2004 SUZUKI GRAND VITARA Disc brake

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.

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VITARA
FRONT BRAKE 5B-7
2) Remove piston seal using a thin blade like a thickness gauge,
etc.
CAUTION:
Be careful not to damage inside (bore side) of cylinder.
INSPECTION
Cylinder Boot
Check boots for breakage, crack and damage. If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate unsmooth re-
turn of the piston. In such a case, replace rubber seal.
ASSEMBLY
Reassemble front brake in reverse order of disassembly, noting the
following points.
CAUTION:

Wash each part cleanly before installation in the same
fluid as the one used in master cylinder reservoir.

Never use other fluid or thinner.

Before installing piston and piston seal to cylinder, apply
fluid to them.

After reassembling brake lines, bleed air from them.
Piston Seal
Piston seal is used to seal piston and cylinder and to adjust clear-
ance between pad and disc. Replace with a new one at every over-
haul. Fit piston seal into groove in cylinder taking care not to twist
it.

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.

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GRAND
VITARA
5C
PARKING AND REAR BRAKE 5C-1
SECTION 5C
PARKING AND REAR BRAKE
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:
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 DESCRIPTION5C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Brake Assembly5C- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSIS5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECK AND ADJUSTMENT5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever5C- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Cable5C- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Drum5C- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Shoe5C- 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder5C-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Back Plate5C-14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUE SPECIFICATIONS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REQUIRED SERVICE MATERIALS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS5C-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

YH4
GRAND
VITARA
1. Brake back plate
2. Brake shoe
3. Shoe return upper spring
4. Adjuster
5. Shoe return lower spring
6. Adjuster lever
7. Adjuster spring
8. Shoe hold down spring
9. Shoe hold down pin
10. Wheel cylinder
11. Link
12. Brake strut
(a)
Tightening torque
(a): 7.5 N.m (0.75 kg-m, 5.5 lb-ft)
5C-2 PARKING AND REAR BRAKE
GENERAL DESCRIPTION
DRUM BRAKE ASSEMBLY
The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is main-
tained appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is
depressed and when parking brake is applied on level road.
It also uses duo servo operation when parking brake is applied on gradient road and load is applied in longitudinal
direction of vehicle.
NOTE:
Replace all components included in repair kits to service this drum brake. Lubricate parts as specified.
WARNING:
If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque
values specified are for dry, unlubricated fasteners.

YH4
GRAND
VITARA
2. Brake cable
3. Locking nut
1. Parking brake cable
2. Equalizer
3. Pin
4. Parking brake lever bolt
5. Parking brake lever assembly1. Parking
brake lever
PARKING AND REAR BRAKE 5C-3
DIAGNOSIS
Refer to Section 5 (BRAKES).
CHECK AND ADJUSTMENT
Refer to Section 5 (BRAKES).
ON-VEHICLE SERVICE
PARKING BRAKE LEVER
REMOVAL
1) Disconnect negative (±) cable at battery.
2) Block vehicle wheels and release parking brake lever.
3) Remove rear center console box.
4) Disconnect lead wire of parking brake switch at coupler.
5) Remove parking brake cable locking nut.
6) Remove parking brake lever bolts and then remove parking
brake lever assembly from equalizer.
7) Remove equalizer from parking brake cable.
NOTE:
Don't disassemble parking brake lever switch. It must be re-
moved and installed as a complete switch assembly.

YH4
GRAND
VITARA
A-1. Color ring
A-2. Cable
A-3. Grommet
A-4. Bolt
A-5. Clamp (if equipped)A-6. Cross-member
A-7. Chassis frame
A-8. Hanger
A-9. Rear axle
A-10. G-sensor (if equipped) B-1. Parking brake switch
B-2. Parking brake lever
B-3. Parking brake lever bolt
B-4. Floor
B-5. Locking nut
B-6. Spacer
B-7. Pin
B-8. Equalizer
B-9. Adjust rod
B-10. Coupler
PARKING AND REAR BRAKE 5C-5
PARKING BRAKE CABLE
REMOVAL
1) Remove brake drum. (Refer to steps 1) to 5) of BRAKE DRUM
REMOVAL of this section.)
2) Check the color of ring or tape for reinstallation.
NOTE:
Color ring on brake cable is for the purpose of identifica-
tion.
3) Disconnect parking brake cable from brake shoe lever. (Refer to
steps 2) to 5) of BRAKE SHOE REMOVAL of this section.)
4) Disconnect brake cable from brake back plate. (Refer to step 4)
of BRAKE BACK PLATE REMOVAL.)
NOTE:
When it is necessary to remove both right and left parking
brake cables, repeat above steps 1) to 3) on right and left
wheels.
5) Remove cable from parking brake lever. (Refer to steps 1) to 5)
of PARKING BRAKE LEVER REMOVAL of this section.)

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GRAND
VITARA
6. Shoe hold down
springs
7. Strut spring
8. Lower shoe return
spring 1. Upper shoe return spring
2. Adjuster
3. Pawl lever
4. Adjuster spring
5. Shoe hold down pins
1. Brake back plate
2. Cable cap
3. Brake cable
PARKING AND REAR BRAKE 5C-9
2) Install brake drum after making sure that inside of brake drum
and brake shoes are free from dirt and oil.
3) Upon completion of all jobs, depress brake pedal with about 30
kg (66 lbs) load three to ten times so as to obtain proper drum-to-
shoe clearance.
Adjust parking brake cable. (For adjustment, refer to PARKING
BRAKE CHECK AND ADJUSTMENT in Section 5.)
4) Tighten rear center console box screws.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening Torque
(b): 100 N
.m (10.0 kg-m, 72.5 lb-ft)
6) Check to ensure that brake drum is free from dragging and prop-
er braking is obtained. Then remove vehicle from hoist and per-
form brake test (foot brake and parking brake).
BRAKE SHOE
REMOVAL
1) Perform steps 1) to 5) of BRAKE DRUM REMOVAL.
WARNING:
Use special care when installing brake shoe return
spring. Failure in its proper installation may allow it to
springback and cause personal injury.
2) Remove shoe hold down springs by turning shoe hold down
pins.
3) Remove upper return spring, struts, adjuster, adjuster lever and
springs.
4) Remove brake shoes and lower shoe return spring.
5) Remove brake shoes and disconnect parking brake cable from
parking brake shoe lever.