Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual — part 49

4A-4 Brake Control System and Diagnosis:

Pedal pulsation
(Pedal pulsates when
depressed for braking)

Damaged or loose wheel bearings

Replace wheel bearings.

Distorted steering knuckle or rear axle
shafts

Replace knuckle or rear axle shaft.

Excessive disc lateral runout

Check per instructions. If not within
specifications, replace or machine the disc.

Parallelism not within specifications

Check per instructions. If not with
specifications, replace or machine the disc.

Rear drums out of round

Check runout. Repair or replace drum as
necessary.

Braking noise

Glazed shoe linings, or foreign matters
stuck to linings

Repair or replace shoe lining.

Worn or distorted shoe linings

Replace shoe lining (or pad).

Loose front wheel bearings

Replace wheel bearing.

Distorted backing plates or loose
mounting bolts

Replace or retighten securing bolts.

Brake warning light turns
ON after engine start

Parking brake applied

Release parking brake and check that brake
warning light turns off.

Insufficient amount of brake fluid

Add brake fluid.

Brake fluid leaking from brake line

Investigate leaky point, correct it and add
brake fluid.

Brake warning light circuit faulty

Repair circuit.

Malfunctioning EBD system, if equipped
with ABS (ESP

®)

Check system referring to “EBD Warning Lamp
(Brake Warning Lamp) Comes ON Steady in
Section 4E”.

Brake warning light turns
on when brake is applied

Brake fluid leaking from brake line

Investigate leaky point, correct it and add
brake fluid.

Insufficient amount of brake fluid

Add brake fluid.

Brake warning light fails
to turn on even when
parking brake is applied

Brake warning light circuit open

Repair circuit.

ABS warning light or
ESP

®

warning light does

not turn ON for 2 – 3 sec.
after ignition switch has
turned ON

ABS warning light circuit open (including
check relay)

Repair or replace.

Malfunctioning ABS (ESP

®)

Check system referring to “ABS Warning Lamp
Does Not Come ON at Ignition Switch ON in
Section 4E” or “ESP

®

Warning Lamp Does

Not Come ON at Ignition Switch ON in Section
4F”.

ABS warning light or
ESP

®

warning light

remains ON after ignition
switch has turned ON for
2 – 3 sec.

Malfunctioning ABS (ESP

®)

Check system referring to “ABS Warning Lamp
Does Not Come ON at Ignition Switch ON in
Section 4E” or “ESP

®

Warning Lamp Does

Not Come ON at Ignition Switch ON in Section
4F”

Condition

Possible cause

Correction / Reference Item

Brake Control System and Diagnosis: 4A-5

Repair Instructions

Front Brake Hose / Pipe Removal and
Installation

S5JB0E4106011

CAUTION

!

Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal

1) Raise and support vehicle properly. Remove tire and

wheel.

NOTE
This operation is not necessary when
removing pipes connecting master cylinder.

2) Clean dirt and foreign material from both flexible

hose end and pipe end fittings.

3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.

Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Make sure that steering wheel is in straight-forward

position and flexible hose has not twist or kink.

• Tighten brake pipe flare nut to specified torque.

Tightening torque
Brake pipe flare nut for M10: 16 N·m (1.6 kgf-m,
12.0 lb-ft)
Brake pipe flare nut for M12: 19 N·m (1.9 kgf-m,
14.0 lb-ft)

• Check to make sure that flexible hose doesn’t contact

any part of suspension, both in extreme right and
extreme left turn conditions.
If it does at any point, remove and correct. Fill and
maintain brake fluid level in reservoir.

• Bleed brake system. Refer to “Air Bleeding of Brake

System in related manual”.

• Perform brake test and check installed part for fluid

leakage.

Rear Brake Hose / Pipe Removal and
Installation

S5JB0E4106012

CAUTION

!

Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal

1) Raise and support vehicle properly. Remove tire and

wheel.

2) Clean dirt and foreign material from both flexible

hose end and pipe end fittings.

3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.

Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Tighten brake pipe flare nut to specified torque.

Tightening torque
Brake pipe flare nut for M10: 16 N·m (1.6 kgf-m,
12.0 lb-ft)

• Fill and maintain brake fluid level in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake

System in related manual”.

• Perform brake test and check each installed part for

fluid leakage.

• Install clamps properly referring to the figure and

tighten bolts.

• When installing hose, make sure that it has no twist or

kink.

Master Cylinder Reservoir Removal and
Installation

S5JB0E4106014

CAUTION

!

Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal

1) Disconnect reservoir lead wire at coupler (1).
2) Clean outside of reservoir (2) and master cylinder

(3).

3

2

1

I5JB0A410011-02

4A-6 Brake Control System and Diagnosis:

3) Take out fluid with syringe or such.
4) Disconnect clutch reservoir hose (1) from reservoir

(2) for M/T vehicle.

5) Remove reservoir connector pin (1) by using special

tool and then reservoir.

Special tool
(A): 09916–44310

Installation

1) Lubricate new grommets with the same fluid as the

one to fill reservoir (1) with. Then press-fit grommets
(3) to master cylinder (2). Grommets (3) must be
seated in place.

2) Install reservoir (1) and drive in reservoir connector

pin (2) by using special tool (A). till both of its ends at
the right and left of reservoir becomes the same
length.

Special tool
(A): 09916–44310

3) Connect clutch reservoir hose (1) to reservoir (2) for

M/T vehicle.

4) Connect reservoir lead wire at coupler.
5) Fill reservoir with specified fluid.
6) After installing, bleed air from brake system referring

to “Air Bleeding of Brake System in related manual”
and at the same time bleed air from clutch system
referring to “Air Bleeding of Clutch System in Section
5C in related manual” for M/T vehicle.

7) Upon completion of installation, check for fluid

leakage.

Master Cylinder Assembly Removal and
Installation

S5JB0E4106015

CAUTION

!

• Never disassemble master cylinder.

Disassembly will spoil its original function.
If faulty condition is found, replace it with
new one as an assembly.

• Do not allow brake fluid to get on painted

surfaces. Painted surfaces will be
damaged by brake fluid, flush it with water
immediately if any fluid is spilled.

2

1

I5JB0A410012-02

1

(A)

I5JB0A410013-02

1

2

3

3

I5JB0A410014-01

I5JB0A410015-01

2

1

I5JB0A410012-02

Brake Control System and Diagnosis: 4A-7

Removal

1) Disconnect reservoir lead wire at coupler (1).

2) Clean outside of master cylinder and take out fluid

with syringe or such.

3) Disconnect clutch reservoir hose (1) from reservoir

(2) for M/T vehicle.

4) Loosen brake pipe flare nuts (2) for master cylinder

(1).

5) Disconnect brake pipes (3) from master cylinder (1).

6) Loosen master cylinder fixing nuts (1) and then

remove master cylinder (2) with reservoir (3) from
brake booster (4).

Installation

1) Install new master cylinder O-ring (1) to master

cylinder.

2) Install master cylinder (2) with reservoir (3) to brake

booster (4).

3) Tighten master cylinder fixing nuts (1) to specified

torque.

Tightening torque
Master cylinder fixing nut (a): 18 N·m (1.8 kgf-
m, 13.0 lb-ft)

1

I5JB0A410016-02

2

1

I5JB0A410012-02

2

3

3

1

I5JB0A410017-01

1

2

1

3

4

I5JB0A410018-02

1

2

3

4

I5JB0A410019-01

1,(a)

1,(a)

I5JB0A410021-02