2004 SUZUKI GRAND VITARA steering

YH4
GRAND
VITARA
4
3
1. Piston stopper circlip
2. Piston stopper
3. Cylinder cup and plate
4. Primary piston
5. Piston cup
6. Secondary piston pressure cup
7. Primary piston Assy
8. Secondary piston
9. Secondary piston Assy
10. Secondary piston stopper bolt
11. Master cylinder body
12. O-ring
[A] [B]
[A]: With ABS
[B]: Without ABS
5. Attaching nut
6. ABS control module
connector
7. Bracket bolt 1. Reservoir cap
2. Reservoir
3. Master cylinder
4. Flare nuts
5A-10 BRAKES PIPE / HOSE / MASTER CYLINDER
MASTER CYLINDER ASSEMBLY
REMOVAL
NOTE:
Do not allow brake fluid to get on painted surfaces.
1) Disconnect reservoir lead wire at coupler.
2) Clean around reservoir cap and take out fluid with syringe or
such.
3) Remove master cylinder with reservoir from brake booster.

For vehicle with ABS
a) Loosen flare nuts for master cylinder and ABS hydraulic
unit as shown.
b) For LH steering vehicle, disconnect ABS control module
connector.
c) For RH steering vehicle, remove ABS hydraulic unit brack-
et bolts.
d) Disconnect brake pipes between master cylinder and ABS
hydraulic unit.

For vehicle without ABS
a) Loosen flare nuts for master cylinder.
b) Disconnect brake pipes for master cylinder.

YH4
GRAND
VITARA
1. Pin
2. Reservoir
3. Master cylinder
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-13
5) Apply thin coat of brake fluid to all around new grommets (2pcs.)
and install them to cylinder body, then install reservoir.
6) Set a new pin in reservoir hole and drive it in. At this time, make
end of pin and end face margin of reservoir equal.
INSTALLATION
NOTE:

See NOTE at the beginning of this section.

Adjust clearance between booster piston rod and primary
piston with special tool, referring to CLEARANCE BETWEEN
BOOSTER PISTON AND MASTER CYLINDER PISTON AD-
JUSTMENT in this section.
1) Install master cylinder to brake booster.
2) Tighten master cylinder attaching nuts to specification.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
3) Connect brake pipes to master cylinder.

For vehicle with ABS
a) Connect brake pipes between master cylinder and ABS hy-
draulic unit.
b) For LH steering vehicle, connect ABS control module con-
nector.
c) For RH steering vehicle, install ABS hydraulic unit bracket
bolts and tighten it to specified torque.
Tightening Torque
(b): 10 N
.m (1.0 kg-m, 7.5 lb-ft)
4) Tighten flare nuts to specification.
Tightening Torque
(c): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
5) Connect reservoir lead wire.
6) Fill reservoir with specified brake fluid.
7) Check brake pedal play and bleed air from system.
8) Perform brake test and check each installed part for fluid leak-
age.

YH4
GRAND
VITARA
5
1
6
4
2
6
3
6
1. Brake master cylinder ass'y
2. Brake booster ass'y
3. Gasket
4. Push rod clevis
5. Nut
6. Clevis pin
7. Clip
8. Nut
9. Brake vacuum hose
1. Steering column
2. Push rod clevis
3. Brake pedal arm
4. Clevis pin
5. Clip
6. Nut
1. ABS hydraulic
unit
2. Brake pipes
5A-14 BRAKES PIPE / HOSE / MASTER CYLINDER
BRAKE BOOSTER
REMOVAL
NOTE:
Do not allow brake fluid to get on painted surfaces.
1) For vehicle equipped with ABS, disconnect brake pipes from
ABS hydraulic unit.
2) Remove master cylinder assembly, referring to MASTER CYL-
INDER ASSEMBLY REMOVAL in this section.
3) Disconnect brake vacuum hose from brake booster.
4) Disconnect push rod clevis from brake pedal arm.
5) Remove attaching nuts and then booster as shown.
CAUTION:
Never disassemble brake booster. Disassembly will spoil
its original function. If it is found faulty, replace it with
new one.

YH4
GRAND
VITARA
5A-16 BRAKES PIPE / HOSE / MASTER CYLINDER
1. Clevis
2. Nut
1. Steering column 4. Clevis pin
2. Push rod clevis 5. Clip
3. Brake pedal arm 6. NutBOOSTER PUSH ROD CLEVIS ADJUSTMENT
Install push rod clevis so that measurement ªaº is obtained and
torque nut to specification.
Tightening Torque
(a): 25 N
.m (2.5 kg-m, 18.0 lb-ft)
Length
ªaº: 109.5 ± 110.5 mm (4.31 ± 4.35 in.)
INSTALLATION
NOTE:

See NOTE at the beginning of this section.

Check length of push rod clevis. (Refer to BOOSTER PUSH
ROD CLEVIS ADJUSTMENT.)

Before installing master cylinder, adjust booster piston rod.
(Refer to CLEARANCE BETWEEN BOOSTER PISTON ROD
AND MASTER CYLINDER PISTON ADJUSTMENT of this sec-
tion.)

Apply silicone grease to master cylinder piston.
1) Install booster to dash panel as shown. Then connect booster
push rod clevis to pedal arm with clevis pin and clip.
2) Tighten booster attaching nuts to the specified torque.
Tightening Torque
(a): 13 N
.m (1.3 kg-m, 9.5 lb-ft)
3) Connect brake vacuum hose to brake booster.
4) For vehicle equipped with ABS, connect brake pipes to ABS hy-
draulic unit. If ABS hydraulic unit bracket bolts removed, tighten
flare nuts to specification after installing master cylinder.
Tightening Torque
(a): 16 N
.m (1.6 kg-m, 12.0 lb-ft)
5) Install master cylinder, referring to MASTER CYLINDER AS-
SEMBLY INSTALLATION in this section.

YH4
GRAND
VITARA
1. 8 mm bolt
5B-10 FRONT BRAKE
FRONT BRAKE DISC
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by loosening carrier bolts (2 pcs.).
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.
3) Remove disc by using 8 mm bolts (2 pcs.).
INSPECTION
Refer to FRONT DISC BRAKE PAD INSPECTION.
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
1) Install disc to wheel hub.
2) Install caliper assembly to steering knuckle.
3) Torque caliper carrier bolts to specification.
Tightening Torque
(a): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
4) Torque front wheel nuts to specifications.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
5) Upon completion of installation, perform brake test.

YH4
GRAND
VITARA
1. Front disk brake
2. Rear drum brake
3. ABS hydraulic unit / control module assembly
with ABS pump motor
relay and fail-safe relay
4. Brake master cylinder / Reservoir
LH steering vehicle
RH steering vehicle
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-3
BRAKE HOSE / PIPE ROUTING

YH4
GRAND
VITARA
1. Wheel speed sensor
(Right-front)
2. Stop lamp switch
3. Data link connector
4. ªABSº warning lamp
5. Wheel speed sensor
(Right-rear)6. Wheel speed sensor
(Left-rear)
7. Ground
8. Diagnosis connector (Black connector)
9. Wheel speed sensor
(Left-front)10. ABS hydraulic unit/control module assembly
with ABS pump motor relay
and fail-safe relay
11. G sensor (For 4WD model only)
12. Wheel speed sensor rotor (ring)
13. 4WD switch (For 4WD model only)
14. EBD warning lamp (Brake warning lamp)
LH steering vehicle
RH steering vehicle
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-5
ABS COMPONENT PARTS LOCATION

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-71
Ignition switch side
1. Ignition switch assembly
2. Clamp screw
3. Interlock cable
Select lever side
Type-1
1. Inner end of interlock cable
2. Interlock cam (or key release cam)
3. Stud bolt4. Cam boss
5. Claw
Select lever side
Type-2
KEY INTERLOCK CABLE
NOTE:
Don't bend interlock cable excessively when removing and
installing it, or system will not operate correctly.
Removal
1) Disconnect negative (±) cable from battery.
2) If equipped with air bag system, disable air bag system.
Refer to ªDisabling Air bag Systemº in Section 10B.
3) Remove steering column hole cover.
4) Tilt steering column if steering column is adjustable.
If no adjustable, loosen steering column bolts.
5) Remove steering column cover.
6) Remove interlock cable clamp screw located at ignition switch
assembly.
7) Disconnect interlock cable inner end.
(Ignition switch side.)
8) With console box removed, take out interlock cable by loosening
lock nuts.
9) Detach cable end from interlock cam (or key release cam) while
pressing claws of interlock cam boss. At this time, be careful not
to cause damage to its claws.