2004 SUZUKI GRAND VITARA Disc brake

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
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-15
1. Booster piston rod
2. Master cylinder piston
1. Master cylinder
2. Piston
3. Pin head
1. Booster body
2. Piston rod
1. Booster piston rod
2. Master cylinder piston
CLEARANCE BETWEEN BOOSTER PISTON ROD AND
MASTER CYLINDER PISTON ADJUSTMENT
The length of booster piston rod is adjusted to provide specified
clearance ªaº between piston rod end and master cylinder piston.

Before measuring clearance, push piston rod several times so as
to make sure reaction disc is in place.

Keep inside of booster at atmospheric pressure for measure-
ment.
1) Set special tool (A) on master cylinder and push pin until con-
tacts piston.
Special Tool
(A): 09950-96010
2) Turn special tool upside down and place it on booster. Adjust
booster piston rod length until rod end contacts pin head.
Special Tool
(A): 09950-96010
Clearance ªbº: 0 mm (0 in.)
NOTE:
Take measurement with booster set vertically and rod at the
center.
3) Adjust clearance by turning adjusting screw of piston rod.
Special Tool
(F): 09952-16010
Reference
When adjusted as above, its negative pressure is applied to boost-
er with engine at idle, piston to piston rod clearance ªaº should be-
come below.
Clearance ªaº: 0.25 ± 0.5 mm (0.010 ± 0.020 in.)

YH4
GRAND
VITARA
1. LSPV
2. Brake pipe
1. LSPV assembly
2. LSPV spring
3. LSPV stay
4. Bolt
5. Stepper bole
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-17
LSPV (Load Sensing Proportioning Valve)
ASSEMBLY (if equipped)
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Hoist vehicle.
3) Disconnect brake pipes from LSPV.
4) Remove LSPV assembly with spring from vehicle body.
5) Remove spring from lever.
CAUTION:

LSPV assembly must not be disassembled.
Replace with new one if defective.

Stopper bolt should not be loosened or tightened. (if
equipped)
INSTALLATION
CAUTION:
Refer to above CAUTION.
Install by reversing removal procedure, noting the following.
1) Apply multi-purpose grease ªAº to upper and lower joint of coil
spring.

YH4
GRAND
VITARA
5B
FRONT BRAKE 5B-1
SECTION 5B
FRONT BRAKE
NOTE:
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 assure
proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening
of the metal.
CONTENTS
GENERAL DESCRIPTION5B- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Pad5B- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Caliper5B- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Disc5B-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIAL5B-11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
[A]: TOKICO produced
[B]: SUMITOMO ELECTRIC produced1. Caliper pin bolt
2. Boot
3. Disc brake caliper
(Disc brake cylinder)
4. Piston seal
5. Disc brake piston
6. Cylinder boot
7. Disc brake inner pad
8. Disc brake outer pad
9. Brake caliper carrier
10. Pad spring
11. Bleeder plug
12. Bleeder plug cap
13. Caliper pin
14. Anti noise shim
15. Inner shim
Tightening torque
(a): 8.5 N.m (0.85 kg-m, 6.5 lb-ft)
(b): 8.0 N.m (0.80 kg-m, 6.0 lb-ft) [A]
[B]
5B-2 FRONT BRAKE
GENERAL DESCRIPTION
DISC BRAKE CALIPER ASSEMBLY
This caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying
force to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston
and the bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in
a clamping action on the disc. This clamping action forces the pads (linings against the disc, creating friction to
stop the vehicle.
NOTE:

Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo-
nents may result. If any component is removed or line disconnected, bleed the brake system.
Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners.

For identification of the brake caliper type, see maker name or mark on brake caliper as shown.

YH4
GRAND
VITARA
1. Caliper
2. Caliper pin bolts
3. Disc
1. Caliper
2. Wire hook
3. Pad
FRONT BRAKE 5B-3
DIAGNOSIS
Refer to Section 5 (BRAKES).
CHECK AND ADJUSTMENT
Refer to Section 5 (BRAKES).
ON-VEHICLE SERVICE
FRONT DISC BRAKE PAD
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper pin bolts.
3) Remove E-ring from strut and then remove caliper from caliper
carrier.
NOTE:
Hang removed caliper with a wire hook or the like so as to
prevent brake hose from bending and twisting excessively
or being pulled. Don't operate brake pedal with pads re-
moved.
4) Remove pads.
INSPECTION
Brake Pad
Check pad lining for wear. When wear exceeds limit, replace with
new one.
CAUTION:
Never polish pad lining with sandpaper. If lining is polished
with sandpaper, hard particles of sandpaper will be depos-
ited in lining and may damage disc. When pad lining re-
quires correction, replace it with a new one.
Pad thickness (lining + rim) ªaº
Standard: 15.0 mm (0.590 in.) For SUMITOMO ELECTRIC. . .
brake calliper
15.5 mm (0.610 in.) For TOKICO brake caliper. . .
Service limit: 7.0 mm (0.275 in.) For SUMITOMO ELECTRIC. .
brake caliper
7.5 mm (0.295 in.) For TOKICO brake caliper. .
NOTE:
When pads are removed, visually inspect caliper for brake
fluid leak. Correct leaky point, if any.

YH4
GRAND
VITARA
5B-4 FRONT BRAKE
1. Wheel nut
2. Washer
(or spacer)
ªAº: Apply grease
Brake Disc
Before this inspection, brake pads must be removed.
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and disc is not defective unless they are serious.
But when there are deep scratches or scratches all over disc sur-
face, replace it. When only one side is scratched, polish and correct
that side.
Disc thickness ªaº
Standard: 22 mm (0.866 in.) For SUMITOMO ELECTRIC. . . . .
brake caliper
17 mm (0.670 in.) For TOKICO brake caliper. . . . .
Service limit: 20 mm (0.787 in.) For SUMITOMO ELECTRIC. .
brake caliper
15 mm (0.590 in.) For TOKICO brake caliper. .
Use wheel nuts and suitable plain washers to hold the disc securely
against the hub, then mount a dial indicator as shown and measure
the runout at 25 mm (0.98 in.) from the outer edge of the disc.
Limit on disc deflection: 0.15 mm (0.006 in.)
NOTE:
Check front wheel bearing for looseness before measure-
ment.
Cylinder Slide Guide Pin / Pin Bolt
Check guide pin for smooth movement as shown.
If it is found faulty, correct or replace. Apply rubber grease to guide
pin outer surface. Rubber grease should be the on whose viscosity
is less affected by such low temperature a ±40
C (±40
F).
Dust Boot
Check boot for breakage, crack and damage. If defective, replace.

YH4
GRAND
VITARA
1. Clips
2. Pads
3. Disc
4. Caliper carrier
5. Sensor
6. Shim
1. Caliper pin bolts
ELECTRIC brake
caliper
FRONT BRAKE 5B-5
INSTALLATION
NOTE:
See NOTE at the beginning of this section.
1) Install pad clips and pads.
NOTE:
Install pad with sensor to body center side of caliper.
2) Install caliper and torque caliper pin bolts to specification.
Tightening Torque
(a), (b): 27 N
.m (2.7 kg-m, 20.0 lb-ft) For TOKICO brake. .
caliper
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft) For SUMITOMO. . . . . .
(b): 85 N
.m (8.5 kg-m, 61.5 lb-ft)
NOTE:
Make sure that boots are fit into groove securely.
3) Torque front wheel nuts to specification.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
4) Upon completion of installation, perform brake test.