Suzuki Grand Vitara JB419. Service manual — part 82

Propeller Shaft: 3D-2

Repair Instructions

Propeller Shaft Removal and Installation

S5JB0B3406002

Removal

1) Hoist vehicle.
2) Give match marks (1) on joint flange and propeller

shaft as shown in the figure.

3) Remove rear propeller shaft.
4) Drain transfer oil when removed front propeller shaft

from transfer, if necessary.

Installation
Reverse removal procedure to install propeller shaft
noting the following points.
• Clean and inspect sliding portion of propeller shaft

end (where oil seal contacts) before installation and if
even small dent or scratch exists, correct end clean it
again.
Then apply grease inside splines of propeller shaft.

“B”: Grease 99000–25010 (SUZUKI Super Grease
A)

• Install propeller shaft aligning match marks.

Otherwise, vibration may occur during driving.

• Use the following specification to torque universal joint

flange nuts and bolts. For front propeller shaft flange
bolt (front differential side), apply thread lock cement
to thread part of bolts if reused.

• Fill transfer oil, if removed front propeller shaft

referring to “Transfer Oil Change in Section 3C in
related manual”, if necessary.

“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)

Tightening torque
Front propeller shaft flange bolt (a): 30 N·m (3.0
kgf-m, 22.0 lb-ft)
Rear propeller shaft flange nut (b): 85 N·m (8.5
kgf-m, 61.5 lb-ft)

[A]: Front propeller shaft
[B]: Rear propeller shaft

I5JB0A340002-02

IYSQ01521009-01

[A]: Front propeller shaft
[B]: Rear propeller shaft

I5JB0A340004-01

3D-3 Propeller Shaft:

Specifications

Tightening Torque Specifications

S5JB0B3407001

NOTE
The specified tightening torque is also described in the following.
“Propeller Shaft Construction”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S5JB0B3408001

NOTE
Required service material is also described in the following.
“Propeller Shaft Construction”

Fastening part

Tightening torque

Note

⋅m

kgf-m

lb-ft

Front propeller shaft flange bolt

3.0

22.0

)

Rear propeller shaft flange nut

8.5

61.5

)

Material

SUZUKI recommended product or Specification

Note

Grease

SUZUKI Super Grease A

P/No.: 99000–25010

)

Thread lock cement

Thread Lock Cement Super 1322

P/No.: 99000–32110

)

Table of Contents 4- i

Section 4

CONTENTS

Brakes

Precautions . . . . . . . . . . . . . 4-*

Precautions. . . . . . . . . . . . . . . .. 4-*

Precautions for Brakes. . . . . . . . . . ... 4-*

Brake Control System and Diagnosis . 4A-*

General Description . . . . . . . . . . . . 4A-*

Brakes Construction. . . . . . . . . . . .4A-*
Front Brake Hose / Pipe Construction. . . . ..4A-*
Rear Brake Hose / Pipe Construction . . . . ..4A-*
Master Cylinder Assembly Construction . . . ..4A-*
Booster Assembly Construction . . . . . . ...4A-*

Diagnostic Information and Procedures. . . 4A-*

Brake Diagnosis Note . . . . . . . . . . ..4A-*
Brakes Symptom Diagnosis. . . . . . . . .4A-*

Repair Instructions . . . . . . . . . . . .. 4A-*

Excessive Pedal Travel Check. . . . . . . .4A-*
Brake Pedal Play Check . . . . . . . . . ..4A-*
Brake Fluid Level Check . . . . . . . . . ..4A-*
Air Bleeding of Brake System . . . . . . . ..4A-*
Brake Pedal Free Height Adjustment. . . . ...4A-*
Brake Light Switch Adjustment . . . . . . . 4A-*
Brake Flexible Hose and Pipe Check. . . . ...4A-*
Master Cylinder Check. . . . . . . . . . .4A-*
Flushing Brake Hydraulic System . . . . . . 4A-*
Booster Operation Check. . . . . . . . . .4A-*
Front Brake Hose / Pipe Removal and

Installation. . . . . . . . . . . . . . ..4A-*

Rear Brake Hose / Pipe Removal and

Installation. . . . . . . . . . . . . . ..4A-*

Master Cylinder Components. . . . . . . ...4A-*
Master Cylinder Reservoir Removal and

Installation. . . . . . . . . . . . . . ..4A-*

Master Cylinder Assembly Removal and

Installation. . . . . . . . . . . . . . ..4A-*

Master Cylinder Assembly Inspection . . . . ..4A-*
Brake Booster Components. . . . . . . . .4A-*
Brake Booster Removal and Installation . . . ..4A-*
Booster Push Rod Clevis Adjustment . . . . ..4A-*

Specifications. . . . . . . . . . . . . ... 4A-*

Tightening Torque Specifications. . . . . . .4A-*

Special Tools and Equipment . . . . . . . . 4A-*

Recommended Service Material. . . . . . ..4A-*
Special Tool . . . . . . . . . . . . . . .4A-*

Front Brakes . . . . . . . . . . . .4B-*

General Description . . . . . . . . . . . . 4B-*

Front Disc Brake Caliper Assembly

Construction . . . . . . . . . . . . . .. 4B-*

Repair Instructions . . . . . . . . . . . .. 4B-*

Front Disc Brake Components . . . . . . . 4B-*
Front Disc Brake Pad On-Vehicle Check . . . 4B-*
Front Disc Brake Pad Removal and

Installation . . . . . . . . . . . . . . . 4B-*

Front Brake Disc and Pad Inspection. . . . .. 4B-*
Front Disc Brake Caliper Removal and

Installation . . . . . . . . . . . . . . . 4B-*

Front Disc Brake Caliper Disassembly and

Assembly. . . . . . . . . . . . . . ... 4B-*

Front Disc Brake Caliper Inspection. . . . . 4B-*
Front Brake Disc Removal and Installation . . . 4B-*
Front Brake Disc Inspection . . . . . . . . 4B-*

Specifications. . . . . . . . . . . . . ... 4B-*

Tightening Torque Specifications. . . . . . 4B-*

Special Tools and Equipment . . . . . . . . 4B-*

Recommended Service Material . . . . . . . 4B-*

Rear Brakes. . . . . . . . . . . ...4C-*

General Description . . . . . . . . . . . . 4C-*

Rear Drum Brake Assembly Construction . . .. 4C-*

Repair Instructions . . . . . . . . . . . .. 4C-*

Rear Drum Brake Assembly Components . . .. 4C-*
Rear Brake Drum Removal and Installation. . 4C-*
Rear Brake Drum and Shoe Inspection . . . .. 4C-*
Rear Brake Shoe On-Vehicle Check. . . . ... 4C-*
Rear Brake Shoe Removal and Installation . . 4C-*
Rear Brake Shoe Inspection . . . . . . . ... 4C-*
Wheel Cylinder Removal and Installation . . ... 4C-*
Wheel Cylinder Inspection . . . . . . . . .. 4C-*
Rear Brake Back Plate Removal and

Installation . . . . . . . . . . . . . . . 4C-*

Specifications. . . . . . . . . . . . . ... 4C-*

Tightening Torque Specifications. . . . . . 4C-*

Special Tools and Equipment . . . . . . . . 4C-*

Recommended Service Material . . . . . . . 4C-*

Parking Brake . . . . . . . . . . ...4D-*

Component Location . . . . . . . . . . ... 4D-*

Parking Brake Cable Location. . . . . . . . 4D-*

Repair Instructions . . . . . . . . . . . .. 4D-*

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.

4-ii Table of Contents

Parking Brake Check and Adjustment . . . . 4D-*
Parking Brake Lever Removal and Installation . 4D-*
Parking Brake Cable Removal and

Installation. . . . . . . . . . . . . . . 4D-*

Specifications. . . . . . . . . . . . . ... 4D-*

Tightening Torque Specifications. . . . . . 4D-*

ABS. . . . . . . . . . . . . . . 4E-1

Precautions. . . . . . . . . . . . . . ...4E-1

Precautions in Diagnosing Troubles . . . . ...4E-1
Precautions in On-Vehicle Service. . . . . ..4E-1
Precautions in Hydraulic Unit Operation

Check. . . . . . . . . . . . . . . . 4E-1

General Description . . . . . . . . . . . .4E-2

ABS Description . . . . . . . . . . . . ..4E-2
ABS Hydraulic Unit / Control Module

Assembly Description . . . . . . . . . ...4E-2