2000 SUZUKI GRAND VITARA cv joint

YH4
GRAND
VITARA
4B-6 PROPELLER SHAFTS
09900-06108
Snap ring pliers
(Closing type)09926-48010
Universal joint
disassembling tool set
TIGHTENING TORQUE SPECIFICATION
FastenerTightening torqueFastenerN.mkg-mlb-ft
Propeller shaft nut / Center support bolt505.036.5
REQUIRED SERVICE MATERIAL
MATERIALRECOMMENDED
SUZUKI PRODUCTUSE
Lithium greaseSUPER GREASE C
(99000-25030)To apply to spider bearing race.
SPECIAL TOOLS

YH4
GRAND
VITARA
[FOR VEHICLE WITHOUT ABS]
[FOR VEHICLE WITH ABS]
1. Master cylinder
2-1. 4-way joint
2-2. 2-way joint
3. LSPV (Load Sensing Proportioning Valve)
4. Rear axle housing
5. ABS actuator (H.U.)
F.R.:Front side
5-2 BRAKES
GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons
(two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make
two independent circuits. One connects front brakes (right and left) and the other connects rear brakes (right and
left).
The load sensing proportioning valve (LSPV) is included in these circuits between the master cylinder and the rear
brake for the vehicle without ABS.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading / trailing
shoes) for the rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and me-
chanical linkage system. The same brake shoes are used for both parking and foot brakes.

YH4
GRAND
VITARA
1. 4-way joint / 2-way joint
2. Master cylinder
3. LSPV
4. Right brake caliper
5. Left brake caliper
6. Right wheel cylinder
7. Left wheel cylinder
8. ABS actuator

: Air bleeding point [A]: Without ABS
[B]: With ABS
1. Plug cap2. Vinyl tube (See-through tube)
3. Container
[A]
[B]
BRAKES 5-7
CHECK AND ADJUSTMENT
BLEEDING BRAKES
CAUTION:
Brake fluid is extremely damaging to paint. If fluid should
accidentally touch painted surface, immediately wipe
fluid from paint and clean painted surface.
NOTE:
For vehicle equipped with ABS, make sure that ignition switch
turns off.
Be sure to bleed air of brake system according to following proce-
dure when its oil hydraulic circuit has been disconnected.
Hydraulic lines of brake system consists of two separate lines, one
for front wheel brakes and the other for rear wheel brakes.
Air bleeding is necessary at right and left front wheel brakes, left
rear wheel brake and LSPV (if equipped without ABS), i.e. 4 places
(3 places for vehicle with ABS) in all.
1) Fill master cylinder reservoir with brake fluid and keep at least
one-half full of fluid during bleeding operation.
2) Remove bleeder plug cap.
Attach a vinyl tube to bleeder plug of wheel cylinder, and insert
the other end into container.
3) Depress brake pedal several times, and then while holding it de-
pressed, loosen bleeder plug about one-third to one half turn.

YH4
GRAND
VITARA
3. LSPV stay
1. Master cylinder
2. Disconnect brake pipe1. LSPV lever
2. LSPV spring
3, ªAº 2
1
2(a)
ªaº
ªbº
5-14 BRAKES
3) Depress brake pedal gradually till fluid pressure of front brake
becomes as specified below and check corresponding pressure
of rear brake then. It should be within specification given below.
Front brake
Rear brake
8,000 kPa
80 kg / cm2
3 Door
6,000 ± 7,300 kPa
60 ± 73 kg / cm2
853 ± 1,038 psi80 kg / cm2
1,138 psi5 Door
4,500 ± 7,300 kPa
45 ± 73 kg / cm2
640 ± 1,038 psi
As done above, apply 100 kg / cm2 pressure to front brake and
check that rear brake pressure then is within specification as giv-
en below.
Front brake
Rear brake
10,000 kPa
100 kg / cm2
3 Door
6,500 ± 8,000 kPa
65 ± 80 kg / cm2
924 ± 1,138 psi100 kg / cm2
1,422 psi5 Door
5,000 ± 8,000 kPa
50 ± 80 kg / cm2
711 ± 1,138 psi
4) If rear brake pressure is not within specification, adjust it by
changing stay ªAº position as follows.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

If rear brake pressure is higher than specification, move stay
ªAº to direction ªaº and if it is lower, to direction ªbº.

Repeat steps 3) and 4) until rear brake pressure is within spec-
ification.

After adjustment, be sure to torque bolt to specification.
5) Disconnect brake pipe (connecting between master cylinder
secondary side and 4-way joint) from master cylinder.
Tighten plug (special tool) to master cylinder.
Depress brake pedal. If rear brake pressure is 95 ± 100 kg / cm
2
when front brake pressure is 100 kg / cm2, it means that front fail-
safe system functions properly.
Front brake
Rear brake
10000 kPa
100 kg / cm2
1422 psi
9500 ± 10000 kPa
95 ± 100 kg / cm2
1350 ± 1422 psi
Special Tool
(A): 09956-02210

YH4
GRAND
VITARA
BRAKES 5-17
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake pipe 2-way (or 4-way) joint bolt232.317.0
Brake pipe flare nut161.611.5
Front caliperM88.00.86.0
Brake bleederplug
Front cali erM108.50.856.5Brake bleeder lugWheel cylinder7.50.755.5
LSPV7.50.755.5
LSPV mounting bolt
LSPV stay bolt232.317.0
LSPV spring nut
Wheel nut10010.072.5
Stop light switch lock nut7.50.755.5
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
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-5
[A]: Vehicle with ABS for right hand steering vehicle
[B]: Vehicle with ABS for left hand steering vehicle
1. E-ring
2. Flexible hose
3. Hose washer
4. Hose bolt
5. Brake caliper
6. 2 way joint
NOTE:
Insert E-ring till its end surface is flush
with or lower than bracket end surface.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
(c): 10 N.m (1.0 kg-m, 7.5 lb-ft)
(b): 21 N.m (2.1 kg-m, 15.5 lb-ft)
A: View A
B: View B
C: View Ca: Clamp a
b: Clamp b
c: Clamp c
d: Clamp d
C
t: Top side
f: Front side
[A]
[B]

YH4
GRAND
VITARA
5A-6 BRAKES PIPE / HOSE / MASTER CYLINDER
NOTE:
Insert E-ring till its end surface is flush
with or lower than bracket end surface.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
[C]: Vehicle without ABS for right hand steering vehicle
[D]: Vehicle without ABS for left hand steering vehicle
1. E-ring
2. Flexible hose
3. Hose washer
4. Hose bolt
5. Brake caliper
6. 4way joint
[C]
[D]
D: View D a: Clamp a
b: Clamp b
c: Clamp c
d: Clamp dt: Top side
f: Front side

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-7
1. Rear axle
2. Shock absorber
3. Clamp
1. Brake pipe (to rear)
2. Brake pipe
(to LSPV, for vehicle without ABS)
3. 4-way (2-way) joint
4. Chassis frame
REAR BRAKE HOSE / PIPE
REMOVAL
1) Raise and suitably support vehicle. Remove tire and wheel.
2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.
INSTALLATION
1) Reverse removal procedure for brake hose or pipe installation procedure.

Be sure to obtain more than 3 mm (0.118 in.) clearance between axle housing and brake pipe.

Install clamps properly referring to figure below and tighten bolts.

When installing hose, make sure that it has no twist or kink.
2) Fill and maintain brake fluid level in reservoir. Bleed brake system.
3) Perform brake test and check each installed part for fluid leakage.