2002 SUZUKI GRAND VITARA brake shoe

YH4
GRAND
VITARA
1. Brake back plate
2. Cable cap
3. Brake cable
1. Parking brake shoe lever
2. Spring
3. Nipple end
5C-6 PARKING AND REAR BRAKE
INSTALLATION
Install parts in reverse order of removal procedure, noting the fol-
lowing.
1) Install brake cable cap to brake back plate securely as shown in
figure.
NOTE:
Color ring or tape on brake cable is for the purpose of identi-
fication. Use cable with the same colored ring as before re-
moval.
2) Install brake cable spring and nipple end to parking brake shoe
lever securely as shown in figure.
3) For brake shoe installation, refer to steps 1) and 4) of BRAKE
SHOE INSTALLATION of this section.
4) For brake drum installation, refer to steps 1) and 3) of BRAKE
DRUM INSTALLATION of this section.
5) For proper routing and secure clamping of parking brake cable.
6) For installation of cable to parking brake lever, refer to PARKING
BRAKE LEVER INSTALLATION of this section.
7) Upon completion of installation, adjust cable. (Refer to PARK-
ING BRAKE CHECK AND ADJUSTMENT in Section 5.) Then
check brake drum for dragging and brake system for proper per-
formance. After removing vehicle from hoist, brake test should
be performed.

YH4
GRAND
VITARA
1. Pawl lever
2. Adjuster
3. Brake shoes
5C-8 PARKING AND REAR BRAKE
Cracked, Scored, or Grooved Drum
A cracked, drum is unsafe for further service and must be replaced.
Do not attempt to weld a cracked drum.
Smooth up any slight scores. Heavy or extensive scoring will cause
excessive brake lining wear and it will probably be necessary to re-
surface drum braking surface.
If brake linings are slightly worn and drum is grooved, drum should
be polished with fine emery cloth but should no be turned.
NOTE:
When drum is removed, visually inspect wheel cylinder for
brake fluid leakage. Correct leaky point, if any.
Brake Shoe
Where lining is worn out beyond service limit, replace shoe.
Thickness ªaº
Standard: 6.5 mm (0.24 in.)
Service limit: 3.0 mm (0.12 in.)
If one of brake linings is to service limit, all linings must be replaced
at the same time.
CAUTION:
Never polish lining with sandpaper. If lining is polished with
sandpaper, hard particles of sandpaper will be deposited in
lining and may damage drum. When it is required to correct
lining, replace it with a new one.
INSTALLATION
NOTE:
See NOTE at the beginning of the section.
1) Before installing brake drum, check outer diameter of brake
shoes. If it is not within value as specified below, adjust it to spec-
ification by turning adjuster.
Outer diameter of brake shoes
ªaº: 219.4 ± 219.7 mm (8.638 ± 8.650 in.)

YH4
GRAND
VITARA
6. Shoe hold down
springs
7. Strut spring
8. Lower shoe return
spring 1. Upper shoe return spring
2. Adjuster
3. Pawl lever
4. Adjuster spring
5. Shoe hold down pins
1. Brake back plate
2. Cable cap
3. Brake cable
PARKING AND REAR BRAKE 5C-9
2) Install brake drum after making sure that inside of brake drum
and brake shoes are free from dirt and oil.
3) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load three to ten times so as to obtain proper drum-to-
shoe clearance.
Adjust parking brake cable. (For adjustment, refer to PARKING
BRAKE CHECK AND ADJUSTMENT in Section 5.)
4) Tighten rear center console box screws.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
6) Check to ensure that brake drum is free from dragging and prop-
er braking is obtained. Then remove vehicle from hoist and per-
form brake test (foot brake and parking brake).
BRAKE SHOE
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
WARNING:
Use special care when installing brake shoe return
spring. Failure in its proper installation may allow it to
springback and cause personal injury.
2) Remove shoe hold down springs by turning shoe hold down
pins.
3) Remove upper return spring, struts, adjuster, adjuster lever and
springs.
4) Remove brake shoes and lower shoe return spring.
5) Remove brake shoes and disconnect parking brake cable from
parking brake shoe lever.

YH4
GRAND
VITARA
5C-10 PARKING AND REAR BRAKE
1. Retainer
2. Parking brake shoe lever
3. Brake shoe
6) Remove parking brake shoe lever from brake shoe.
INSPECTION
Parking Shoe Lever
Inspect brake shoe lever for free movement against brake shoe
web. If defective, correct or replace.
Strut, Adjuster
Check thread or ratchet of strut and adjuster for wear, sticking and
corrosion.
Springs
Inspect for damage or weakening.
Inspect each part with arrow for rust. If found defective, replace.
Brake Shoe
Refer to BRAKE DRUM INSPECTION.

YH4
GRAND
VITARA
6. Shoe hold down
springs
7. Strut spring
8. Lower shoe return
spring 1. Upper shoe return spring
2. Adjuster
3. Pawl lever
4. Adjuster spring
5. Shoe hold down pins1. Lower return spring
2. Lower strut
PARKING AND REAR BRAKE 5C-11
INSTALLATION
1) Assemble parts as shown in reverse order of removal.
2) Install shoe hold down springs by pushing them down in place
and turning hold down pins.
3) Install adjuster and upper shoe return spring.
4) Install adjuster lever, adjuster spring and strut spring.
5) For procedure hereafter, refer to steps 1) to 6) of BRAKE DRUM
INSTALLATION.

YH4
GRAND
VITARA
1. Wheel cylinder
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts1. Bleeder plug cap
5C-12 PARKING AND REAR BRAKE
WHEEL CYLINDER
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Loosen brake pipe flare nut (or nuts) but only within the extent
that fluid does not leak.
4) Remove wheel cylinder mounting bolts. Disconnect brake pipe
(or pipes) from wheel cylinder and put wheel cylinder bleeder
plug cap onto pipe to prevent fluid from spilling.
INSPECTION
Inspect wheel cylinder disassembled parts for wear, cracks, corro-
sion or damage.
NOTE:
Clean wheel cylinder components with brake fluid.
INSTALLATION (For non sealed type)
1) Take off bleeder plug cap from brake pipe and connect pipe (or
pipes) to wheel cylinder just enough to prevent fluid from leak-
ing.
2) Tighten wheel cylinder to brake back plate to specified torque.
Tightening Torque
(a): 8.5 N
.m (0.85 kg-m, 6.5 lb-ft)
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)

YH4
GRAND
VITARA
2
1. Wheel cylinder
2. Gasket
1. Brake back plate
2. Brake pipe flare nut
3. Brake pipe
4. Wheel cylinder bolts
PARKING AND REAR BRAKE 5C-13
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to steps 1) to 5) of BRAKE SHOE
INSTALLATION.
NOTE:
Be sure to bleed brake system. (for bleeding operation, re-
fer to BLEEDING BRAKES in Section 5.)
INSTALLATION (For gasket sealed type)
1) Install gasket to joint seam of wheel cylinder and brake back
plate. Then take off bleeder plug cap from brake pipe and con-
nect pipe (or pipes) to wheel cylinder just enough to prevent fluid
from leaking.
NOTE:
Be sure to check gasket for deterioration or any damage be-
fore installation and replace if found defective.
2) Tighten wheel cylinder to brake back plate to specified torque.
3) Torque flare nut (or nuts) of brake pipe which was connected in
step 1) to specification.
Tightening Torque
(a): 11 N
.m (1.1 kg-m, 8.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
4) Install bleeder plug cap taken off from pipe back to bleeder plug.
5) For procedure hereafter, refer to BRAKE SHOE INSTALLA-
TION.
NOTE:
Be sure to bleed brake system. Refer to ªCHECK AND AD-
JUSTMENTº in BRAKES section.

YH4
GRAND
VITARA
5C-14 PARKING AND REAR BRAKE
1
2
3
1. Brake back plate
2. Cable cap
3. Brake cable
1. Wheel bearing retainer nut
1. Rear axle shaft
2. Wheel bearing
3. Brake back plate(A)
BRAKE BACK PLATE
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
2) Perform steps 2) to 4) of BRAKE SHOE REMOVAL.
3) Perform steps 3) and 4) of WHEEL CYLINDER REMOVAL.
4) Remove cable from brake back plate by squeezing parking
brake cable cap.
5) Drain rear differential gear oil.
6) Remove wheel bearing retainer nuts from rear axle housing.
7) Using special tools, draw out rear axle shaft with brake back
plate.
Special Tool
(A): 09943-35512
(B): 09942-15510
8) Remove brake back plate from rear axle shaft.