1987 SUZUKI GRAND VITARA Service Repair Manual

1. Valve stopper key
Booster air valve assembly
Fig. 19-72
10) Remove reaction disc from booster piston
with fingers.
Fig. 19-74
11) Remove oil seal from booster No. 2 body
with special tools as shown.
NOTE:
Removed oil seal must not be reused.
;1
Special tool~09951-082101
Special toolk
109951~W~lO,\ 0
9) Remove diaphragm from pressure plate.
NOTE:
Don’t use screwdriver or any other tool for
removal. Pull it off by hand carefully handling
pressure plate groove area where diaphragm is
fitted.
1. Hammer lightly2. No. 2 body3. Oil seal
Fig. 19-75
Fig. 19-73
19-32

INSPECTION
Inner Parts
NOTE:
After disassembly, soak all metal parts in ethyl
alcohol. Wipe rubber diaphragm and plastic parts
with a clean cloth. Use ethyl alcohol damped
cloth to wipe out heavy dirt Application of
much ethyl alcohol especially to rubber parts is
prohibited.
[ Rubber parts]
Wipe fluid from rubber parts and carefully
inspect each rubber part for cuts, nicks or other
damage. These parts are the key to the control
of air flow. If there is any question as to the
serviceability of rubber parts, REPLACE them.
[Metal parts]
BADLY DAMAGED ITEMS, OR THOSE
WHICH WOULD TAKE EXTENSIVE WORK
OR TIME TO REPAIR, SHOULD BE REPLAC-
ED. IN CASE OF DOUBT, INSTALL NEW
PARTS.
Inspection/Adjustment of Clearance Between
Booster Piston Rod and Master Cylinder Piston
The length of booster piston rod is adjusted to
provide specified clearance between piston rod
end and master cylinder piston.
Master
Fig. 19-76
Clearance
(D): Booster piston rod -mwe
(09950-98210)
3
1. Gasket2. Master cylinder
3. Piston
4. Pin head
Fig. 19-77
2) Turn special tool upside down and place it on
booster. Adjust booster piston rod length
until rod end contacts pin head.
3) Adjust clearance by turning adjusting bolt of
piston rod.
pistonrod
Before measuring clearance, push piston rod
several times so as to make sure reaction disc
is in place.
Take measurement with gasket installed to
master cylinder.
Keep inside of booster at atmospheric pressure
for measurement.
1) Set special tool (D) on master cylinder and
push pin until it contacts piston.
1. Booster body
2. Piston rod
%arance 0 mm (0 in.)betweenspecial tool andiston rod
Reference
When adjusted as above, if negative pressure is
applied to booster with engine at idle, piston to
piston rod clearance should become 0.1 - 0.5
mm (0.004 - 0.020 in.).
19-33
Fig. 19-78

BOOSTER INSPECTION TABLE
Part
1. Booster piston
2. Air valve ass’y
(Control valve spring)
3. Reaction disc
4. Diaphragm and boot
5. Piston rod
6. Booster No. 1 & No. 2
body.
7. Air filters and separator
Inspect ForCorrective Action
Cracks, distortion or damage.Replace.
Damaged or worn seal surfaces.Replace.
Damage or wear.Replace.
Damage.Replace.
Damage or bend.Replace.
1. Scratches, scores, pits, dents, orReplace, unless easily
other damage affecting rolling orrepaired.
sealing of diaphragm or other seals.
2. Cracks, damage at ears, damagedReplace, unless easily
threads on studs.repa i red.
3. Bent or nicked locking lugs.Replace, unless easily
repaired.
4. Loose studs.Replace.
Dirt.Replace.
Fig. 19-79
19-34

ASSEMBLY
NOTE:
See NOTE at the beginning of this section.
Be sure to use silicon grease wherever appli-
cation of grease is instructed during assembly.
Use of oil and grease for installation of check
valve and its grommet is strictly prohibited.
1) Apply grease to oil seal outer surface and oil
seal lip as shown.
Press-fit oil seal to booster No. 2 body by
using special tool (B) and (C).
Apply grease here
1. Hammer2. No. 2 body3. Oil seal
(6) : Oil seal remover& installer No. 1(09951’38210)
Oil seal remover
Fig. 19-80
2) Install booster air valve assembly to booster
piston. Before installation, apply grease as
shown.
Sliding surface against piston(sealed surface)
Fig. 19-81
3) Compress air valve assembly and insert valve
stopper key.
NOTE:
Be sure that valve assembly is in piston “A”
as indicated in figure. (Don’t force installation.)
Push
n
1. Air valve assembly2. Valve stopper key3. Booster piston
Fig. 19-82
4) Install diaphragm to pressure plate by hand.
NOTE:
Check to be sure that diaphragm is seated
securely in pressure plate groove for diaphragm
by turning diaphragm.
Groove2. Diaphragm
3. Booster piston4. Pressure plate
Apply grease to entire mating surfacesof pistonand diaphragm
Fig. 19-83
5) Install reaction disc to booster piston after
greasing its entire face.
6) Install booster piston to booster No. 2 body.
Fig. 19-84
Special tool
(09917-682101
19-35
1.

2,
Fig. 19-85
1. Booster No. 2 body2. Diaphragm
3. Pressure plate
Check all around boosterNo. 2 body to make surethat diaphragm is seatedsecurely in its outergroove as shown in “A”.
7) Install air cleaner separator and then 2 ele-
ments to rod of air valve assembly.
8) Install body boot to booster No. 2 body.
Bath ends of boot must be fitted securely
as shown.
Fig. 19-86
1.No. 2 body
2.Boot
3.Rod
4.Booster piston
9) Place No. 1 body on special tool (A). Then
install piston return spring, being careful
for its installing direction.1. Piston return
Fig.
2. Booster No. 1
:Booster overhaultool set
(09950-88210)
1
I
19-87
10) Place booster No. 2 body on piston return
spring. Then check to be sure that spring is
in piston spring guide.
Fig.. 19-88
1. No. 2 body
2. Return spring
3. Piston
\Put spring into pistonspring guide.
11) Put No. 1 and No. 2 bodies together by
aligning markings made before disassembly.
Holding No. 2 body with upper plate (special
tool) as shown, torque 2 nuts equally to
specification.
Special tool nutsN.mkg-mlb-ft
tightening torque3-50.3 - 0.52.2 - 3.6
NOTE:
When holding No. 2 body, use care so that
diaphragm is not caught by projections at 16
locations around No. 1 body.
ml
Tighten right and left nuts equally.
A 3-5N.m
markings.Special tool(Booster overhaul tool set)(08850-88210)
Fig. 19-89
12) Turn special tool bolt counterclockwise until
No. 1 body projecting part comes to mid-
position of No. 2 body depressed parts as
shown.
No. 1 body
No. 1 body projecting part
No. 2 bodydepressedpart
Fig. 19-90
19-36

13) Remove booster from special tool and
install push rod clevis so that below measure-
ment “A” is obtained and torque nut to
specification.
-41. Clevis
2. Nut
Gasket20 - 30 N
“A”
125.5- 126.5mm(4.94 - 4.98 in.)\
.rnkg-m).5 lb-ft)
Fig. 19-91
14) Insert piston rod into booster piston.
NOTE:
Whenever booster was disassembled, make sure
to check clearance between piston rod and
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
Adjust clearance between booster piston rod
and master cylinder piston with special tool.
(See page 19-33.)
Check length of push rod clevis. (Refer to
Fig. 19-91).
1) Install booster to dash panel as shown. Then
connect booster push rod clevis to pedal arm
with pin and split pin.
2) Torque booster attaching nuts to specifica-
tion.
3) Install master cylinder to booster and torque
attaching nuts to specification.
4) Connect 2 brake pipes and torque flare nuts
to specification. (See p. 19-29).
5) Fill reservoir with specified fluid.
6) Bleed air from brake system. (See BLEEDING
BRAKES on p. 19-46).
7) After installing, check pedal height and play.
(See p. 19-43).
master cylinder piston after reassembly. (For
details, refer to p. 19-33.)
20 30 N.m-(2.0 - 3.0 kg-m)(14.5 - 21.5 lb-ftl
10 - 16 N.m(1.0-1.6 kg-m)(7.5 - 11.5 lb-ft)
Fig. 19-9219-37

Fig. 19-6-1
19-38
19-6. PARKING BRAKE

19-7. BRAKE PIPES AND HOSES
REMOVAL AND INSTALLATION
1) Take out fluid with a cyringe or such.
2) Clean dirt and foreign material from both
hose end or pipe end fittings. Remove brake
hose or pipe.
3) Reverse removal procedure for brake hose
or pipe installation.When installing hose,
make sure that it has no twists or kinks.
Inspect to see that hose doesn’t make contact
with any part of suspension. Check in extreme
right and extreme left turn conditions. If
hose makes .any contact, remove and correct.
Fill and maintain brake fluid level in reser-
voir. Bleed brake system.
NOTE:
Be sure to install brake flexible hose E-ring
into hose groove.
z+
\E-ring
Upon completion of installation, check each
joint for fluid leakage with brake pedal
CAUTION:I
Refer to Fig. 19-38 when connecting
brake flexible hose to brake caliper and
tighten to specified torque.
Be sure to install brake pipe in proper
position referring to Fig. 19-7-2 and
clamp it securely and correctly.
Tightening torque
19-39
Fig. 19-7-1
depressed.