1987 SUZUKI GRAND VITARA Service Repair Manual

B-way joint
View from arrow @
From master cylinderFrom master cylinder(Primary side)4(Secondary side)
To P & B valve
To front rightflexible hose
Brake flexible hose and E-ring
Make sure that flexible hose is not twisted when it isinstalled or connected to the pipe.When installing flexible hose to bracket, align 6vertexes of metal fixture on hose with internal anglesof bracket.insert E-ring till Ewing end surface is flush with orlower than bracket end surface. (Refer to p. 19-39.) For installation of flexible hose to brake caliper,refer top. 19-19. Install the flexible hose so that it won’t be kinkedwhen the steering wheel is straightened.After installing the flexible hose, turn the steeringwheel to the right fully and check that the clearancebetween the wheel/tire and flexible hose is largerthan 25 mm (0,984 in) in that state and then checklikewise with the steering wheel turned to the fullleft position. (This is to ensure that more than 25mm (0.984 in) clearance is maintained even whenbumping or rebounding fully).
Clamp
Upper sideA“A”71’/
sre~~To
Tr
Fuel pipe0Body sidebracket
Hitch lug “B” of brake pipe clampto groove “A” of body side bracketand fix clamp to bodv side bracketwith its screw. Secure fuel pipe atthe same time.
Fig. 19-7-2
19-40
P & B valve

Clamp
Up side
Brake pipe
Brake pipes (Right side)
Install brake pipe to
Up sidewheel cylinder pro-perly using care forits installing posi-tion.
cylinder
Blake backing Plato (Right & Left)
When installing backing plateontoaxle housing, applySEALING COMPOUND 366E(99000-31090) to mating sur-faces of both parts.
Brake backing plate
compound
hose groove securelyand clamp hose.
Air bleeder
(To flexible hose)
wheel cylinder pro-perly using care foritsinstallrng posi-tion.
Rear axle
IBrake pipe
1Rear axle
P & B valve
View from arrow @
Up side
From 6-way joint
Plug
To rear flexible hose
19-41

19-8. MAINTENANCE SERVICE
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 determine if the car
stops evenly and effectively.
Also drive car to see if it leads to one side or the
other without brake application. If it does,
check tire pressure, front end alignment and
front suspension attachments for looseness.
See diagnosis chart for other causes.
BRAKE FLUID LEAKS
Check 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.
BRAKE FLUID LEVEL INSPECTION
Be sure to use particular brake fluid either as
marked on reservoir cap of that car or recom-
mended in owner’s manual which comes along
with that car.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When warning light lights sometimes during
driving, replenish fluid to MAX line.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.
FILL RESERVOIR
CAUTION:
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 hy-
draulic 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 which 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. 19-8-2
Fig. 19-8-1
19-42

BRAKE PEDAL FREE HEIGHT ADJUSTMENT
Brake pedal height is normal if brake pedal is
as high as clutch pedal.
1) When booster push rod clevis has been
reinstalled, it is important that measurement
between booster mounting surface (with a
gasket attached) and the center of clevis
pin hole is adjusted within 125.5 mm -
126.5 mm (4.94 - 4.98 in.). (See page
19-37.)
2) When stop light switch has been removed,
refer to the following STOP LIGHT SWITCH
ADJUSTMENT for proper installation.
The services in above steps 1) and 2) may
affect brake pedal height.
STOP LIGHT SWITCH ADJUSTMENT
Adjustment should be made as follows when
installing the switch.
Pull up brake pedal toward you and while
holding it there, adjust switch position so that
clearance between the end of thread and brake
pedal contact plate (shown as “A” in figure) is
within 0.5 -1 .O mm (0.02 - 0.04 in.). Then
tighten lock nut to specified torque.
1. Brake pedal
2. Contact plate
3. Stop light switch4. Lock nut
EXCESSIVE PEDAL TRAVEL CHECK
1) Start the engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximate-
ly 30 kg (66 Ibs) load, measure pedal arm to
wall clearance “B”.It mustn’t be less than
75 mm (2.95 in.).
Fig. 19-8-4
4) If clearance “B” is less than 75 mm (2.95 in.),
the most possible cause is either rear brake
shoes are worn out beyond limit or air is in
lines.
Should clearance “8” remain less than 75 mm
(2.95 in.) even after replacement of brake
shoes and bleeding of system, other possible
but infrequent cause is malfunction of rear
brake shoe adjusters or booster push rod
length out of adjustment for the car with
brake booster.
See p. 19-22 for brake shoe inspection.
See p. 19-46 for bleeding brake system.
Remove brake drums for adjuster inspection.
(See p. 19-23.) If defective, correct or replace.
Fig. 19-8-3
19-43

BRAKE HOSE AND PIPE INSPECTION
Hose
The brake hose assembly should be checked for
road hazard damage, for cracks and chafing of
outer cover, for leaks and blisters. A light and
mirror may be needed for an adequate inspec-
tion. If any of the above conditions are observ-
ed on brake hose, it will be necessary to replace
it.
DISC INSPECTION
Inspect disc periodically according to mainte-
nance schedule.
For more information, refer to p. 19-17.
REAR BRAKE SHOE & LINING INSPECTION
Inspect brake shoe & lining according to mainte-
nance schedule.
For shoe and lining inspection, refer to p. 19-22.
Fig. 19-8-5
Pipe
Inspect the tube for damage, cracks, dents and
corrosion. If any defect is found, replace it.
Fig. 19-8-6\ ’
PAD LINING INSPECTION
Inspect pad linings periodically according to
maintenance schedule and whenever wheels are
removed (for tire rotation or other reason).
For wear check of pad linings, refer to p. 19-16.
REAR BRAKE DRUM INSPECTION
Inspect brake drum according to maintenance
schedule.
For more information, refer to p. 19-21.
PARKING BRAKE INSPECTION AND
ADJUSTMENT
1) Parking brake lever stroke inspection.
Hold the center of parking brake lever grip
and pull it up with 20 to 25 kg (44 to 55 lb)
force.
With parking brake lever pulled up as above,
count ratchet notches in “A” as shown in
figure. There should be 3 to 8 notches.
Also, check if both right and left rear wheels
are locked firmly.
If number of notches is out of specification,
adjust cable by referring to adjustment
procedure described on the next page so as to
obtain specified parking brake stroke.
NOTE:
Check tooth tip of each notch for damage or
wear. If any damage or wear is found, replace
parking brake lever.
Pull up
4
Fig. 19-8-7
19-44

2) Parking brake lever stroke adjustment
a) If parking brake lever stroke was found out of
specification when checked as described on
the previous page, adjust parking brake cable.
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 force.
Rear brake shoes are not worn beyond limit,
and self adjusting mechanism operates proper-
ly.
b) After confirming that above 5 conditions are
all satisfied, adjust parking brake lever stroke
by loosening or tightening adjusting nut
indicated in figure and tighten stopper nut to
the pin.
NOTE:
For cable adjustment, loosen stopper nut and
turn adjusting nut while holding hold nut
with spanner so as to prevent inner cable
from getting twisted.
Check brake drum for dragging after adjust-
ment.
Parking brake stroke;
when lever is pulledWithin 3 - 8 notches
up at 20 kg (44 lb)
’ yLyFrking brake lever
Cable adjustingnutPi:St&per nut cab’e
Fig. 19-8-8
No. 1
BRAKE PEDAL PLAY INSPECTION
Pedal play should be within below specification.
If out of specification, check stop light switch
for proper installation position and adjust if
necessary.
Also check pedal shaft bolt and master cylinder
pin installation for looseness and replace if
defective.
play1 -8mm(0.04 - 0.32tn.1
Fig. 19-8-9
REAR DRUM BRAKE SHOE ADJUSTMENT
Rear brake has self-adjusting mechanism but it
does require adjustment for proper drum to shoe
clearance when brake shoe has been replaced or
brake drum has been removed for some other
service.
Adjustment is automatically accomplished by
depressing brake pedal 3 to 5 times with apprd-
ximately 30 kg (66 Ibs) load after all parts are
installed.
Then check brake drum for dragging and brake
system for proper performance. After lowering
car from lift, brake test should be performed.
FLUSHING BRAKE HYDRAULIC SYSTEM
It is recommended that entire hydraulic system
be thoroughly flushed with clean brake fluid
whenever new parts are installed in hydraulic
system.
Periodical change of brake fluid is also recom-
mended.
3) Parking brake cable inspection
Check brake cable for damage and also for
smooth movement. Replace if deteriorated.19-45

BLEEDING BRAKES
NOTE:
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted surface,
immediately wipe fluid from paint and clean
painted surface.
With this vehicle, air bleeding is required at four
places: right and left front wheels, P & B valve
and rear wheel cylinder on left side as marked
with dot (0) in Fig. 19-8-10. And at each of these
places, there is air bleeder plug.
Whenever brake pipe or hose has been discon-
nected at any place, carry out air bleeding so as
to make sure that no air remains in brake circuit.
CAUTION:
Upon completion of air bleeding at four
places, be sure to tighten each air bleeder
plug to specified torque and check entire
brake circuit to make sure that no fluid
leakage exists.
Right brake caliper
?Ir ____ -- ---------------,IIAn
i
Left brake caliper
1Left wheel cylinder
Fig. 19-8-10
1) Fill master cylinder reservoir with brake fluid
and keep at least half filled during bleeding
operation.
2) Remove bleeder plug cap.
Attach vinyl tube to bleeder plug of wheel
cylinder, and insert the other end into contai-
ner.
See-through tube1. Plug cap2. Vinyl tube
2
3. Container
1
Fig. 19-8-11
3) Depress brake pedal several times, and then
while holding it depressed, loosen bleeder
plug about one-third to one-half turn.
Depress brake pedal several times and withpedal depressed, loosen bleeder plug a little.
Fig. 19-8-12
4) When fluid pressure in the cylinder is almost
depleted, retighten bleeder plug.
With brake pedalretighten bleederplug.
Fig. 19-8-13
19-46

5) Repeat this operation until there are no more
air bubbles in hydraulic line.
6) When bubbles stop, depress and hold brake
pedal and tighten bleeder plug.
7) Then attach bleeder plug cap.
Fig. 19-8-14
8) After completing bleeding operation, apply
fluid pressure to pipe line and check for
leakage.
9) Replenish fluid into reservoir up to specified
level.
Fig. 19-8-15
INSPECT BOOSTER OPERATION
There are two ways to perform this inspection,
with and without a tester. Ordinarily, it is possi-
ble to roughly determine its condition without
using a tester.
NOTE:
For this check, make sure that no air is in
hydraulic line.
INSPECTION WITHOUT TESTER
Check Air Tightness
1) Start engine.
2) Stop engine after running for 1 or 2 minutes.
3) Depress brake pedal several times with the
same load as in ordinary braking and observe
pedal travel. If pedal goes down deep the
first time but its travel decreases as it is
depressed the second and more times, air
tightness is obtained.
GOOD
10) Check brake pedal for “sponginess”. If
’ found spongy, repeat entire procedure of
bleeding.
Fig. 19-8-16
19-47