1999 SUZUKI GRAND VITARA Section 8f

YH4
GRAND
VITARA
5
BRAKES 5-1
GENERAL DESCRIPTION5- 2 . . . . . . . . . . . . . .
DIAGNOSIS5- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Road Testing Brakes 5- 3. . . . . . . . . . . . . . . . . .
Brake Fluid Leaks 5- 3. . . . . . . . . . . . . . . . . . . .
Substandard or Contaminated
Brake Fluid 5- 3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 5- 4. . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5- 7 . . . . . . . . . . . .
Bleeding Brakes 5- 7. . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Free Height Check 5- 9. . . . . . . .
Brake Light Switch Adjustment 5- 9. . . . . . . . .
Excessive Pedal Travel Check 5- 9. . . . . . . . .
Brake Pedal Play Check 5-10. . . . . . . . . . . . . . .
Brake Fluid Level Check 5-10. . . . . . . . . . . . . . . Brake Hose and Pipe Check 5-10. . . . . . . . . . .
Master Cylinder Check 5-10. . . . . . . . . . . . . . . .
Brake Disc Check 5-11. . . . . . . . . . . . . . . . . . . .
Brake Pad Check 5-11. . . . . . . . . . . . . . . . . . . . .
Brake Shoe Check 5-11. . . . . . . . . . . . . . . . . . . .
Parking Brake Check and
Adjustment 5-12. . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Brake Hydraulic System 5-13. . . . . . .
Fluid Pressure Test 5-13. . . . . . . . . . . . . . . . . . .
Booster Operation Check 5-15. . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS5-17 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5-17 . . . . . . . .
SPECIAL TOOLS5-18 . . . . . . . . . . . . . . . . . . . . . .
SECTION 5
BRAKES
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:

When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E or 5E1 first.

All brake fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and / or could result in major repair expense. They must be replaced with one of same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to as-
sure proper retention of all parts. There is to be no welding as it may result in extensive damage and
weakening of the metal.
DIAGNOSIS5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PIPE / HOSE / MASTER CYLINDER5A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE5B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING AND REAR BRAKE5C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS

YH4
GRAND
VITARA
5-6 BRAKES
ConditionPossible CauseCorrection
Brake warning light
turns on after
engine start
Parking brake applied.

Insufficient amount of brake fluid.

Brake fluid leaking from brake line.

Brake warning light circuit faulty.

Malfunctioning EBD system, if equipped
with ABS.Release parking brake and check
that brake warning light turns off.
Add brake fluid.
Investigate leaky point, correct it and
add brake fluid.
Repair circuit.
Check system referring to
ªDIAGNOSISº of ABS section.
Brake warning light
turns on when
brake is applied
Brake fluid leaking from brake line.

Insufficient amount of brake fluid.Investigate leaky point, correct it and
add brake fluid.
Add brake fluid.
Brake warning light
fails to turn on
even when parking
brake is applied
Bulb burnt out.

Brake warning light circuit open.Replace bulb.
Repair circuit.
ABS warning light
does not turn on
for 2 sec. after
ignition switch has
turned ON
Bulb burnt out.

ABS warning light circuit open, if equipped
with ABS. (including check relay)Replace bulb.
Check system referring to
ªDIAGNOSISº of ABS section.
ABS warning light
remains on after
ignition switch has
turned on for 2 sec.
Malfunctioning ABS, if equipped with ABS.Check system referring to
ªDIAGNOSISº of ABS section.

YH4
GRAND
VITARA
5-8 BRAKES
4) When fluid pressure in the cylinder is almost depleted, retigh-
ten bleeder plug.
5) Repeat this operation until there are no more air bubbles in hy-
draulic line.
6) When bubbles stop, depress and hold brake pedal and tighten
bleeder plug.
For tightening torque specification of air bleeder plug, re-
fer to ªTIGHTENING TORQUE SPECIFICATIONº in this
section.
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid pressure to
pipe line and check for leakage.
9) Replenish fluid into reservoir up to specified level.
10) Check brake pedal for ªsponginessº. If found spongy, repeat
entire procedure of bleeding.

YH4
GRAND
VITARA
1. Stop light switch
BRAKES 5-9
BRAKE PEDAL FREE HEIGHT CHECK
Remove foot rest and displace carpet and dash silencer(s) so as to
measure brake pedal free height between pedal face and asphalt
sheet installed on dash panel.
Brake pedal free height ªaº from asphalt sheet:
208 ± 218 mm (8.19 ± 8.58 in.)
If the measurement is not within the specification, check the posi-
tion of booster push rod clevis and / or stop light switch according
to the instruction shown in this section.
The free height varies depending on installation position of booster
push rod clevis and stop light switch.
BRAKE LIGHT SWITCH ADJUSTMENT
Adjustment should be made as follows when installing switch. Pull
up brake pedal toward you and while holding it there, adjust switch
position so that clearance between end of thread and brake pedal
return cushion (shown as ªbº in figure).
Then tighten lock nut to specified torque.
Clearance ªbº: 1.5 ± 2.0 mm (0.06 ± 0.08 in.)
Tightening Torque
(b): 7.5 N
.m (0.75 kg-m, 5.5 lb-ft)
EXCESSIVE PEDAL TRAVEL CHECK
1) Remove foot rest and displace carpet and dash silencer(s).
2) Start engine.
3) Depress brake pedal a few times.
4) With brake pedal depressed with approximately 30 kg (66 lbs)
load, measure pedal to asphalt sheet clearance ªcº.
Clearance ªcº: over 115 mm (4.53 in.)
5) If clearance ªcº is less than specification, the most possible
cause is either rear brake shoes are worn out beyond limit or air
is in lines.
Should clearance ªcº remain less than specification even after
replacement of brake shoes and bleeding of system, other pos-
sible but infrequent cause is malfunction of rear brake shoe ad-
justers or booster push rod length out of adjustment.

YH4
GRAND
VITARA
1. Pad rim
2. Lining
3. Disc
1. Rubber plug
2. Brake shoe
3. Brake shoe rim
BRAKES 5-11
BRAKE DISC CHECK
Refer to FRONT DISC BRAKE PAD of Section 5B for inspection
point and procedure.
BRAKE PAD CHECK
Inspect pad linings periodically according to maintenance schedule
whenever wheels are removed (for tire rotation or other reason).
Take a look through hole of caliper and check lining thickness of in-
side pad.
Thickness ªeº
Standard: 10.0 mm (0.39 in.)
Service Limit: 2.0 mm (0.08 in.)
If one of brake pad is worn to service limit, all linings must be re-
placed at the same time.
BRAKE SHOE CHECK
Inspection should be carried out on following points after brake ped-
al travel ªcº (pedal to asphalt sheet clearance) check as described
on previous page of this section, even when it is more than 115 mm
(4.53 in.).
Amount of brake shoe wear can be checked as follows.
1) Hoist vehicle.
2) Remove rubber plug from brake back plate.
3) Through hole of back plate, visually check for thickness of brake
shoe lining. If lining thickness ªfº is found less than below speci-
fied wear limit, replace with new brake shoes.
Thickness ªfº
Service Limit: 1.0 mm (0.04 in.)

YH4
GRAND
VITARA
1. Air bleeder plug
2. Weight
3. Attachment2
ªLº
BRAKES 5-13
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 recommended.
FLUID PRESSURE TEST(if equipped with
LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.
1) Stop vehicle on level floor and place approximately about
200 kg (441 lbs) weight on rear housing so that rear axle weight
800 kg (1764 lb).
Rear axle weight ªLº: 800 kg (1764 lb)
2) Install special tool to front and rear brake.
NOTE:
Special tool should be connected to breather of front (driv-
er's side brake) and rear brakes.
Special Tool
Front brake
(A): 09956-02310
(B): 09952-46510 (Attachment for vehicle with SUMITOMO
ELECTRIC brake caliper)
(C): 55473-82030 (Air bleeder plug supplied as a spare part)
Rear brake
(A): 09956-02310
(B): 09952-36310 (Attachment for thread diameter 7 mm of
bleeder plug) or
09952-46510 (Attachment for thread diameter 8 mm of
bleeder plug)
(C): 55473-82030 (Air bleeder plug supplied as a spare part)
NOTE:

Special tool (B) is used instead of thread diameter 10 mm
attachment of special tool (A).
So remove the attachment from (A) and install (B) as
shown in figure.

For vehicle with TOKICO brake caliper, use the attach-
ment included in special tool (A).

For identification of brake caliper type, refer to GENERAL
DESCRIPTION in SECTION 5B.

YH4
GRAND
VITARA
5A
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-1
SECTION 5A
BRAKES PIPE/HOSE/MASTER CYLINDER
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System

Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.

Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
All brake fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and / or could result in major repair expense. They must be replaced with one of same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening
of the metal.
CONTENTS
GENERAL DESCRIPTION5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster Assembly5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSPV (Load Sensing Proportioning Valve) Assembly 5A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Hose / Pipe5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Brake Hose / Pipe5A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Reservoir5A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly5A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Booster5A-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSPV (Load Sensing Proportioning Valve) Assembly 5A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
1. LSPV
2. LSPV lever
3. Spring
4. LSPV stay
5. Brake flare nut
[A]: Type A
[B]: Type B
1. Plunger
2. Lip seal
3. LSPV lever
4. Sensor spring
5. From master cylinder
primary chamber
(Rear wheel brake)
6. From master cylinder
secondary chamber
(Front wheel brake)
7. To rear wheel brake
8. Pin
9. Bolt hole
[A] [B]
44
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3
LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped)
As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear
wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the
vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Also, it releases the above described control over the hydraulic pressure applied to the rear wheel brake, should
any failure occur in the hydraulic circuit of the front wheel brake so that the hydraulic pressure produced in the mas-
ter cylinder is applied to the rear wheel brake directly to operate it.
CONSTITUTION
The LSPV components are grouped into three sections as follows.
ªAº: Sensor section
The main parts in this section are a lever and a spring which senses variation in the vehicle height as affected
by the loaded condition and converts it into the load.
ªBº: Hydraulic pressure control section
Included in this section are a stepped plunger and valve mechanism to execute proportional control.
ªCº: Fail-safe section
The main parts in this section are a chamber which draws in the hydraulic pressure from the front wheel brake
system and a fail-safe piston which releases the valve mechanism in the control section connected to the rear
wheel brake, should any failure occur in the front wheel brake system.