2004 SUZUKI GRAND VITARA Air condition

YH4
GRAND
VITARA
1. Boot
2. Snap ring
1. Circlip
2 Snap ring plier
3. Cage
FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL 4A2-5
DISASSEMBLY
1) Remove boot band of differential side joint.
2) Slide boot toward the center of shaft and remove snap ring from
outer race, then take shaft out of outer race.
3) Remove circlip and then cage.
4) Remove inside and outside boots from shaft.
CAUTION:

Do not disassemble wheel side joint (outboard joint). If
any malcondition is found in joint, replace it as assem-
bly.

Do not disassemble ball joint of differential side joint.
If any malcondition is found in ball joint, replace differ-
ential side joint assembly.
INSPECTION

Check boots for breakage or deterioration. Replace them as nec-
essary.

Check circlip, snap ring and boot bands for breakage or deforma-
tion. Replace as necessary.
CLEANING

Wash disassembled parts (except boots) in degreaser. After
washing, dry parts completely by blowing air.

Clean boots with cloth. DO NOT wash boots in degreaser, such
as gasoline or kerosene, etc.
Washing in degreaser causes deterioration of boot.

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
BRAKES 5-3
SUBSTANDARD OR
CONTAMINATED BRAKE FLUID
Improper brake fluid, mineral oil or water in the fluid
may cause the brake fluid to boil or the rubber compo-
nents in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts
have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the
drum brake wheels.
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol
out of the system. Replace all rubber parts in the sys-
tem, including hoses. Also, when working on the
brake mechanisms, check for fluid on the linings. If ex-
cessive fluid is found, replace the linings.
If master cylinder piston seals are satisfactory, check
for leakage or excessive heat conditions. If condition
is not found, drain fluid, flush with brake fluid, refill and
bleed system.
The system must be flushed if there is any doubt as
to the grade of fluid in the system or if fluid has been
used which contained parts that have been subjected
to contaminated fluid.
DIAGNOSIS
ROAD TESTING BRAKES
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both
light and heavy pedal forces at various speeds to de-
termine if the vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the
other without brake application. If it does, check the
tire pressure, front end alignment and front suspen-
sion attachments for looseness. See diagnosis chart
for other causes.
BRAKE FLUID LEAKS
Check the master cylinder fluid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low level indicates a leak in the
system. In such a case, check the entire brake system
for leakage. If even a slight evidence of leakage is
noted, the cause should be corrected or defective
parts should be replaced.
If fluid level is lower than the minimum level of reser-
voir, refilling is necessary. Fill reservoir with specified
brake fluid.
Brake fluid: Refer to reservoir tank cap.
CAUTION:
Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
tank cap, do not use or mix different type of
fluid when refilling; otherwise serious damage
will occur.
Do not use old or used brake fluid, or any fluid
from a unsealed container.

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
5-6 BRAKES
ConditionPossible CauseCorrection
Brake warning light
turns on after
engine start
Parking brake applied.

Insufficient amount of brake fluid.

Brake fluid leaking from brake line.

Brake warning light circuit faulty.

Malfunctioning EBD system, if equipped
with ABS.Release parking brake and check
that brake warning light turns off.
Add brake fluid.
Investigate leaky point, correct it and
add brake fluid.
Repair circuit.
Check system referring to
ªDIAGNOSISº of ABS section.
Brake warning light
turns on when
brake is applied
Brake fluid leaking from brake line.

Insufficient amount of brake fluid.Investigate leaky point, correct it and
add brake fluid.
Add brake fluid.
Brake warning light
fails to turn on
even when parking
brake is applied
Bulb burnt out.

Brake warning light circuit open.Replace bulb.
Repair circuit.
ABS warning light
does not turn on
for 2 sec. after
ignition switch has
turned ON
Bulb burnt out.

ABS warning light circuit open, if equipped
with ABS. (including check relay)Replace bulb.
Check system referring to
ªDIAGNOSISº of ABS section.
ABS warning light
remains on after
ignition switch has
turned on for 2 sec.
Malfunctioning ABS, if equipped with ABS.Check system referring to
ªDIAGNOSISº of ABS section.

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
GOOD
NO GOOD
BRAKES 5-15
6) Upon completion of fluid pressure test, bleed brake system and
perform brake test.
BOOSTER OPERATION CHECK
There are two ways to perform this inspection, with and without a
tester. Ordinarily, it is possible to roughly determine its condition
without using a tester.
NOTE:
For this check, make sure that no air is in hydraulic line.
INSPECTION WITHOUT TESTER
Check Air Tightness
1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same load as in ordi-
nary braking and observe pedal travel. If pedal goes down deep
the first time but its travel decreases as it is depressed the se-
cond and more times, air tightness is obtained.
4) If pedal travel doesn't change, air tightness isn't obtained.
NOTE:
If defective, inspect vacuum lines and sealing parts, and re-
place any faulty part.
When this has been done, repeat the entire test.