2002 SUZUKI GRAND VITARA brake shoe
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YH4
GRAND
VITARA
5-4 BRAKES
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Not enough brak-
ing forceBrake oil leakage from brake lines.
Brake disc or pads stained with oil.
Overheated brakes.
Poor contact of shoes on brake drum.
Brake shoes linings stained with oil or wet
with water.
Badly worn brake shoe linings.
Defective wheel cylinders.
Malfunctioning caliper assembly.
Air in system.
Maladjusted sensor spring length of LSPV.
Broken sensor spring of LSPV.
Defective collar of LSPV.
Malfunctioning ABS (Antilock brake system),
if equipped.Locate leaking point and repair.
Clean or replace.
Determine cause and repair.
Repair for proper contact.
Replace.
Replace.
Repair or replace.
Repair or replace.
Bleed system.
Check or adjust.
Replace.
Replace.
Check system and replace as
necessary.
Brake pull
(Brakes not work-
ing in unison)Pad or shoe linings are wet with water or
stained with oil in some brakes.
Drum-to-shoe clearance out of adjustment in
some brakes.
(Malfunctioning auto adjusting mechanism)
Drum is out of round in some brakes.
Wheel tires are inflated unequally.
Malfunctioning wheel cylinders.
Disturbed front end alignment.
Unmatched tires on same axle.
Restricted brake pipes or hoses.
Malfunctioning caliper assembly.
Loose suspension parts.
Loose calipers.Replace.
Check for inoperative auto adjusting
mechanism.
Replace.
Inflate equally.
Repair or replace.
Adjust as prescribed.
Tires with approximately the same
amount of tread should be used on the
same axle.
Check for soft hoses and damaged
lines.
Replace with new hoses and new
brake pipes.
Check for stuck or sluggish pistons
and proper lubrication of caliper slide
bush.
Caliper should slide.
Check all suspension mountings.
Check and torque bolts to specifica-
tions.
Noise (High pitched
squeak without
brake applied)Front lining worn out.Replace linings.
Rear brake locked
prematurelyMaladjusted sensor spring length of LSPV.
Malfunction LSPV assembly.Check or adjust.
Replace assembly.
Brake locked
(For vehicles
equipped with
ABS)Malfunctioning ABS, if equipped.Check system and replace as
necessary.
Page 281 of 801
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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 noiseGlazed 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.
Page 285 of 801
YH4
GRAND
VITARA
1. Stop light switch
BRAKES 5-9
BRAKE PEDAL FREE HEIGHT CHECK
Remove foot rest and displace carpet and dash silencer(s) so as to
measure brake pedal free height between pedal face and asphalt
sheet installed on dash panel.
Brake pedal free height ªaº from asphalt sheet:
208 ± 218 mm (8.19 ± 8.58 in.)
If the measurement is not within the specification, check the posi-
tion of booster push rod clevis and / or stop light switch according
to the instruction shown in this section.
The free height varies depending on installation position of booster
push rod clevis and stop light switch.
BRAKE LIGHT SWITCH ADJUSTMENT
Adjustment should be made as follows when installing switch. Pull
up brake pedal toward you and while holding it there, adjust switch
position so that clearance between end of thread and brake pedal
return cushion (shown as ªbº in figure).
Then tighten lock nut to specified torque.
Clearance ªbº: 1.5 ± 2.0 mm (0.06 ± 0.08 in.)
Tightening Torque
(b): 7.5 N
.m (0.75 kg-m, 5.5 lb-ft)
EXCESSIVE PEDAL TRAVEL CHECK
1) Remove foot rest and displace carpet and dash silencer(s).
2) Start engine.
3) Depress brake pedal a few times.
4) With brake pedal depressed with approximately 30 kg (66 lbs)
load, measure pedal to asphalt sheet clearance ªcº.
Clearance ªcº: over 115 mm (4.53 in.)
5) If clearance ªcº is less than specification, the most possible
cause is either rear brake shoes are worn out beyond limit or air
is in lines.
Should clearance ªcº remain less than specification even after
replacement of brake shoes and bleeding of system, other pos-
sible but infrequent cause is malfunction of rear brake shoe ad-
justers or booster push rod length out of adjustment.
Page 287 of 801
YH4
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VITARA
1. Pad rim
2. Lining
3. Disc
1. Rubber plug
2. Brake shoe
3. Brake shoe rim
BRAKES 5-11
BRAKE DISC CHECK
Refer to FRONT DISC BRAKE PAD of Section 5B for inspection
point and procedure.
BRAKE PAD CHECK
Inspect pad linings periodically according to maintenance schedule
whenever wheels are removed (for tire rotation or other reason).
Take a look through hole of caliper and check lining thickness of in-
side pad.
Thickness ªeº
Standard: 10.0 mm (0.39 in.)
Service Limit: 2.0 mm (0.08 in.)
If one of brake pad is worn to service limit, all linings must be re-
placed at the same time.
BRAKE SHOE CHECK
Inspection should be carried out on following points after brake ped-
al travel ªcº (pedal to asphalt sheet clearance) check as described
on previous page of this section, even when it is more than 115 mm
(4.53 in.).
Amount of brake shoe wear can be checked as follows.
1) Hoist vehicle.
2) Remove rubber plug from brake back plate.
3) Through hole of back plate, visually check for thickness of brake
shoe lining. If lining thickness ªfº is found less than below speci-
fied wear limit, replace with new brake shoes.
Thickness ªfº
Service Limit: 1.0 mm (0.04 in.)
Page 288 of 801
YH4
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VITARA
1. Parking brake lever
2. Brake cable
3. Self locking nut
5-12 BRAKES
PARKING BRAKE CHECK AND
ADJUSTMENT
CHECK
Hold center of parking brake lever grip and pull it up with 20 kg
(40 lbs) force.
With parking brake lever pulled up as shown, count ratchet
notches.
There should be 5 to 7 notches.
Also, check if both right and left rear wheels are locked firmly.
To count number of notches easily, listen to click sounds that ratchet
makes while pulling parking brake lever without pressing its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable by referring
to adjustment procedure described on the following as to obtain
specified parking brake stroke.
NOTE:
Check tooth tip of each notch for damage or wear. If any dam-
age or wear is found, replace parking brake lever.
ADJUSTMENT
NOTE:
Make sure for following conditions before cable adjustment.
No air is trapped in brake system.
Brake pedal travel is proper.
Brake pedal has been depressed a few times with about
30 kg (66 lbs) load.
Parking brake lever has been pulled up a few times with
about 20 kg (44 lbs) force.
Rear brake shoes are not worn beyond limit, and self adjust-
ing mechanism operates properly.
To slacken parking brake cable, loosen self locking nut as far
as end of bolt. Then depress brake pedal a few times with
about 30 kg (66 lbs) load.
After confirming that above 6 conditions are all satisfied, adjust
parking brake lever stroke by loosening or tightening locking nut.
NOTE:
Check brake drum for dragging after adjustment.
Parking brake stroke: 5 to 7 notches
(When lever is pulled up at 20 kg (44 lbs).)
Page 325 of 801
YH4
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 326 of 801
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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.
Page 329 of 801
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A-1. Color ring
A-2. Cable
A-3. Grommet
A-4. Bolt
A-5. Clamp (if equipped)A-6. Cross-member
A-7. Chassis frame
A-8. Hanger
A-9. Rear axle
A-10. G-sensor (if equipped) B-1. Parking brake switch
B-2. Parking brake lever
B-3. Parking brake lever bolt
B-4. Floor
B-5. Locking nut
B-6. Spacer
B-7. Pin
B-8. Equalizer
B-9. Adjust rod
B-10. Coupler
PARKING AND REAR BRAKE 5C-5
PARKING BRAKE CABLE
REMOVAL
1) Remove brake drum. (Refer to steps 1) to 5) of BRAKE DRUM
REMOVAL of this section.)
2) Check the color of ring or tape for reinstallation.
NOTE:
Color ring on brake cable is for the purpose of identifica-
tion.
3) Disconnect parking brake cable from brake shoe lever. (Refer to
steps 2) to 5) of BRAKE SHOE REMOVAL of this section.)
4) Disconnect brake cable from brake back plate. (Refer to step 4)
of BRAKE BACK PLATE REMOVAL.)
NOTE:
When it is necessary to remove both right and left parking
brake cables, repeat above steps 1) to 3) on right and left
wheels.
5) Remove cable from parking brake lever. (Refer to steps 1) to 5)
of PARKING BRAKE LEVER REMOVAL of this section.)