2000 SUZUKI GRAND VITARA Brake master cylinder

YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
5B
5C
5E1
6A1
6A2
6A4
6B
6C
6E1
6E2
6F1
6F2
6G
6G1
6H
6K
7A1
7B1
7C1
7D
7E
7F
8
8B
8C
8D
8G
9
10
10A
8A
10B
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.

YH4
GRAND
VITARA
1
1. Clutch pedal free travel
MAINTENANCE AND LUBRICATION 0B-15
CHASSIS AND BODY
ITEM 6-1
Clutch
Pedal inspection
Check clutch pedal for height and free travel referring to Section
7C1. Adjust or correct if necessary.
Fluid inspection
1) Check around master cylinder and reservoir for fluid leakage.
If found leaky, correct.
2) Check fluid level.
If fluid level is lower than the minimum level of reservoir, refilling
is necessary. Fill reservoir with specified brake fluid indicated on
clutch reservoir cap.
For the details, refer to On-vehicle service in Section 7C1.
CAUTION:
Since clutch system of this vehicle is factory-filled with
glycol-base brake fluid, do not use or mix different type
of fluid when refilling system; otherwise serious damage
will occur. Do not use old or used brake fluid, or one taken
from unsealed container.
ITEM 6-2
Brake Discs, Pads, Brake Drums and Shoes Inspection
[Brake discs and pads]
1) Remove wheel and caliper but don't disconnect brake hose from
caliper.
2) Check front disc brake pads and discs for excessive wear, dam-
age and deflection. Replace parts as necessary. For details, re-
fer to Section 5B.
Be sure to torque caliper pin bolts to specification.
[Brake drums and shoes]
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for excessive wear
and damage, while wheels and drums are removed. At the same
time, check wheel cylinders for leaks. Replace these parts as
necessary.
For details, refer to Section 5C.

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
[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
BRAKES 5-3
SUBSTANDARD OR
CONTAMINATED BRAKE FLUID
Improper brake fluid, mineral oil or water in the fluid
may cause the brake fluid to boil or the rubber compo-
nents in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the
drum brake wheels.
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol
out of the system. Replace all rubber parts in the sys-
tem, including hoses. Also, when working on the
brake mechanisms, check for fluid on the linings. If ex-
cessive fluid is found, replace the linings.
If master cylinder piston seals are satisfactory, check
for leakage or excessive heat conditions. If condition
is not found, drain fluid, flush with brake fluid, refill and
bleed system.
The system must be flushed if there is any doubt as
to the grade of fluid in the system or if fluid has been
used which contained parts that have been subjected
to contaminated fluid.
DIAGNOSIS
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 de-
termine if the vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the
other without brake application. If it does, check the
tire pressure, front end alignment and front suspen-
sion attachments for looseness. See diagnosis chart
for other causes.
BRAKE FLUID LEAKS
Check the 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.
If fluid level is lower than the minimum level of reser-
voir, refilling is necessary. Fill reservoir with specified
brake fluid.
Brake fluid: Refer to reservoir tank cap.
CAUTION:
Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
tank cap, do not use or mix different type of
fluid when refilling; otherwise serious damage
will occur.
Do not use old or used brake fluid, or any fluid
from a unsealed container.

YH4
GRAND
VITARA
BRAKES 5-5
ConditionPossible CauseCorrection
Excessive pedal
travel (Pedal
stroke too large)
Partial brake system failure.

Insufficient fluid in master cylinder
reservoirs.

Air in system. (pedal soft / spongy)

Rear brake system not adjusted.
(malfunctioning auto adjusting mechanism)

Bent brake shoes.

Worn rear brake shoes.Check brake systems and repair as
necessary.
Fill reservoirs with approved brake
fluid.
Check for leaks and air in brake
systems.
Check warning light. Bleed system if
required.
Bleed system.
Repair auto adjusting mechanism.
Adjust rear brakes.
Replace brake shoes.
Replace brake shoes.
Dragging brakes
(A very light drag
is present in all
disc brakes
immediately
after pedal is
released)
Master cylinder pistons not returning
correctly.

Restricted brake pipes or hoses.

Incorrect parking brake adjustment on rear
brakes.

Weakened or broken return springs in the
brake.

Sluggish parking-brake cables or linkage.

Wheel cylinder or caliper piston sticking.

Malfunctioning ABS, if equipped with ABS.Replace master cylinder.
Check for soft hoses or damaged
pipes and replace with new hoses
and / or new brake pipes.
Check and adjust to correct specifi-
cations.
Replace.
Repair or replace.
Repair as necessary.
Check system and replace as
necessary.
Pedal pulsation
(Pedal pulsates
when depressed
for braking)
Damaged or loose wheel bearings.

Distorted steering knuckle or rear axle
shafts.

Excessive disc lateral runout.

Parallelism not within specifications.

Rear drums out of round.Replace wheel hub component.
Replace knuckle or rear axle shaft.
Check per instructions. If not within
specifications, replace or machine
the disc.
Check per instructions. If not within
specifications, replace or machine
the disc.
Check runout.
Repair or replace drum as
necessary.
Braking noise
Glazed shoe linings, or foreign matters
stuck to linings.

Worn or distorted shoe linings.

Loose front wheel bearings.

Distorted backing plates or loose mounting
bolts.Repair or replace shoe lining.
Replace shoe lining (or pad).
Replace wheel hub component.
Replace or retighten securing bolts.

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
5-10 BRAKES
BRAKE PEDAL PLAY CHECK
Pedal play should be within specification. If out of specification,
check brake 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.
Pedal play ªdº: 1 ± 8 mm (0.04 ± 0.32 in.)
BRAKE FLUID LEVEL CHECK
Be sure to use particular brake fluid either as indicated on reservoir
cap of that vehicle or recommended in owner's manual which
comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked on reser-
voir.
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.
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 hydraulic brake system and water mixed into brake fluid
will lower fluid boiling point. Keep all fluid containers
capped to prevent contamination.
BRAKE HOSE AND PIPE CHECK
The brake hose assembly should be checked for road hazard dam-
age, for cracks and chafing of the outer cover, for leaks and blisters.
A light and mirror may be needed for an adequate inspection. If any
of the above conditions are observed on the brake hose, it is neces-
sary to replace it.
Inspect the pipe for damage, cracks, dents and corrosion. If any de-
fect is found, replace it.
MASTER CYLINDER CHECK
Check for a cracked master cylinder casting or brake fluid around
the master cylinder. Leaks are indicated only if there is at least a
drop of fluid. A damp condition is not abnormal.