2004 SUZUKI GRAND VITARA rod

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.

YH4
GRAND
VITARA
BRAKES 5-17
TIGHTENING TORQUE SPECIFICATIONS
FasteningpartsTightening torqueFastening artsN.mkg-mlb-ft
Brake pipe 2-way (or 4-way) joint bolt232.317.0
Brake pipe flare nut161.611.5
Front caliperM88.00.86.0
Brake bleederplug
Front cali erM108.50.856.5Brake bleeder lugWheel cylinder7.50.755.5
LSPV7.50.755.5
LSPV mounting bolt
LSPV stay bolt232.317.0
LSPV spring nut
Wheel nut10010.072.5
Stop light switch lock nut7.50.755.5
REQUIRED SERVICE MATERIAL
MATERIALSRECOMMENDED
SUZUKI PRODUCTUSE
Brake fluid
Indicated on reservoir
cap or described in owner's
manual of vehicle
To fill master cylinder reservoir.

To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when
they are disassembled.

YH4
GRAND
VITARA
[A]: With ABS
[B]: Without ABS
1. Piston stopper circlip
2. Piston stopper
3. Cylinder cup
4. Plate
5. Primary piston
6. Piston cup
7. Primary piston return spring
8. Primary spring retainer
9. Secondary piston pressure cup
10. Secondary piston
11. Return spring secondary seat
12. Secondary piston return spring
13. Secondary piston stopper bolt
14. Master cylinder body
ªAº: Primary piston
ªBº: Secondary piston
[B] [A]
5A-2 BRAKES PIPE / HOSE / MASTER CYLINDER
GENERAL DESCRIPTION
MASTER CYLINDER ASSEMBLY
The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (ªaº
in the figure below) and secondary (ªbº) chambers. The hydraulic pressure produced in the primary chamber (ªaº)
acts on the front (for vehicle without ABS, rear) wheel brakes.
Also, the hydraulic pressure produced in the secondary chamber (ªbº) acts on the rear (for vehicle without ABS,
front) wheel brakes.
NOTE:
Replace all components included in repair kits to service this master cylinder. Lubricate rubber parts with
clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on brake parts as damage to rub-
ber components may result. If any hydraulic component is removed or brake line disconnected, bleed the
brake system.
The torque values specified are for dry, unlubricated fasteners.
BOOSTER ASSEMBLY
The booster is located between the master cylinder and the brake pedal. It is so designed that the force created
when the brake pedal is depressed is mechanically increased combined with the engine vacuum.
The booster has two diaphragms of
ù7.5 in. (191 mm) effective diameter.
CAUTION:

Never disassemble brake booster assembly. If it is found faulty, replace it with new assembly.

The torque values specified are for dry, unlubricated fasteners. If any hydraulic component is re-
moved or brake line disconnected, bleed the brake system.

YH4
GRAND
VITARA
1. LSPV
2. LSPV lever
3. Spring
4. LSPV stay
5. Brake flare nut
[A]: Type A
[B]: Type B
1. Plunger
2. Lip seal
3. LSPV lever
4. Sensor spring
5. From master cylinder
primary chamber
(Rear wheel brake)
6. From master cylinder
secondary chamber
(Front wheel brake)
7. To rear wheel brake
8. Pin
9. Bolt hole
[A] [B]
44
BRAKES PIPE / HOSE / MASTER CYLINDER 5A-3
LSPV (Load Sensing Proportioning Valve) ASSEMBLY (if equipped)
As shown in figure below, LSPV is included within the brake circuit which connects the master cylinder and the rear
wheel brake. It controls the hydraulic pressure applied to the rear wheel brake according to the loaded state of the
vehicle (or weight of the load), whereby preventing the rear wheels from getting locked prematurely.
Also, it releases the above described control over the hydraulic pressure applied to the rear wheel brake, should
any failure occur in the hydraulic circuit of the front wheel brake so that the hydraulic pressure produced in the mas-
ter cylinder is applied to the rear wheel brake directly to operate it.
CONSTITUTION
The LSPV components are grouped into three sections as follows.
ªAº: Sensor section
The main parts in this section are a lever and a spring which senses variation in the vehicle height as affected
by the loaded condition and converts it into the load.
ªBº: Hydraulic pressure control section
Included in this section are a stepped plunger and valve mechanism to execute proportional control.
ªCº: Fail-safe section
The main parts in this section are a chamber which draws in the hydraulic pressure from the front wheel brake
system and a fail-safe piston which releases the valve mechanism in the control section connected to the rear
wheel brake, should any failure occur in the front wheel brake system.

YH4
GRAND
VITARA
5A-12 BRAKES PIPE / HOSE / MASTER CYLINDER
Vehicle not equipped with ABSVehicle equipped with ABS
1. Rod
2. Circlip
INSPECTION
Inspect all disassembled parts for wear or damage, and replace
parts if necessary.
NOTE:

Wash disassembled parts with brake fluid.

Do not reuse piston cups.
Inspect master cylinder bore for scoring or corrosion. It is best to re-
place corroded cylinder.
Corrosion can be identified as pits or excessive roughness.
NOTE:
Polishing bore or master cylinder with cast aluminum body
with anything abrasive is prohibited, as damage to cylinder
bore may occur.
Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from
cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot
be kept from cylinder bore surfaces.
ASSEMBLY
NOTE:

See NOTE at the beginning of this section.

Before assembling, wash each part in fluid recommended to
use for that vehicle.
1) Install secondary piston assembly into cylinder.
2) Install primary piston assembly in cylinder.
3) Depress, and install circlip.
4) Install piston stopper bolt with pistons pushed in all the way and
tighten it to specified torque (For vehicle without ABS).
Tightening Torque
(a): 10 N
.m (1.0 kg-m, 7.5 lb-ft)

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
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.)