Suzuki Grand Vitara JB416 / JB420 / JB419. Manual — part 271

4A-15 Brake Control System and Diagnosis:

Master Cylinder Assembly Removal and
Installation

S6JB0A4106015

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.

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) (M/T model).

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) Apply grease to piston rod “A”.

Use specified grease to spare parts.

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

booster (4).

1

I5JB0A410016-02

2

1

I5JB0A410012-02

2

3

3

1

I5JB0A410017-01

1

2

1

3

4

I5JB0A410018-02

1

2

3

4

“A”

I6JB0B410003-01

Brake Control System and Diagnosis: 4A-16

4) 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)

5) Connect brake pipes to master cylinder and tighten

brake 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)

6) Connect clutch reservoir hose (1) to reservoir (2) (M/

T model).

7) Connect reservoir lead wire at coupler.
8) Fill reservoir with specified brake fluid.
9) After installing, bleed air from brake system referring

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

10) Perform brake test and check each installed part for

fluid leakage.

Master Cylinder Assembly Inspection

S6JB0A4106016

• 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)

1,(a)

I5JB0A410021-02

1,(a)

I5JB0A410020-01

2

1

I5JB0A410012-02

I5JB0A410022-01

4A-17 Brake Control System and Diagnosis:

Brake Booster Components

S6JB0A4106017

NOTE
The difference between RHD model and LHD model booster components is the location of vacuum
hose.

I6JB0A410002-03

[A]: RHD model

1. Brake master cylinder

assembly

6. Clevis pin

11. To brake vacuum hose

[B]: LHD model

2. Brake booster assembly

7. Clip

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

[C]: M16A engine model

3. Gasket

8. Booster attaching nut

: 13 N

⋅m (1.3 kgf-m, 9.5 lb-ft)

[D]: J20A engine model

4. Push rod clevis

9. Brake vacuum hose

: Be sure to direct arrow mark to engine
side, and location mark (12) to upward.

: 26 N

⋅m (2.6 kgf-m, 19.0 lb-ft)

[E]: F9Q engine model

5. Clevis pin lock nut

10. Master cylinder fixing nut

: Do not reuse.

Brake Control System and Diagnosis: 4A-18

Brake Booster Removal and Installation

S6JB0A4106018

CAUTION

!

Never disassemble brake booster.
Disassembly will spoil its original function. If
is found faulty, replace it with new one.

Removal

1) Disconnect brake pipes from ABS (ESP

®) hydraulic

unit / control module assembly.

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.

Installation

NOTE

• Check length of push rod clevis (2). Refer

to “Booster Push Rod Clevis Adjustment”.

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

referring to “Brake Booster Components”.

4) Install master cylinder referring to “Master Cylinder

Assembly Removal and Installation”.

5) Connect brake pipes to ABS (ESP

®) hydraulic unit /

control module assembly 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” and at the same
time bleed air from clutch system referring to “Air
Bleeding of Clutch System in Section 5C” (M/T
model).

8) Perform brake test and check each installed part for

fluid leakage.

Booster Push Rod Clevis Adjustment

S6JB0A4106019

Install push rod clevis (1) so that measurement “a” is
obtained and torque nut (2) to specification.

Tightening torque
Clevis pin lock nut (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)

Clevis installing position (length “a”)
“a”: 133.5 – 134.5 mm (5.26 – 5.30 in.)

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

IYSQ01410050-01