1999 SUZUKI GRAND VITARA tightening torque specification

YH4
GRAND
VITARA
1. Clips
2. Pads
3. Disc
4. Caliper carrier
5. Sensor
6. Shim
1. Caliper pin bolts
ELECTRIC brake
caliper
FRONT BRAKE 5B-5
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
1) Install pad clips and pads.
NOTE:
Install pad with sensor to body center side of caliper.
2) Install caliper and torque caliper pin bolts to specification.
Tightening Torque
(a), (b): 27 N
.m (2.7 kg-m, 20.0 lb-ft) For TOKICO brake. .
caliper
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft) For SUMITOMO. . . . . .
(b): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
NOTE:
Make sure that boots are fit into groove securely.
3) Torque front wheel nuts to specification.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
4) Upon completion of installation, perform brake test.

YH4
GRAND
VITARA
1. Caliper pin bolts
1. Flexible hose bolt
FRONT BRAKE 5B-9
Caliper
Before installing caliper (cylinder body) to carrier, check to ensure
that guide pin (pin bolt) inserted in each caliper carrier hole can be
moved smoothly in thrust direction.
NOTE:
Where temperature gets as low as ±30
C in cold weather, use
rubber grease whose viscosity varies very little even at ±40
C
(±40
F).
INSTALLATION
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts to specifications.
Tightening Torque
(a), (b): 27 N
.m (2.7 kg-m, 20.0 lb-ft) For TOKICO brake. .
caliper
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft) For SUMITOMO. . . . .
(b): 85 N.m (8.5 kg-m, 61.5 lb-ft) ELECTRIC brake
85 N.m (8.5 kg-m, 61.5 lb-ft)caliper
NOTE:
Make sure that boots are fit into groove securely.
3) Install brake flexible hose as shown and torque hose mounting
bolt to specification.
Tightening Torque
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
4) Torque wheel nuts to specification.
Tightening Torque
(c): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
5) After completing installation, fill reservoir with brake fluid and
bleed brake system. Perform brake test and check each
installed part for oil leakage.

YH4
GRAND
VITARA
1. 8 mm bolt
5B-10 FRONT BRAKE
FRONT BRAKE DISC
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by loosening carrier bolts (2 pcs.).
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.
3) Remove disc by using 8 mm bolts (2 pcs.).
INSPECTION
Refer to FRONT DISC BRAKE PAD INSPECTION.
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
1) Install disc to wheel hub.
2) Install caliper assembly to steering knuckle.
3) Torque caliper carrier bolts to specification.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
4) Torque front wheel nuts to specifications.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
5) Upon completion of installation, perform brake test.

YH4
GRAND
VITARA
FRONT BRAKE 5B-11
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake caliper bleeder plug
(For SUMITOMO ELECTRIC brake caliper)8.00.806.0
Brake caliper bleeder plug
(For TOKICO brake caliper)8.50.856.5
Caliper pin bolt (For TOKICO brake caliper)272.720.0
Caliper pin bolt (M10)
(For SUMITOMO ELECTRIC brake caliper)505.036.5
Caliper pin bolt (M12)
(For SUMITOMO ELECTRIC brake caliper)858.561.5
Flexible hose bolt232.317.0
Brake carrier bolt858.561.5
Wheel nut10010.072.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Brake fluid
Indicated on reservoir
cap or described in owner's
manual of vehicle
To fill master cylinder reservoir.

To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when
they are disassembled.

YH4
GRAND
VITARA
5C
PARKING AND REAR BRAKE 5C-1
SECTION 5C
PARKING AND REAR BRAKE
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 DESCRIPTION5C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brake Assembly5C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Cable5C- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Drum5C- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shoe5C- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder5C-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Back Plate5C-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
1. Wheel cylinder
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts1. Bleeder plug cap
5C-12 PARKING AND REAR BRAKE
WHEEL CYLINDER
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Loosen brake pipe flare nut (or nuts) but only within the extent
that fluid does not leak.
4) Remove wheel cylinder mounting bolts. Disconnect brake pipe
(or pipes) from wheel cylinder and put wheel cylinder bleeder
plug cap onto pipe to prevent fluid from spilling.
INSPECTION
Inspect wheel cylinder disassembled parts for wear, cracks, corro-
sion or damage.
NOTE:
Clean wheel cylinder components with brake fluid.
INSTALLATION (For non sealed type)
1) Take off bleeder plug cap from brake pipe and connect pipe (or
pipes) to wheel cylinder just enough to prevent fluid from leak-
ing.
2) Tighten wheel cylinder to brake back plate to specified torque.
Tightening Torque
(a): 8.5 N
.m (0.85 kg-m, 6.5 lb-ft)
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)

YH4
GRAND
VITARA
2
1. Wheel cylinder
2. Gasket
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts
PARKING AND REAR BRAKE 5C-13
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to steps 1) to 5) of BRAKE SHOE
INSTALLATION.
NOTE:
Be sure to bleed brake system. (for bleeding operation, re-
fer to BLEEDING BRAKES in Section 5.)
INSTALLATION (For gasket sealed type)
1) Install gasket to joint seam of wheel cylinder and brake back
plate. Then take off bleeder plug cap from brake pipe and con-
nect pipe (or pipes) to wheel cylinder just enough to prevent fluid
from leaking.
NOTE:
Be sure to check gasket for deterioration or any damage be-
fore installation and replace if found defective.
2) Tighten wheel cylinder to brake back plate to specified torque.
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to BRAKE SHOE INSTALLA-
TION.
NOTE:
Be sure to bleed brake system. Refer to ªCHECK AND AD-
JUSTMENTº in BRAKES section.

YH4
GRAND
VITARA
PARKING AND REAR BRAKE 5C-17
09943-35512
Brake drum remover
(Front wheel hub remover)09942-15510
Sliding hammer
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Wheel cylinder bleeder plug7.50.755.5
Parking brake lever bolt232.317.0
Wheel cylinder bolt (For non sealed type)8.50.856.5
Wheel cylinder bolt (For gasket sealed type)111.112.0
Brake pipe flare nut161.612.0
Brake back plate nut232.317.0
Wheel nut10010.072.5
REQUIRED SERVICE MATERIALS
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Brake fluid
Indicated on reservoir
cap or described in owner's
manual of vehicle
To fill master cylinder reservoir.

To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when
they are disassembled.
Water tight
sealantSEALING COMPOUND 366E
99000-31090
To apply to mating surfaces of brake back
plate and rear wheel cylinder.
SealantSUZUKI BOND NO. 1215
99000-31110

To apply to mating surfaces of brake back
plate and rear axle housing.

To apply mating surfaces of brake back
plate and rear wheel bearing retainer.
SPECIAL TOOLS