
ing mechanism operates properly.

To slacken parking brake cable, loosen self locking nut as far
as end of bolt. Then depress brake pedal a few times with
about 30 kg (66 lbs) load.
After confirming that above 6 conditions are all satisfied, adjust
parking brake lever stroke by loosening or tightening locking nut.
NOTE:
Check brake drum for dragging after adjustment.
Parking brake stroke: 5 to 7 notches
(When lever is pulled up at 20 kg (44 lbs).)

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.