Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual — part 50
4A-8 Brake Control System and Diagnosis:
4) Connect brake pipes to master cylinder and
tightenbrake pipe flare nuts (1) to specified torque.
Tightening torque
Brake pipe flare nut for M10 (a): 16 N·m (1.6 kgf-
m, 12.0 lb-ft)
Brake pipe flare nut for M12 (a): 19 N·m (1.9 kgf-
m, 14.0 lb-ft)
5) Connect clutch reservoir hose (1) to reservoir (2) for
M/T vehicle.
6) Connect reservoir lead wire at coupler.
7) Fill reservoir with specified brake fluid.
8) 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.
9) Perform brake test and check each installed part for
fluid leakage.
Master Cylinder Assembly Inspection
S5JB0E4106016
• Check master cylinder for corrosion and smooth
operation.
• Inspect distance “a” to be the following.
If measurement is out of specification, replace master
cylinder assembly.
Distance
“a”: 72.0 mm (2.83 in.)
1,(a)
I5JB0A410020-01
2
1
I5JB0A410012-02
I5JB0A410022-01
Brake Control System and Diagnosis: 4A-9
Brake Booster Components
S5JB0E4106017
NOTE
The difference between RH steering vehicle and LH steering vehicle booster components is the
location of vacuum hose.
1
2
3
4
5
6
7
8
10
(a)
(b)
(c)
9
11
I5JB0D410001-01
1. Brake master cylinder assembly
5. Clevis pin lock nut
9. Brake vacuum hose
: 13 N
⋅m (1.3 kgf-m, 9.5 lb-ft)
2. Brake booster assembly
6. Clevis pin
10. Master cylinder fixing nut
: 26 N
⋅m (2.6 kgf-m, 19.0 lb-ft)
3. Gasket
7. Clip
11. To intake manifold
4. Push rod clevis
8. Booster attaching nut
: 18 N
⋅m (1.8 kgf-m, 13.0 lb-ft)
4A-10 Brake Control System and Diagnosis:
Brake Booster Removal and Installation
S5JB0E4106018
Removal
1) Disconnect brake pipes from ABS (ESP
®) hydraulic
unit / control module assembly if equipped.
2) Remove master cylinder assembly, referring to
“Master Cylinder Assembly Removal and
Installation”.
3) Disconnect brake vacuum hose from brake booster.
4) Remove clip (2) and the disconnect clevis pin (3).
5) Remove attaching nuts (1) and then remove booster
as shown in the figure.
CAUTION
!
Never disassemble brake booster.
Disassembly will spoil its original function. If
is found faulty, replace it with new one.
Installation
NOTE
• Check length of push rod clevis (2). Refer
to “Booster Push Rod Clevis Adjustment
in related manual”.
1) Install gasket to booster and then install booster to
dash panel as shown in the figure. Then connect
booster push rod clevis (2) to pedal arm (3) with
clevis pin inserting from left (4) and clip (5).
2) Tighten booster attaching nuts (6) to the specified
torque.
Tightening torque
Booster attaching nut (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
3) Connect brake vacuum hose to brake booster.
4) Install master cylinder referring to “Master Cylinder
Assembly Removal and Installation”.
5) Connect brake pipes to ABS (ESP
®) hydraulic unit /
control module assembly (if equipped) referring to
“ABS (ESP
®) Hydraulic Unit / Control Module
Assembly Removal and Installation in Section 4E”.
6) Fill reservoir with specified brake fluid.
7) 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.
8) Perform brake test and check each installed part for
fluid leakage.
4. Steering column
5. Brake pedal arm
5
2
1
4
3
1
I5JB0A410024-01
1. Steering column
3
5
6,(a)
1
4
6,(a)
2
I5JB0A410025-01
Brake Control System and Diagnosis: 4A-11
Specifications
Tightening Torque Specifications
S5JB0E4107001
NOTE
The specified tightening torque is also described in the following.
“Front Brake Hose / Pipe Construction”
“Brake Booster Components”
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A in related
manual”.
Special Tools and Equipment
Special Tool
S5JB0E4108001
Fastening part
Tightening torque
Note
N
⋅m
kgf-m
lb-ft
Brake pipe flare nut for M10
16
1.6
12.0
Brake pipe flare nut for M12
19
1.9
14.0
Master cylinder fixing nut
18
1.8
13.0
Booster attaching nut
13
1.3
9.5
09916–44310
Valve guide remover (5 mm)
)
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