Disc & Drum: Other Suzuki Vitara I

BLEEDING BRAKE SYSTEM

Raise and support vehicle. Fill master cylinder reservoir to maximum mark with clean brake fluid. Bleed brakes in sequence. See BRAKE BLEEDING SEQUENCE table. After bleeding brakes, depress brake pedal with a force equal to an abrupt stop. If sponginess exists, repeat bleeding procedure.

BRAKE BLEEDING SEQUENCE

BRAKE BLEEDING SEQUENCE

Grand Vitara & Vitara

Length of brake booster piston rod is adjusted to provide clearance between brake booster piston rod and master cylinder piston. Remove vacuum brake booster from vehicle. See POWER BRAKE BOOSTER under REMOVAL & INSTALLATION. Push piston rod several times to ensure reaction disc is in place. Remove piston rod seal from booster (if equipped). Set Booster Piston Rod Gauge (09950-96010) on master cylinder, and push pin head until it contacts piston. Perform STEP 1 in illustration. (Scheme 15) Turn gauge upside down and place it on booster. No clearance should exist between pin head and brake booster piston rod. Perform STEP 2 in illustration. (Scheme 15) Adjust by turning adjusting bolt of booster piston rod using Special Tool (09952-16010).

Scheme 15

XL-7

Length of brake booster piston rod is adjusted to provide clearance between brake booster piston rod and master cylinder piston. Remove vacuum brake booster from vehicle. See POWER BRAKE BOOSTER under REMOVAL & INSTALLATION. Push piston rod several times to ensure reaction disc is in place. Measure distance between piston rod and mating surface of brake booster. Perform STEP 1 in illustration. (Scheme 16) Depth should be.622-.653" (15.8-16.6 mm). If depth is not within specification, adjust to.642-.653" (16.3-16.6 mm) by turning adjusting screw of booster piston rod using Special Tool (09952-16021). Perform STEP 2 in illustration. (Scheme 16)

Scheme 16

BRAKE BOOSTER PUSH ROD (BRAKE PEDAL HEIGHT)

Remove vacuum brake booster from vehicle. See POWER BRAKE BOOSTER under REMOVAL & INSTALLATION. Measure distance between booster mounting surface (with gasket on) and center of clevis pin hole. (Scheme 17) Adjust push rod if not within specification. See BOOSTER PUSH ROD LENGTH table.

BOOSTER PUSH ROD LENGTH

Scheme 17

BRAKE LIGHT SWITCH

Loosen brake light switch lock nut. Pull brake pedal up. Adjust stoplight switch position so clearance between end of switch thread and brake pedal contact is as specified. See BRAKE LIGHT SWITCH CLEARANCE table. Tighten lock nut. See TORQUE SPECIFICATIONS .

BRAKE LIGHT SWITCH CLEARANCE

BRAKE PEDAL CLEARANCE

1. Remove foot rest, dash silencers and carpet. Start engine and depress brake pedal a few times. Depress and hold pedal with 66 lbs. (30 kg) of force. Measure pedal to floor clearance "C". See «BRAKE PEDAL CLEARANCE»(ref-163365-S14060867802004062800000) table. (Scheme 18)
2. If clearance is less than specified, check rear brake shoes for wear limit. Check for air in brake lines. Check push rod length adjustment. Check adjustment of rear brake shoe adjusters.

BRAKE PEDAL CLEARANCE

Scheme 18

LOAD SENSING PROPORTIONING VALVE (WITHOUT ABS)

On models without ABS, Load Sensing Proportioning Valve (LSPV) limits brake pressure to rear brakes depending on load. Before inspection and fluid pressure test, ensure fuel tank is full and spare tire, tools, jack and jack handle are installed. No other load should be placed in vehicle. Check for and repair any fluid leaks. Perform inspection and pressure test. See INSPECTION and FLUID PRESSURE TEST .

PARKING BRAKE

Note. Before adjusting parking brake, ensure following 6 conditions are all satisfied: No air is trapped in brake system. Brake pedal travel is correct. Brake pedal has been depressed a few times with a force of about 66 lbs. (30 kg). Parking brake lever has been pulled up a few times with a force of about 44 lbs. (20 kg). If new parking brake cable has been installed, pull up parking brake lever a few times with a force of about 110 lbs. (50 kg). Rear brake shoes are not worn beyond specification and self-adjusting mechanism operates properly. Add slack to parking brake cable by loosening adjusting bolt self-locking nut to end of bolt and depress brake pedal a few times with a force of about 66 lbs. (30 kg).

Slowly pull parking brake lever without pushing release button with 44 lbs. (20 kg) of force and count number of clicks. See PARKING BRAKE ADJUSTMENT table. Ensure both rear wheels are firmly locked. If number of clicks is out of specification, adjust cable. After adjustment, ensure rear wheels turn freely with parking brake off.

PARKING BRAKE ADJUSTMENT

FRONT ROTOR

Note. When front brakes are serviced, check rotor thickness. See DISC BRAKE SPECIFICATIONS .

Note. LSPV assembly is not serviceable and should be replaced if defective.

MASTER CYLINDER

Note. DO NOT allow brake fluid to contact painted surfaces.

PROPORTIONING VALVE (VITARA)

Note. Vitara models with ABS are equipped with a proportioning valve.

REAR DRUM

Note. When rear drum is removed, check diameter. See DRUM BRAKE SPECIFICATIONS .

FRONT BRAKE CALIPER

Note. When overhauling caliper, if cylinder bores are pitted or scored beyond repair, replace entire assembly.

Note. Use illustration for exploded view of front brake caliper assembly. see scheme 9see scheme 10.

1. Remove master cylinder from vehicle and separate reservoir from master cylinder. See «MASTER CYLINDER»(ref-163365-S02611857532004062800000) and «MASTER CYLINDER RESERVOIR»(ref-163365-S39640113092004062800000) under REMOVAL & INSTALLATION.
2. Remove circlip. (Scheme 19) On ABS vehicles, carefully pull out primary piston, then carefully pull out secondary piston. On non-ABS vehicles, remove piston stopper bolt and carefully apply air at stopper bolt hole to remove secondary piston.
3. To install, reverse removal procedure. On non-ABS vehicles, install piston stopper bolt after all components and circlip have been installed.

Scheme 19

Remove master cylinder from vehicle. See MASTER CYLINDER under REMOVAL & INSTALLATION. Master cylinder is not serviceable. If measurement shown in illustration is not 2.26" (57.4 mm) or greater, replace master cylinder. (Scheme 20)

Scheme 20

REAR WHEEL CYLINDER

Note. Use illustration for exploded view of rear wheel cylinder assembly. see scheme 16

GRAND VITARA & XL-7

DISC BRAKE SPECIFICATIONS (2003-04)

VITARA

DISC BRAKE SPECIFICATIONS (2003-04)

DRUM BRAKE SPECIFICATIONS (2003-04)

DRUM BRAKE SPECIFICATIONS (2003-04)

TIGHTENING TORQUE SPECIFICATIONS - FRONT (2003-04)

TIGHTENING TORQUE SPECIFICATIONS - REAR (2003-04)

TIGHTENING TORQUE SPECIFICATIONS - BRAKE CONTROL SYSTEMS (2003-04)

TIGHTENING TORQUE SPECIFICATIONS - FRONT (2003-04)

TIGHTENING TORQUE SPECIFICATIONS - REAR (2003-04)

TIGHTENING TORQUE SPECIFICATIONS - BRAKE CONTROL SYSTEMS (2003-04)