2002 SUZUKI GRAND VITARA ten

YH4
GRAND
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).)

YH4
GRAND
VITARA
3. LSPV stay
1. Master cylinder
2. Disconnect brake pipe1. LSPV lever
2. LSPV spring
3, ªAº 2
1
2(a)
ªaº
ªbº
5-14 BRAKES
3) Depress brake pedal gradually till fluid pressure of front brake
becomes as specified below and check corresponding pressure
of rear brake then. It should be within specification given below.
Front brake
Rear brake
8,000 kPa
80 kg / cm2
3 Door
6,000 ± 7,300 kPa
60 ± 73 kg / cm2
853 ± 1,038 psi80 kg / cm2
1,138 psi5 Door
4,500 ± 7,300 kPa
45 ± 73 kg / cm2
640 ± 1,038 psi
As done above, apply 100 kg / cm2 pressure to front brake and
check that rear brake pressure then is within specification as giv-
en below.
Front brake
Rear brake
10,000 kPa
100 kg / cm2
3 Door
6,500 ± 8,000 kPa
65 ± 80 kg / cm2
924 ± 1,138 psi100 kg / cm2
1,422 psi5 Door
5,000 ± 8,000 kPa
50 ± 80 kg / cm2
711 ± 1,138 psi
4) If rear brake pressure is not within specification, adjust it by
changing stay ªAº position as follows.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)

If rear brake pressure is higher than specification, move stay
ªAº to direction ªaº and if it is lower, to direction ªbº.

Repeat steps 3) and 4) until rear brake pressure is within spec-
ification.

After adjustment, be sure to torque bolt to specification.
5) Disconnect brake pipe (connecting between master cylinder
secondary side and 4-way joint) from master cylinder.
Tighten plug (special tool) to master cylinder.
Depress brake pedal. If rear brake pressure is 95 ± 100 kg / cm
2
when front brake pressure is 100 kg / cm2, it means that front fail-
safe system functions properly.
Front brake
Rear brake
10000 kPa
100 kg / cm2
1422 psi
9500 ± 10000 kPa
95 ± 100 kg / cm2
1350 ± 1422 psi
Special Tool
(A): 09956-02210

YH4
GRAND
VITARA
BRAKES 5-17
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake pipe 2-way (or 4-way) joint bolt232.317.0
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
LSPV7.50.755.5
LSPV mounting bolt
LSPV stay bolt232.317.0
LSPV spring nut
Wheel nut10010.072.5
Stop light switch lock nut7.50.755.5
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.

YH4
GRAND
VITARA
5A
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-1
SECTION 5A
BRAKES PIPE/HOSE/MASTER CYLINDER
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 DESCRIPTION5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster Assembly5A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSPV (Load Sensing Proportioning Valve) Assembly 5A- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Hose / Pipe5A- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Brake Hose / Pipe5A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Reservoir5A- 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly5A-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Booster5A-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LSPV (Load Sensing Proportioning Valve) Assembly 5A-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5A-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
[A]: With ABS
[B]: Without ABS
1. Piston stopper circlip
2. Piston stopper
3. Cylinder cup
4. Plate
5. Primary piston
6. Piston cup
7. Primary piston return spring
8. Primary spring retainer
9. Secondary piston pressure cup
10. Secondary piston
11. Return spring secondary seat
12. Secondary piston return spring
13. Secondary piston stopper bolt
14. Master cylinder body
ªAº: Primary piston
ªBº: Secondary piston
[B] [A]
5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER
GENERAL DESCRIPTION
MASTER CYLINDER ASSEMBLY
The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (ªaº
in the figure below) and secondary (ªbº) chambers. The hydraulic pressure produced in the primary chamber (ªaº)
acts on the front (for vehicle without ABS, rear) wheel brakes.
Also, the hydraulic pressure produced in the secondary chamber (ªbº) acts on the rear (for vehicle without ABS,
front) wheel brakes.
NOTE:
Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with
clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rub-
ber components may result. If any hydraulic component is removed or brake line disconnected, bleed the
brake system.
The torque values specified are for dry, unlubricated fasteners.
BOOSTER ASSEMBLY
The booster is located between the master cylinder and the brake pedal. It is so designed that the force created
when the brake pedal is depressed is mechanically increased combined with the engine vacuum.
The booster has two diaphragms of
ù7.5 in. (191 mm) effective diameter.
CAUTION:

Never disassemble brake booster assembly. If it is found faulty, replace it with new assembly.

The torque values specified are for dry, unlubricated fasteners. If any hydraulic component is re-
moved or brake line disconnected, bleed the brake system.

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-5
[A]: Vehicle with ABS for right hand steering vehicle
[B]: Vehicle with ABS for left hand steering vehicle
1. E-ring
2. Flexible hose
3. Hose washer
4. Hose bolt
5. Brake caliper
6. 2 way joint
NOTE:
Insert E-ring till its end surface is flush
with or lower than bracket end surface.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 11.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
(c): 10 N.m (1.0 kg-m, 7.5 lb-ft)
(b): 21 N.m (2.1 kg-m, 15.5 lb-ft)
A: View A
B: View B
C: View Ca: Clamp a
b: Clamp b
c: Clamp c
d: Clamp d
C
t: Top side
f: Front side
[A]
[B]

YH4
GRAND
VITARA
5A-6 BRAKES PIPE / HOSE / MASTER CYLINDER
NOTE:
Insert E-ring till its end surface is flush
with or lower than bracket end surface.
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)
[C]: Vehicle without ABS for right hand steering vehicle
[D]: Vehicle without ABS for left hand steering vehicle
1. E-ring
2. Flexible hose
3. Hose washer
4. Hose bolt
5. Brake caliper
6. 4way joint
[C]
[D]
D: View D a: Clamp a
b: Clamp b
c: Clamp c
d: Clamp dt: Top side
f: Front side

YH4
GRAND
VITARA
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-7
1. Rear axle
2. Shock absorber
3. Clamp
1. Brake pipe (to rear)
2. Brake pipe
(to LSPV, for vehicle without ABS)
3. 4-way (2-way) joint
4. Chassis frame
REAR BRAKE HOSE / PIPE
REMOVAL
1) Raise and suitably support vehicle. Remove tire and wheel.
2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose or pipe.
INSTALLATION
1) Reverse removal procedure for brake hose or pipe installation procedure.

Be sure to obtain more than 3 mm (0.118 in.) clearance between axle housing and brake pipe.

Install clamps properly referring to figure below and tighten bolts.

When installing hose, make sure that it has no twist or kink.
2) Fill and maintain brake fluid level in reservoir. Bleed brake system.
3) Perform brake test and check each installed part for fluid leakage.