2002 SUZUKI GRAND VITARA Assembly

YH4
GRAND
VITARA
1. LSPV
2. Brake pipe
1. LSPV assembly
2. LSPV spring
3. LSPV stay
4. Bolt
5. Stepper bole
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-17
LSPV (Load Sensing Proportioning Valve)
ASSEMBLY (if equipped)
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Hoist vehicle.
3) Disconnect brake pipes from LSPV.
4) Remove LSPV assembly with spring from vehicle body.
5) Remove spring from lever.
CAUTION:

LSPV assembly must not be disassembled.
Replace with new one if defective.

Stopper bolt should not be loosened or tightened. (if
equipped)
INSTALLATION
CAUTION:
Refer to above CAUTION.
Install by reversing removal procedure, noting the following.
1) Apply multi-purpose grease ªAº to upper and lower joint of coil
spring.

YH4
GRAND
VITARA
5B
FRONT BRAKE 5B-1
SECTION 5B
FRONT BRAKE
NOTE:
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.
CONTENTS
GENERAL DESCRIPTION5B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Pad5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper5B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Disc5B-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

YH4
GRAND
VITARA
FRONT BRAKE 5B-7
2) Remove piston seal using a thin blade like a thickness gauge,
etc.
CAUTION:
Be careful not to damage inside (bore side) of cylinder.
INSPECTION
Cylinder Boot
Check boots for breakage, crack and damage. If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate unsmooth re-
turn of the piston. In such a case, replace rubber seal.
ASSEMBLY
Reassemble front brake in reverse order of disassembly, noting the
following points.
CAUTION:

Wash each part cleanly before installation in the same
fluid as the one used in master cylinder reservoir.

Never use other fluid or thinner.

Before installing piston and piston seal to cylinder, apply
fluid to them.

After reassembling brake lines, bleed air from them.
Piston Seal
Piston seal is used to seal piston and cylinder and to adjust clear-
ance between pad and disc. Replace with a new one at every over-
haul. Fit piston seal into groove in cylinder taking care not to twist
it.

YH4
GRAND
VITARA
1. 8 mm bolt
5B-10 FRONT BRAKE
FRONT BRAKE DISC
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by loosening carrier bolts (2 pcs.).
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.
3) Remove disc by using 8 mm bolts (2 pcs.).
INSPECTION
Refer to FRONT DISC BRAKE PAD INSPECTION.
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
1) Install disc to wheel hub.
2) Install caliper assembly to steering knuckle.
3) Torque caliper carrier bolts to specification.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
4) Torque front wheel nuts to specifications.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
5) Upon completion of installation, perform brake test.

YH4
GRAND
VITARA
5C
PARKING AND REAR BRAKE 5C-1
SECTION 5C
PARKING AND REAR BRAKE
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:
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.
CONTENTS
GENERAL DESCRIPTION5C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brake Assembly5C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Cable5C- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Drum5C- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shoe5C- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder5C-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Back Plate5C-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
1. Brake back plate
2. Brake shoe
3. Shoe return upper spring
4. Adjuster
5. Shoe return lower spring
6. Adjuster lever
7. Adjuster spring
8. Shoe hold down spring
9. Shoe hold down pin
10. Wheel cylinder
11. Link
12. Brake strut
(a)
Tightening torque
(a): 7.5 N.m (0.75 kg-m, 5.5 lb-ft)
5C-2 PARKING AND REAR BRAKE
GENERAL DESCRIPTION
DRUM BRAKE ASSEMBLY
The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main-
tained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is
depressed and when parking brake is applied on level road.
It also uses duo servo operation when parking brake is applied on gradient road and load is applied in longitudinal
direction of vehicle.
NOTE:
Replace all components included in repair kits to service this drum brake. Lubricate parts as specified.
WARNING:
If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque
values specified are for dry, unlubricated fasteners.