2001 SUZUKI GRAND VITARA piston

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-11
1. Pin
2. Master cylinder
3. Reservoir
4. Circlip
1. Stopper bolt
2. Compressed air
DISASSEMBLY
1) Remove reservoir pin and reservoir.
2) Remove circlip.
3) For vehicle with ABS
Pull out primary piston assembly straight so as not to cause any
damage to inside of cylinder wall.
Pull out secondary piston assembly straight so as not to cause
any damage to inside of cylinder wall and by tapping flange with
a piece of wood or something soft.
3') For vehicle without ABS
Remove piston stopper bolt. Then remove secondary piston by
blowing compressed air into hole from which piston stopper bolt
was removed.
Be cautious during removal as secondary piston jumps out.

YH4
GRAND
VITARA
5A-12 BRAKES PIPE / HOSE / MASTER CYLINDER
Vehicle not equipped with ABSVehicle equipped with ABS
1. Rod
2. Circlip
INSPECTION
Inspect all disassembled parts for wear or damage, and replace
parts if necessary.
NOTE:

Wash disassembled parts with brake fluid.

Do not reuse piston cups.
Inspect master cylinder bore for scoring or corrosion. It is best to re-
place corroded cylinder.
Corrosion can be identified as pits or excessive roughness.
NOTE:
Polishing bore or master cylinder with cast aluminum body
with anything abrasive is prohibited, as damage to cylinder
bore may occur.
Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from
cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot
be kept from cylinder bore surfaces.
ASSEMBLY
NOTE:

See NOTE at the beginning of this section.

Before assembling, wash each part in fluid recommended to
use for that vehicle.
1) Install secondary piston assembly into cylinder.
2) Install primary piston assembly in cylinder.
3) Depress, and install circlip.
4) Install piston stopper bolt with pistons pushed in all the way and
tighten it to specified torque (For vehicle without ABS).
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)

YH4
GRAND
VITARA
1. Pin
2. Reservoir
3. Master cylinder
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-13
5) Apply thin coat of brake fluid to all around new grommets (2pcs.)
and install them to cylinder body, then install reservoir.
6) Set a new pin in reservoir hole and drive it in. At this time, make
end of pin and end face margin of reservoir equal.
INSTALLATION
NOTE:

See NOTE at the beginning of this section.

Adjust clearance between booster piston rod and primary
piston with special tool, referring to CLEARANCE BETWEEN
BOOSTER PISTON AND MASTER CYLINDER PISTON AD-
JUSTMENT in this section.
1) Install master cylinder to brake booster.
2) Tighten master cylinder attaching nuts to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
3) Connect brake pipes to master cylinder.

For vehicle with ABS
a) Connect brake pipes between master cylinder and ABS hy-
draulic unit.
b) For LH steering vehicle, connect ABS control module con-
nector.
c) For RH steering vehicle, install ABS hydraulic unit bracket
bolts and tighten it to specified torque.
Tightening Torque
(b): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
4) Tighten flare nuts to specification.
Tightening Torque
(c): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
5) Connect reservoir lead wire.
6) Fill reservoir with specified brake fluid.
7) Check brake pedal play and bleed air from system.
8) Perform brake test and check each installed part for fluid leak-
age.

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-15
1. Booster piston rod
2. Master cylinder piston
1. Master cylinder
2. Piston
3. Pin head
1. Booster body
2. Piston rod
1. Booster piston rod
2. Master cylinder piston
CLEARANCE BETWEEN BOOSTER PISTON ROD AND
MASTER CYLINDER PISTON ADJUSTMENT
The length of booster piston rod is adjusted to provide specified
clearance ªaº between piston rod end and master cylinder piston.

Before measuring clearance, push piston rod several times so as
to make sure reaction disc is in place.

Keep inside of booster at atmospheric pressure for measure-
ment.
1) Set special tool (A) on master cylinder and push pin until con-
tacts piston.
Special Tool
(A): 09950-96010
2) Turn special tool upside down and place it on booster. Adjust
booster piston rod length until rod end contacts pin head.
Special Tool
(A): 09950-96010
Clearance ªbº: 0 mm (0 in.)
NOTE:
Take measurement with booster set vertically and rod at the
center.
3) Adjust clearance by turning adjusting screw of piston rod.
Special Tool
(F): 09952-16010
Reference
When adjusted as above, its negative pressure is applied to boost-
er with engine at idle, piston to piston rod clearance ªaº should be-
come below.
Clearance ªaº: 0.25 ± 0.5 mm (0.010 ± 0.020 in.)

YH4
GRAND
VITARA
5A-16 BRAKES PIPE / HOSE / MASTER CYLINDER
1. Clevis
2. Nut
1. Steering column 4. Clevis pin
2. Push rod clevis 5. Clip
3. Brake pedal arm 6. NutBOOSTER PUSH ROD CLEVIS ADJUSTMENT
Install push rod clevis so that measurement ªaº is obtained and
torque nut to specification.
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
Length
ªaº: 109.5 ± 110.5 mm (4.31 ± 4.35 in.)
INSTALLATION
NOTE:

See NOTE at the beginning of this section.

Check length of push rod clevis. (Refer to BOOSTER PUSH
ROD CLEVIS ADJUSTMENT.)

Before installing master cylinder, adjust booster piston rod.
(Refer to CLEARANCE BETWEEN BOOSTER PISTON ROD
AND MASTER CYLINDER PISTON ADJUSTMENT of this sec-
tion.)

Apply silicone grease to master cylinder piston.
1) Install booster to dash panel as shown. Then connect booster
push rod clevis to pedal arm with clevis pin and clip.
2) Tighten booster attaching nuts to the specified torque.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
3) Connect brake vacuum hose to brake booster.
4) For vehicle equipped with ABS, connect brake pipes to ABS hy-
draulic unit. If ABS hydraulic unit bracket bolts removed, tighten
flare nuts to specification after installing master cylinder.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
5) Install master cylinder, referring to MASTER CYLINDER AS-
SEMBLY INSTALLATION in this section.

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-19
09922-85811
Connector pin remover09950-96010
Booster piston rod gauge09952-16010
Booster piston rod adjuster
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake flexible hose bolt (Brake caliper / 2 (4) way joint)232.317.0
Master cylinder attaching nut131.39.5
Booster nut131.39.5
Clevis nut252.518
2-way (or 4-way) joint mounting bolt101.07.5
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
LSPV8.00.86.0
LSPV mounting bolt
LSPV stay bolt232.317.0
LSPV spring nut
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.
SPECIAL TOOLS

YH4
GRAND
VITARA
[A]: TOKICO produced
[B]: SUMITOMO ELECTRIC produced1. Caliper pin bolt
2. Boot
3. Disc brake caliper
(Disc brake cylinder)
4. Piston seal
5. Disc brake piston
6. Cylinder boot
7. Disc brake inner pad
8. Disc brake outer pad
9. Brake caliper carrier
10. Pad spring
11. Bleeder plug
12. Bleeder plug cap
13. Caliper pin
14. Anti noise shim
15. Inner shim
Tightening torque
(a): 8.5 N.m (0.85 kg-m, 6.5 lb-ft)
(b): 8.0 N.m (0.80 kg-m, 6.0 lb-ft) [A]
[B]
5B-2 FRONT BRAKE
GENERAL DESCRIPTION
DISC BRAKE CALIPER ASSEMBLY
This caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying
force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston
and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in
a clamping action on the disc. This clamping action forces the pads (linings against the disc, creating friction to
stop the vehicle.
NOTE:

Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo-
nents may result. If any component is removed or line disconnected, bleed the brake system.
Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners.

For identification of the brake caliper type, see maker name or mark on brake caliper as shown.

YH4
GRAND
VITARA
1. Caliper
2. Flexible hose
3. Hose mounting bolt
4. Wire hook
5. Container
1. Cloth
5B-6 FRONT BRAKE
FRONT DISC BRAKE CALIPER
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove brake flexible hose mounting bolt from caliper. As this
will allow fluid to flow out of hose, have a container ready before-
hand.
3) Remove caliper pin bolts.
4) Remove caliper.
DISASSEMBLY
Before disassembly, clean all around caliper with brake fluid.
1) Remove anti noise shim (if equipped) and blow compressed air
into cylinder through bolt hole where flexible hose was fitted.
With this air pressure, piston can be pushed out of cylinder.
WARNING:
Do not apply too highly compressed air which will cause
piston to jump out of cylinder. It should be taken out grad-
ually with moderately compressed air. Do not place your
fingers in front of piston when using compressed air.