2003 SUZUKI GRAND VITARA Adjust

YH4
GRAND
VITARA
1. Paint
3F-4 WHEELS AND TIRES
Higher than Recommended Pressure Can Cause:
1. Hard ride
2. Tire bruising or carcass damage
3. Rapid tread wear at center of tire
Unequal Pressure on Same Axle Can Cause:
1. Uneven braking
2. Steering lead
3. Reduced handling
4. Swerve on acceleration
Valve caps should be kept on valves to keep dust and
water out.Lower than Recommended Pressure Can Cause:
1. Tire squeal on turns
2. Hard steering
3. Rapid and uneven wear on the edges of the tread
4. Tire rim bruises and rupture
5. Tire cord breakage
6. High tire temperatures
7. Reduced handling
8. High fuel consumption
MAINTENANCE AND MINOR ADJUSTMENTS
WHEEL AND TIRE
Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced.
STUDS
If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure.
MATCHED TIRES AND WHEELS
(For vehicle equipped with steel wheels)
Tires and wheels are matchmounted at the assembly plant.
This means that the radially stiffest part of the tire, or ªhigh spotº, is
matched to the smallest radius or ªlow spotº of the wheel.
This is done to provide the smoothest possible ride.
The ªhigh spotº of the tire is originally marked by paint dot on the
outboard sidewall. This paint dot will eventually wash off the tire.
The ªlow spotº of the wheel is originally marked by paint dot on the
wheel rim-flange. Properly assembled, the wheel rims' paint dot
should be aligned with the tires' paint dot as shown in left figure.
Whenever a tire is dismounted from its wheel, it should be re-
mounted so that the tire and wheel are matched. If the tire's paint
dot cannot be located, a line should be scribed on the tire and wheel
before dismounting to assure that it is remounted in the same posi-
tion.
INFLATION OF TIRES
The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering, tread
wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should
be checked monthly or before any extended trip. Set to the specifications on the tire placard located on the side
of instrument panel.
It is normal for tire pressure increase when the tires become hot during driving. Do not bleed or reduce tire pressure
after driving. Bleeding reduces the ªCold Inflation Pressureº.

YH4
GRAND
VITARA
WHEELS AND TIRES 3F-7
TIRE
MOUNTING AND DEMOUNTING
Use tire changing machine to mount or demount tires. Follow equip-
ment manufacturer's instructions. Do not use hand tools or tire
irons alone to change tires as they may damage tire beads or wheel
rim.
Rim bead seats should be cleaned with wire brush or coarse steel
wool to remove lubricants, old rubber and light rust. Before mount-
ing or demounting tire, bead area should be well lubricated with ap-
proved tire lubricant.
After mounting, inflate to 240 kPa (35psi) so that beads are com-
pletely seated. Then adjust pressure to specified shown an tire
placard.
WARNING:
Do not stand over tire when inflating. Bead may break when
bead snaps over rim's safety hump and cause serious per-
sonal injury.
Do not exceed 240 kPa (35 psi) pressure when inflating. If
240 kPa (35 psi) pressure will not seat beads, deflate, re-lu-
bricate and reinflate. Over inflation may cause bead to break
and cause serious personal injury.
Install valve core and inflate to proper pressure.
TIRE REPAIR
There are many different materials and techniques on the market
to repair tires. As not all of these work on all types of tires, tire
manufacturers have published detailed instructions on how and
when to repair tires. These instructions can be obtained from the
tire manufacturer.

YH4
GRAND
VITARA
ªAº: Fill grease 90 ± 95 g (3.2 ± 3.4 oz)
1. Circlip
[LH] [RH] Differential side
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-7
7) Apply grease to entire surface of cage.
Use joint grease in tube included in spare part or joint grease
(99000-25120).
8) Insert cage into outer race and fit circlip into groove of outer
race.
CAUTION:
Position opening of circlip ªaº so that it will not be lined
up with a ball.
9) Apply grease to inside of outer race, and fit boot to outer race.
Fill up inside of boot with joint grease.
ªAº: Joint Grease 99000-25120
(about 90 ± 95g / 3.2 ± 3.4 oz)
10) Fitting boot to outer race, adjust so that measurements ªbº and
ªcº become as indicated in figure.
Length ªbº: 203.2 ± 213.2 mm
(8.00 ± 8.40 in.)
196.8 ± 206.8 mm
(7.75 ± 8.14 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
ªcº: 125.5 ± 135.5 mm
(4.94 ± 5.33 in.)
127.5 ± 137.5 mm
(5.02 ± 5.41 in.) M
/
T vehicle with . . . . . . . . .
H25 engine
Before fixing boot band, insert screwdriver into boot on joint
side and allow air to enter boot so that air pressure in boot be-
comes the same as atmospheric pressure.
11) Clamp boot band. Check boots for distortion or dent.

YH4
GRAND
VITARA
5
BRAKES 5-1
GENERAL DESCRIPTION5- 2 . . . . . . . . . . . . . .
DIAGNOSIS5- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Road Testing Brakes 5- 3. . . . . . . . . . . . . . . . . .
Brake Fluid Leaks 5- 3. . . . . . . . . . . . . . . . . . . .
Substandard or Contaminated
Brake Fluid 5- 3. . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis Table 5- 4. . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5- 7 . . . . . . . . . . . .
Bleeding Brakes 5- 7. . . . . . . . . . . . . . . . . . . . . .
Brake Pedal Free Height Check 5- 9. . . . . . . .
Brake Light Switch Adjustment 5- 9. . . . . . . . .
Excessive Pedal Travel Check 5- 9. . . . . . . . .
Brake Pedal Play Check 5-10. . . . . . . . . . . . . . .
Brake Fluid Level Check 5-10. . . . . . . . . . . . . . . Brake Hose and Pipe Check 5-10. . . . . . . . . . .
Master Cylinder Check 5-10. . . . . . . . . . . . . . . .
Brake Disc Check 5-11. . . . . . . . . . . . . . . . . . . .
Brake Pad Check 5-11. . . . . . . . . . . . . . . . . . . . .
Brake Shoe Check 5-11. . . . . . . . . . . . . . . . . . . .
Parking Brake Check and
Adjustment 5-12. . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Brake Hydraulic System 5-13. . . . . . .
Fluid Pressure Test 5-13. . . . . . . . . . . . . . . . . . .
Booster Operation Check 5-15. . . . . . . . . . . . . .
TIGHTENING TORQUE
SPECIFICATIONS5-17 . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5-17 . . . . . . . .
SPECIAL TOOLS5-18 . . . . . . . . . . . . . . . . . . . . . .
SECTION 5
BRAKES
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:

When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E or 5E1 first.

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 as-
sure proper retention of all parts. There is to be no welding as it may result in extensive damage and
weakening of the metal.
DIAGNOSIS5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE PIPE / HOSE / MASTER CYLINDER5A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE5B-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARKING AND REAR BRAKE5C-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTENTS

YH4
GRAND
VITARA
5-4 BRAKES
DIAGNOSIS TABLE
ConditionPossible CauseCorrection
Not enough brak-
ing force
Brake 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
prematurely
Maladjusted 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.

YH4
GRAND
VITARA
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 noise
Glazed 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.

YH4
GRAND
VITARA
1. 4-way joint / 2-way joint
2. Master cylinder
3. LSPV
4. Right brake caliper
5. Left brake caliper
6. Right wheel cylinder
7. Left wheel cylinder
8. ABS actuator

: Air bleeding point [A]: Without ABS
[B]: With ABS
1. Plug cap2. Vinyl tube (See-through tube)
3. Container
[A]
[B]
BRAKES 5-7
CHECK AND ADJUSTMENT
BLEEDING BRAKES
CAUTION:
Brake fluid is extremely damaging to paint. If fluid should
accidentally touch painted surface, immediately wipe
fluid from paint and clean painted surface.
NOTE:
For vehicle equipped with ABS, make sure that ignition switch
turns off.
Be sure to bleed air of brake system according to following proce-
dure when its oil hydraulic circuit has been disconnected.
Hydraulic lines of brake system consists of two separate lines, one
for front wheel brakes and the other for rear wheel brakes.
Air bleeding is necessary at right and left front wheel brakes, left
rear wheel brake and LSPV (if equipped without ABS), i.e. 4 places
(3 places for vehicle with ABS) in all.
1) Fill master cylinder reservoir with brake fluid and keep at least
one-half full of fluid during bleeding operation.
2) Remove bleeder plug cap.
Attach a vinyl tube to bleeder plug of wheel cylinder, and insert
the other end into container.
3) Depress brake pedal several times, and then while holding it de-
pressed, loosen bleeder plug about one-third to one half turn.

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.