2001 SUZUKI GRAND VITARA section 6

FRONT DRIVE SHAFT/SHAFT BEARING, OIL SEAL 4A2-1
4A2
SECTION 4A2
FRONT DRIVE SHAFT/SHAFT BEARING,
OIL SEAL
CONTENTS
On-Vehicle Service....................................... 4A2-2
Drive Shaft ................................................. 4A2-2Required Service Material ........................... 4A2-4

NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.

PROPELLER SHAFTS 4B-1
4B
SECTION 4B
PROPELLER SHAFTS
CONTENTS
General Description ....................................... 4B-1
On-Vehicle Service......................................... 4B-2
Propeller Shaft ............................................. 4B-2Tightening Torque Specification .................. 4B-2
Required Service Material ............................. 4B-2

General Description
Two universal non-constant velocity joints which are called cardan joints are provided on front propeller shaft
and one universal non-constant velocity joint, two universal constant velocity joints and a rubber mounting cen-
ter support are provided on rear propeller shaft. On the front end of rear propeller shaft, cardan joint same as
that of front propeller shaft is provided. On the rear end of rear propeller shaft, ball fixed type constant velocity
joint (BJ) is provided. On the middle of rear propeller shaft, double offset type constant velocity joint (DOJ) is
provided just behind the center support.
Most universal joints require no maintenance. They are lubricated for life and can not be lubricated on the vehi-
cle. If a universal joint becomes noisy or worn, it must be replaced.
The propeller shaft is a balanced unit. Handle it carefully so that balance can be maintained.NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.
1. Front propeller shaft
2. Rear propeller shaft

4B-2 PROPELLER SHAFTS
On-Vehicle Service
Propeller Shaft
For the descriptions other than those mentioned below, refer to
the same item in the same section of the Service Manual men-
tioned in the FOREWORD of this manual.
INSTALLATION
Use the following specification to torque universal joint flange
nuts. For rear propeller shaft flange bolt, apply thread lock
cement to thread part of bolts if reused.
“A” : Cement 99000-32110
Tightening torque
Front propeller shaft flange nuts (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Rear propeller shaft flange nuts (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
Tightening Torque Specification
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Front propeller shaft flange nuts 50 5.0 36.5
Rear propeller shaft flange nuts 60 6.0 46.5
Center support bolts 50 5.0 36.5
MaterialRecommended SUZUKI product
(Part Number)Use
Thread lock cement THREAD LOCK CEMENT SUPER 1322
(99000-32110)Rear propeller shaft flange bolts

BRAKES 5-1
5
SECTION 5
BRAKES
CONTENTS
Diagnosis .......................................................... 5-2
Diagnosis Table ............................................. 5-2
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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” 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
“LOCK” 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:
For the description (items) not found in this section refer to the same section of the Service Manual
mentioned in the FOREWORD of this manual.
When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E2 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 assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.

5-2 BRAKES
Diagnosis
Diagnosis Table
For the item not found in this column, refer to the same item of the same section in the service manual men-
tioned in the FOREWORD of this manual.
Condition Possible Cause Correction
Brake warning light
turns on after engine
startParking brake applied Release parking brake and check
that brake warning light turns off.
Insufficient amount of brake fluid Add brake fluid.
Brake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Brake warning light circuit faulty Repair circuit.
Malfunctioning EBD system Check system referring to “DIAG-
NOSIS” of Section 5E2.
ABS warning light
does not turn on for 2
– 3 sec. after ignition
switch has turned ON.Bulb burnt out Replace bulb.
ABS warning light circuit open (including check
relay)Check system referring to “DIAG-
NOSIS” in Section 5E2.
ABS warning light
remains on after igni-
tion switch has turned
on for 2 – 3 sec.Malfunctioning ABS Check system referring to “DIAG-
NOSIS” in Section 5E2.

BRAKES PIPE/HOSE/MASTER CYLINDER 5A-1
5A
SECTION 5A
BRAKES PIPE/HOSE/MASTER CYLINDER
CONTENTS
General Description ....................................... 5A-2
Master Cylinder Assembly............................ 5A-2
On-Vehicle Service......................................... 5A-3
Front Brake Hose/Pipe ................................. 5A-3
Master Cylinder Reservoir ............................ 5A-6Master Cylinder Assembly ........................... 5A-7
Brake Booster .............................................. 5A-8
Tightening Torque Specification ................ 5A-10
Special Tool .................................................. 5A-10

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
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” 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
“LOCK” 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:
For the descriptions (items) not found in this section, refer to the same section of the Service Man-
ual mentioned in the FOREWORD of this manual.
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.

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)