1987 SUZUKI GRAND VITARA Service Repair Manual

6) Remove brake drum and check fan-shaped
ratchet position.
If it has shifted off its previous position in step
2) when it was pushed down, it proves proper
operation of shoe adjusting system.
PRECAUTIONS ON INSTALLATION
Wheel Cylinder
1) Tighten wheel cylinder to brake back plate to
specified torque.
2)Tighten flare nut of brake pipe to specified
torque.
3) Install breather plug cap.
8-12N.m14-18N.m-(0.8 - 1.2 kg-m)(I .41.8 kg-m)4,(6.0 - 8.5 lb-ft)(10.5-13.0 lb-ft)
1. Brake back plate3. Brake pipe
2. Brake pipe flare nut4. Wheel cylinder bolts
Fig. 19-50
Brake Shoes
1) Assemble parts as shown in the reverse order
of removal.
If not, replace strut assembly.
Fig. 19-49-4
NOTE:
For brake drum installation, refer to steps 1)
through 8) of brake drum installation in this
section (p. 19-25).
Fig. 19-50-1
NOTE:
When installing shoes, use care not to cause
damage to wheel cylinder boots.
19-24

2) Install shoe hold down springs by pushing
them down in place and turning hold down
pins.
Brake Drum
1) Install parking brake shoe lever stopper plate,
referring to the following figure for its instal-
lation direction.
Upper side
-) Parking brakeshoe lever side
1. Parking brake shoelever stopper plate2. Parking brake shoelever3. Brake back plate
Fig. 19-521. Parking brake shoe lever stopperPlate
2) Connect brake cable joint to parking brake
shoe lever by using joint pin.
Insert joint pin down from the top and
install clip into joint pin hole securely.
NOTE:
Check to ensure that clip is in good condition
before installing it. If deformed or broken,
replace.
1. Joint pin2. Cable joint
3. Parking brake shoe lever
4. Clip
Fig. 19-52-1
3) Install parking brake shoe lever return spring.
Fig. 19-53

Fig. 19-51
19-25

4) Before installing brake drum, to maximize
brake shoe-todrum clearance, put screw
driver between rod and ratchet and push
down ratchet as shown in figure.
\
2. Ratchet
3. Driver
Below figure shows ratchet positionwhere brake shoe-to-drum clearanceis maximum.
Fig. 19-54
5) Install brake drum after making sure that
inside of brake drum and brake shoes are free
from dirt and oil.
6) Torque wheel nuts and brake drum nuts to
specification.
NOTE:
If brake backing plate was removed from wheel
cylinder or brake pipe was disconnected from
wheel cylinder. Bleed air from brake system.
(For bleeding operation, refer to p. 19-46.)
7) Upon completion of all jobs, depress brake
pedal with about 30 kg (66 Ibs) load four or
five times so as to obtain proper drum-to-
shoe clearance.
8) Check to ensure that brake drum is free from
dragging and proper braking is obtained. Then
remove car from hoist and perform brake test
(foot brake and parking brake).
Fig. 19-55
19-26

19-4. MASTER CYLINDER
REMOVAL
1) Clean outside of reservoir.
2) Take out fluid with a syringe or such.
3) Remove reservoir connector screw.
4) Remove reservoir.
1. Reservoir
2. Connector screw3. Grommets
4. Flare nuts
5. Attaching nuts
Fig. 19-56
5) Disconnect 2 brake pipes from master cylin-
der.
NOTE:
Do not allow brake fluid to get on painted
surfaces.
6) Remove 2 attaching nuts and washers.
7) Remove master cylinder.
DISASSEMBLY
1) Remove circlip.
2) Remove primary piston by using compressed
air as shown. Be cautious during removal as
primary piston will jump out.
Fig. 19-57

2. Compressed air3. Master cylinder
3) Remove piston stopper bolt. Then remove
secondary piston by blowing compressed air
into hole from which piston stopper bolt was
removed.
1. stopper bolt
2.Compressed air
Fig. 19-58
1. Circlip
19-27

INSPECTION OF COMPONENTS
Master Cylinder Inner Parts
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.
Reservoir
NOTE:
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil or
a container which is wet from water. Mineral oil
will cause swelling and distortion of rubber
parts in the hydraulic brake system and water
will mix with brake fluid, lowering the fluid
boiling point. Keep all fluid containers capped
to prevent contamination.
Fluid to fill reservoir with is indicated on
reservoir cap of the car with embossed letters or
in owner’s manual supplied with the car.
Add fluid up to MAX line.
Fig. 19-59
Inspect master cylinder bore for scoring or
corrosion.It is best to replace a corroded
cylinder. Corrosion can be identified as pits or
excessive roughness.
NOTE:
Polishing bore of 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 will remain on
cylinder bore surface.Fig. 19-60

19-28

ASSEMBLYPRECAUTION OF INSTALLATION
NOTE:NOTE:
Before assembling, wash each part in fluidSee NOTE at the beginning of this section.
recommended to use for the car.Adjust clearance between booster piston rod
1) Assemble secondary piston as shown below.
FBh
and primary piston with special tool (See page
19-33).
Fig. 19-61
1) Install master cylinder as shown and torque
attaching nuts to specification.
2) Connect 2 hydraulic lines and torque flare
1.
2.
3.
4.
5.
I I345
Secondary piston return spring
Return spring seat
Piston cupSecondary piston
Piston pressure cap
2) Install secondary piston assembly into cylin-
der.
3) Install primary piston in cylinder.
4) Depress, and install circlip.
nuts to specification.
3) When using new grommets, lubricate them
with the same fluid as the one to fill reser-
voir with. Then press-fit grommets to master
cylinder. Grommets must be seated in place.
4) Install reservoir and tighten screw to specified
torque.
5) Fill reservoir with specified fluid.
After installing, check brake pedal height,
bleed air from system (See p. 19-43 and
p. 19-46) and also check for fluid leakage.
:
Fig. 19-622. Circlip
1. Rod
5) Install piston stopper bolt with pistons pushed
in all the way and tighten it to specified
torque.
(0.8 - 1.2 kam)
1.Reservoir10 - 16 N.mcap42.Reservoir(1 .O - 1 .6 kg-m)14-18N.m(7.5 - 11.5 lb-ftl--I3.Master cylinder(1 .4 - 1.8 kg-m)4.Flare nuts(10.5 -13.0 lb-ft)
5.Attaching nuts
6.Gasket
7.Grommets
Fig. 19-64
Fig. 19-63(6.0 - 8.5 lb-ft).
6) For installation on car, refer to INSTALLA-
TION.
19-29

19-5. BRAKE BOOSTERDISASSEMBLY
REMOVAL
1) Take out fluid from master cylinder with a
syringe or such.
2) Disconnect 2 brake pipes from master cylinder
and remove master cylinder from booster.
3) Disconnect vacuum hose from booster.
4) Disconnect push rod clevis from brake pedal
arm.
5) Remove attaching nuts and then booster as
shown.
Vacuum hose
2.Booster3. Push rod clevis
4.Dash panel5.Attaching nuts6.Master cylinder
7.Gasket
8. Split pin
9. Master cylinder pin
10. Gasket11 Attaching nuts
Fig. 19-65
49
-@P
Iii
1. Vacuum check valve
2. Grommet3. Booster No. 1 body4. Piston rod
5. Reaction disc6. Booster piston return
spring7. Valve stopper key8. Booster piston9. Booster air valve assembly10. Pressure plate
Fig. 19-66
11.Diaphragm12.Booster No. 2body
13.No. 2 body oilseal14. Air cleaner separator15. Air cleaner element
16.Body bootNut
18.Bracket
19. Push rod clevis
1) Remove piston rod from booster.
2) Remove push rod clevis and nut.
Fig. 19-67
19-30
1.
17.

3) Set booster to special tool (A) as shown.
NOTE:
When setting, check to be sure that booster
vacuum check valve is not in faulty contact with
base of special tool.
Tighten 2 nuts on upper part of special tool
evenly to specified torque.
Special tool nutsN.mkg-mlb-ft
tightening torque3-50.3 - 0.52.2 - 3.6
NOTE:
Be careful not to over-tighten nuts, or booster
body will be deformed.
Tighten right and left nuts equally.3 - 5 N.m
(A): Booster overhaul tool set(09950-88210)
Fig. 19-68
4) Turn special tool bolt clockwise until No. 1
body projecting part and No. 2 body depress-
ed part fit each other.
Once they are matched, make match marking
on No. 1 and No. 2 bodies to facilitate their
installation.
No. 1 body projecting part
No. 1 body projecting part
No. 2 body depressed part
Make match markingI
Fig. 19-70
5) Remove booster from special tool and sepa-
rate No. 1 body and No. 2 body. Remove
piston return spring.
NOTE:
When separating two bodies, hold both bodies
carefully to prevent either body from jumping
off by spring force.
6) From booster No. 2 body, remove boot, air
cleaner elements and air cleaner separator in
this order.
7) Using camshaft pulley holder (special tool
09917-68210), turn booster piston counter-
clockwise and remove piston.
Fig. 19-71
8) While compressing air valve spring (by moving
rod up and down as shown), remove valve
stopper key. Then remove booster air valve
assembly from booster piston.
NOTE:
Booster air valve assembly can’t be disassembled.
Fig. 19-69
19-31