2001 SUZUKI GRAND VITARA brakes

5A-6 BRAKES PIPE/HOSE/MASTER CYLINDER
Master Cylinder Reservoir
REMOVAL
1) Disconnect reservoir lead wire at coupler.
2) Clean outside of reservoir (1).
3) Take out fluid with syringe or such.
4) Remove reservoir stopper (3).
5) Remove reservoir (1).
INSTALLATION
1) When using new grommets, lubricate them with the same
fluid as the one to fill reservoir (1) with. Then press-fit grom-
mets to master cylinder (2). Grommets must be seated in
place.
2) Install reservoir (1) and then insert stopper (3).
3) Connect reservoir lead wire.
4) Fill reservoir (1) with specified fluid.
5) Upon completion of installation, check for fluid leakage.
2. Master cylinder
1
3
2
NOTE:
Do not allow brake fluid to get on painted surfaces.
2. Stopper
3. Grommets
3
31
2
NOTE:
See NOTE at the beginning of this section.
1
3
2

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-7
Master Cylinder Assembly
REMOVAL
1) Disconnect reservoir lead wire (1) at coupler.
2) Clean around reservoir cap (2) and take out fluid with
syringe or such.
3) Disconnect brake pipes from master cylinder (3) and ABS
actuator (4).
INSPECTION
Inspect distance “A” to be the following.
Distance “A” :
57.4 mm (2.26 in) or more
If measurement is out of above specification, replace master cyl-
inder assembly.
INSTALLATION
1) Install master cylinder to brake booster.
2) Tighten master cylinder attaching nuts to specified torque.
Tightening torque
Master cylinder attaching nut (b) :
13 N·m (1.3 kg-m, 9.5 lb-ft)
3) Connect hydraulic lines to master cylinder and ABS actuator
and tighten flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (c) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
4) Connect reservoir lead wire (1).
5) Fill reservoir with specified brake fluid.
6) After installing, check brake pedal play and bleed air from
system (Refer to “BRAKE PEDAL PLAY CHECK” and
“BLEEDING BRAKE” in Section 5).
7) Perform brake test and check each installed part for fluid
leakage. NOTE:
Do not allow brake fluid to get on painted surfaces.
21
4
3
“A”
NOTE:
See NOTE at the beginning of this section.
1
(b)
(c)

5A-8 BRAKES PIPE/HOSE/MASTER CYLINDER
Brake Booster
CLEARANCE BETWEEN BOOSTER PISTON ROD AND
MASTER CYLINDER PISTON CHECK AND ADJUSTMENT
The length of booster piston rod (1) is adjusted to provide speci-
fied clearance “0” between piston rod (1) end and master cylinder
piston (2).
1) Before measuring clearance, push piston rod several times
so as to make sure reaction disc is in place.
2) Keep inside of booster at atmospheric pressure for measure-
ment.
3) Check depth of piston rod, i.e. distance between piston rod
and mating surface of booster-to-master cylinder.
Depth “c” of piston rod for check :
15.8 – 16.6 mm (0.623 – 0.653 in.)
1. Brake master cylinder assembly 4. Push rod clevis 7. Clip
2. Brake booster assembly 5. Nut 8. Plate
3. Gasket 6. Clevis pin 9. Seal
19
2 3
8546 7

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-9
4) If measured depth is out of above specifications, adjust to
specifications below by turning adjusting screw of piston rod.
Special tool
(F) : 09952-16021
Depth “d” of piston rod for adjustment :
16.3 – 16.6 mm (0.642 – 0.653 in.)

5A-10 BRAKES PIPE/HOSE/MASTER CYLINDER
Tightening Torque Specification
Special Tool
Fastening partTightening torque
Nm kg-m lb-ft
Brake flexible hose bolt (Brake caliper/2 way joint) 23 2.3 17.0
Brake hose / pipe bracket bolt 10 1.0 7.5
ABS actuator bracket bolt 10 1.0 7.5
Master cylinder attaching nut 13 1.3 9.5
Booster nut 13 1.3 9.5
Clevis nut 25 2.5 18.0
2-way joint mounting bolt 10 1.0 7.5
Brake pipe flare nut 16 1.6 12.0
Brake bleeder plug (Front caliper (M8)) 8 0.8 6.0
Brake bleeder plug (Wheel cylinder) 7.5 0.75 5.5
Wheel nut 100 10.0 72.5
09952-16021 09950-78220
Booster piston rod
adjusterFlare nut wrench
(10 mm)

5E2-4 ANTILOCK BRAKE SYSTEM (ABS)
ABS Hydraulic Unit/control Module Assembly
ABS control module is a component of ABS hydraulic unit/control
module assembly and has the following functions.
Self-diagnosis function
ABS control module diagnoses conditions of the system compo-
nent parts (whether or not there is any abnormality) all the time
and indicates the results (warning of abnormality occurrence and
DTC) through the ABS warning lamp as described below.
1) When ignition switch is turned ON, ABS warning lamp lights
for 2 seconds to check its bulb and circuit.
2) When no abnormality has been detected (the system is in
good condition), ABS warning lamp turns OFF after 2 sec-
onds.
3) When an abnormality in the system is detected, ABS warn-
ing lamp lights and the area where that abnormality lies is
stored in the memory of EEPROM in ABS control module.
4) When Diag. switch terminal (2) of diagnosis connector (1)
(monitor connector) is grounded, the abnormal area is output
as DTC. It is indicated by flashing of ABS warning lamp.
(Refer to the table below.)
5) For procedure to clear all DTC’s, refer to “DIAGNOSTIC
TROUBLE CODE CLEARANCE” in this section.
Also ABS control module turns ON EBD warning lamp (brake
warning lamp) depending on the trouble that detected by the
module and EBD warning lamp does not indicate DTC.
Fail-safe function
When an abnormality occurs (an abnormal DTC is detected),
ABS control module turns OFF the fail-safe relay which supplies
power to ABS hydraulic unit. Thus, with ABS not operating,
brakes function just like the brake system of the vehicle without
ABS.
SYSTEM CONDITIONABS WARNING LAMP
Diag. switch
terminal is
not groundedDiag. switch
terminal is
grounded
In good
condition
at presentNo trouble in the past OFF DTC 12
Trouble occurred in
the pastOFF History DTC
Abnormal-
ity exists
at presentNo trouble in the past ON Current DTC
Trouble occurred in
the pastONCurrent and
history DTCs
3. Ground terminal
4. Service wire

5E2-6 ANTILOCK BRAKE SYSTEM (ABS)
ABS Diagnostic Flow Table
Refer to the following pages for the details of each step.
Step Action Yes No
11)Perform “Customer Complaint Analysis”.
2) Perform “Problem Symptom Confirmation”.
3) Perform “Diagnostic Trouble Code Check, Record and
Clearance”.
Is there any malfunction DTC?Go to Step 2. Go to Step 5.
21)Perform “DRIVING TEST”.
Is trouble symptom identified?Go to Step 3. Go to Step 6.
3 1) Check diagnostic trouble code.
Is it malfunction code?Go to Step 4. Go to Step 5.
4 1) Inspect and repair referring to applicable diagnostic trouble
code table in this section.
2) Perform “FINAL CONFIRMATION TEST” after cleared
DTC.
Does trouble recur?Go to Step 7. End.
5 1) Inspect and repair referring to “DIAGNOSIS” in “BRAKES”
section.
2) Perform “FINAL CONFIRMATION TEST”.––
6 1) Check intermittent troubles referring to “INTERMITTENT
AND POOR CONNECTION” in “GENERAL INFORMA-
TION” section and related circuit of trouble code recorded
in Step 2.
2) Perform “FINAL CONFIRMATION TEST” after cleared
diagnostic trouble code.
Does trouble recur?Go to Step 7. End.
71)Perform “Diagnostic Trouble Code Check, Record and
Clearance”.
Is there any malfunction code?Go to Step 2. Go to Step 5.

5E2-8 ANTILOCK BRAKE SYSTEM (ABS)
b) Problem Symptom Confirmation
Check if what the customer claimed in “CUSTOMER QUESTIONNAIRE” is actually found in the vehicle
and if that symptom is found, whether it is identified as a failure. (This step should be shared with the cus-
tomer if possible.) Check warning lamps related to brake system referring to “EBD WARNING LAMP
(BRAKE WARNING LAMP) CHECK” and “ABS WARNING LAMP CHECK” in this section.
c) Diagnostic Trouble Code (DTC) Check, Record and Clearance
Perform “DIAGNOSTIC TROUBLE CODE CHECK” procedure in this section, record it and then clear it
referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section.
If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again
when the ignition switch is turned ON, attempt to diagnose the trouble based on the DTC recorded in this
step may mislead the diagnosis or make diagnosing difficult. Proceed to Step 2) to check control module for
proper self-diagnosis function.
If the malfunction DTC which was once displayed and then cleared can be detected (indicated) again when
ignition switch is turned ON, proceed to Step 3).
2) DRIVING TEST
Test drive the vehicle at 40 km/h for more than a minute and check if any trouble symptom (such as abnor-
mal lighting of ABS warning light) exists.
If the malfunction DTC is confirmed again at ignition switch ON, driving test as described in above is not nec-
essary. Proceed to Step 3).
3) DIAGNOSTIC TROUBLE CODE CHECK
Recheck diagnostic trouble code referring to “DTC CHECK” as shown in the following page.
4) DIAGNOSTIC TROUBLE CODE FLOW TABLE
According to Diagnostic flow table for the diagnostic trouble code confirmation in Step 3), locate the cause of
the trouble, namely in a sensor, switch, wire harness, connector, actuator assembly or other part and repair
or replace faulty parts.
5)“DIAGNOSIS” IN “BRAKES” SECTION
Check the parts or system suspected as a possible cause referring to “DIAGNOSIS” in “BRAKES” section
and based on symptoms appearing on the vehicle (symptom obtained through Steps 1)-a, 1)-b and 2) and
repair or replace faulty parts, if any).
6) CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“INTERMITTENT TROUBLE” in “GENERAL INFORMATION” section and related circuit of trouble code
recorded in Step 1)-c.
7) FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the ABS is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear the DTC once and perform test driving and confirm
that no DTC is indicated.