2003 SUZUKI GRAND VITARA hand brake

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
5A-18 BRAKES PIPE / HOSE / MASTER CYLINDER
1. LSPV spring bolt
2. LSPV bolt
3. Brake pipe flare nut
4. Air bleeding plug
1. LSPV lever
2. Stopper bolt (if equipped)
3. Coil spring ªAº: Don't turn(a)
2) Torque each bolt and nut to specification as indicated respec-
tively in figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft) (brake flare nut)
(c): 7.5 N
.m (0.75 kg-m, 9.0 lb-ft) (bleeder plug)
3) Upon completion of installation, fill reservoir tank with specified
fluid and bleed air from brake system.
NOTE:
Make sure to bleed air from LSPV bleeder without failure.
4) After bleeding air, check that LSPV is installed properly, referring
to following INSPECTION & ADJUSTMENT.
INSPECTION & ADJUSTMENT
Confirm the following before inspection and adjustment.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.

Vehicle is free from any other load.
With vehicle in above conditions;
1) Place it on level floor.
2) Push up (for 5 door model) or push down (for 3 door model)
LSPV lever with finger till it stops and measure length ªLº of coil
spring as it is pulled.
3) Spring length ªLº should be the value specified below.
Spring length (between spring end and spring bolt)
ªLº: 103 mm (4.06 in.) (5 door model). . . . .
ªLº: 157 mm (6.18 in.) (3 door model). . . . .
4) If it isn't, adjust it to specification by changing stay positions as
shown in figure. After adjustment, tighten bolt to specified
torque.
For details, refer to left figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
NOTE:
Check to make sure that LSPV body and brake pipe joints
are free from fluid leakage. Replace defective parts, if any.

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
1. Boot
2. Piston
5B-8 FRONT BRAKE
Piston and Boot
1) Before inserting piston into cylinder, install boot onto piston as
shown.
2) Fit boot as it is in above figure into boot groove in cylinder with
fingers.
Check to make sure that boot is fitted into boot groove in cylinder
completely in its circumference.
3) Insert piston into cylinder by hand and fit boot in boot groove in
piston.
4) To confirm that boot is fitted in its groove in cylinder properly, pull
piston out of cylinder a little but do not take it all out.
5) Insert piston into cylinder by hand.
6) Install anti noise shim, if equipped.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-31
1. Diagnosis
connector
(6 pins connector)
2. Diag. switch
terminal
3. Ground
4. Service wire
Brake
pedal
Ignition
sw.
Motor
Solenoid
Rear3.0 sec.
3.0
ON-VEHICLE SERVICE
PRECAUTION
When connector are connected to ABS hydraulic unit / control mod-
ule assembly, do not disconnect connectors of sensors and turn
ignition switch ON. Then DTC will be set in ABS control module.
ABS HYDRAULIC UNIT OPERATION CHECK
1) Check that basic brake system other than ABS is in good condi-
tion.
2) Check that battery voltage is 11V or higher.
3) With ªABSº warning lamp, check that no abnormality is de-
tected in ABS. Refer to ªDIAGNOSTIC TROUBLE CODE
(DTC) CHECKº in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake dragging
occurs. If it does, correct.
7) With diag. switch terminal of diagnosis connector connected to
ground by using service wire, turn ignition switch ON and check
if ªABSº warning lamp indicates DTC 12.
8) Turn ignition switch OFF.
9) Perform following checks with help of another person.
Brake pedal should be depressed and then ignition switch
turned ON by one person and wheel should be turned by
another person's hand. At this time, check that:

Operation sound of solenoid is heard and wheel turns only
about 0.5 sec. (Brake force is depressurized).

Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF
ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace hydrau-
lic unit / control module assembly.
11) Turn ignition switch OFF and remove service wire from diagno-
sis connector.

YH4
GRAND
VITARA
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-33
1. ABS hydraulic unit /
control module
assembly
2. Nut
1. To left-front
2. To right-front
3. To rear
4. From master cylinder4) Remove three nuts and take out ABS hydraulic unit / control
module assembly from bracket.
CAUTION:

Do not give an impact to hydraulic unit.

Use care not to allow dust to enter hydraulic unit.

Do not place hydraulic unit on its side or upside down.
Handling it in inappropriate way will affect its original
performance.
INSTALLATION
1) Install hydraulic unit by reversing removal procedure.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
(b): 21 N
.m (2.1 kg-m, 15.5 lb-ft)
(c): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
2) Bleed air from brake system. Refer to ªBLEEDING BRAKESº in
Section 5.
3) Check each installed part for fluid leakage and perform hydraulic
unit operation check.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-23
User name: Model: VIN:
Date of issue: Date of Reg: Date of problem: Mileage:
PROBLEM SYMPTOMS
Engine does not start
Vehicle does not move
(forward, rearward)
No lock-up (TCC clutch operation)
Shift point too high or too low
Excessive gear change shockEngine stops
Transmission does not shift
(1st, 2nd, 3rd, 4th, Rev) gear
Automatic shift does not occur
Transmission slipping in
(1st, 2nd, 3rd, 4th, Rev) gear
Other:
VEHICLE/ ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS
Environmental Condition
Weather
Temperature
Frequency
RoadFair/Cloudy/Rain/Snow/Always/Other ( )
Hot/Warm/Cool/Cold/(
C
F)/Always
Always/Sometimes/( times/ day, month)/Only Once
Urban/Suburb/Highway/Mountainous (uphill/downhill)/Paved road/Gravel/
Other( )
Vehicle Condition
Engine
Brake
O/D cut switch
P/N change switch
(P,R,N,D,2,L) range/(
) range
Cold/Warming up phase/Warmed up
At stop/During driving (constant speed/accelerating/decelerating/
right hand corner/left hand corner)/Other ( )/Speed ( km/h mile/h)
Speed( r/min)/Throttle opening(idle/about %/full)
Apply/Not apply
ON/OFF
Power/Normal
Malfunction indicator lamp condition
Always ON Sometimes ON Always OFF Good condition
Diagnostic trouble
codeFirst check : No codeMalfunction code( )
Second check : No code Malfunction code( )
Transmission range
Transmission temp.
Vehicle
CUSTOMER PROBLEM INSPECTION FORM (EXAMPLE)
NOTE:
The above form is a standard sample. It should be modified according to conditions characteristic of each
market.