Suzuki Grand Vitara JB416 / JB420. Manual — part 201

4B-3 Front Brakes:

Front Disc Brake Pad On-Vehicle Check

S5JB0A4206001

Inspect pad linings periodically according to
maintenance schedule whenever wheels are removed
(for tire rotation or other reason). Take a look through
hole of caliper and check lining thickness of outside and
inside pads.
If one of brake pad is worn to service limit, all linings
must be replaced at the same time.

Front brake pad thickness “a”
Standard: 11.0 mm (0.43 in.)
Limit: 2.0 mm (0.08 in.)

Front Disc Brake Pad Removal and Installation

S5JB0A4206002

Removal

1) Hoist vehicle and remove front wheel.
2) Remove caliper pin bolts (2).

3) Remove caliper (1) from caliper carrier.

NOTE
Hang removed caliper (1) with a wire hook (2)
or the like so as to prevent brake hose from
bending and twisting excessively or being
pulled. Don’t operate brake pedal with pads
removed.

4) Remove pads (3).

Installation

1) Install pad spring (1) and pads (2).

NOTE
Install brake pad with wear indicator (5) to
vehicle center side on right wheel brake.

1. Pad rim

3. Disc

2. Lining

1. Caliper
3. Disc

3

1

1

2

I5JB0A420002-01

3

1

2

I5JB0A420003-01

3. Disc

6. Shim

4. Caliper carrier

I1SQ01420004-01

5

2

2

1

3

4

6

6

6

I5JB0A420004-01

Front Brakes: 4B-4

2) Install caliper and tighten caliper (slide) pin bolts (1)

to specification.

NOTE
Make sure that boots are fit into groove
securely.

Tightening torque
Caliper pin bolt (a): 36 N·m (3.6 kgf-m, 26.0 lb-ft)

3) Tighten front wheel nuts to specification.

Tightening torque
Wheel nut (a): 100 N·m (10.0 kgf-m, 72.5 lb-ft)

4) Upon completion of installation, perform brake test.

Front Brake Disc and Pad Inspection

S5JB0A4206003

Brake Pad
Check pad lining for wear. When wear exceeds limit,
replace with new one.

CAUTION

!

Never polish pad lining with sandpaper. If
lining is polished with sandpaper, hard
particles of sandpaper will be deposited in
lining and may damage disc. When pad lining
requires correction, replace it with a new one.

NOTE
When pads are removed, visually inspect
caliper for brake fluid leak. Correct leaky
point, if any.

Front disc brake pad thickness (lining thickness)
Standard: 11.0 mm (0.43 in.)
Limit: 2.0 mm (0.08 in.)

Brake Disc
Before this inspection, brake pads must be removed.
Check disc surface for scratches in wearing parts.
Scratches on disc surface noticed at the time of
specified inspection or replacement are normal and disc
is not defective unless they are serious.
But when there are deep scratches or scratches all over
disc surface, replace it. When only one side is scratched,
polish and correct that side.

Front brake disc thickness “a”
Standard: 25 mm (1.020 in.)
Limit: 23 mm (0.905 in.)

Use wheel nuts (1) and suitable plain washers (2) to hold
the disc securely against the hub, then mount a dial
gauge (3) as shown in the figure and measure the runout
at 25 mm (0.98 in.) from the outer edge of the disc.

NOTE
Check front wheel bearing for looseness
before measurement.

1,(a)

I5JB0A420005-01

IYSQ01220010-01

I2RH01420005-01

IYSQ01420008-01

4B-5 Front Brakes:

Front brake disc deflection
Limit: 0.1 mm (0.004 in.)

Slide Pin Bolt / Cylinder Slide Pin
Check slide pin (bolt) for smooth movement as shown in
the figure.
If it is found faulty, correct or replace. Apply rubber
grease to slide pin (bolt) outer surface. Rubber grease
should be the on whose viscosity is less affected by such
low temperature a –40

°C (–40 °F).

Dust Boot
Check boot for breakage, crack and damage. If
defective, replace.

Front Disc Brake Caliper Removal and
Installation

S5JB0A4206005

Removal

1) Hoist vehicle and remove front wheel.
2) Remove brake flexible hose mounting bolt (1) from

caliper (2). As this will allow fluid to flow out of hose
(3), have a container ready beforehand.

CAUTION

!

Be careful not to twist flexible hose while
loosening the bolt.

3) Remove caliper pin bolts (1).
4) Remove caliper (2).

Installation

1) Apply rubber grease to slide pin, then install caliper

to caliper carrier.

NOTE
Use rubber grease whose viscosity varies
very little even at –40

°C (–40 °F) if applied.

2) Tighten caliper pin bolts (1) to specifications.

NOTE
Make sure that boots are fit into groove
securely.

Tightening torque
Caliper pin bolt (a): 36 N·m (3.6 kgf-m, 26.0 lb-ft)

IYSQ01420009-01

IYSQ01420021-01

1

2

3

I5JB0A420006-01

1

2

I5JB0A420007-01

1,(a)

I5JB0A420008-01

Front Brakes: 4B-6

3) Install brake flexible hose as shown and tighten

flexible hose joint bolt (1) to specification.

Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)

4) Tighten front wheel nuts to specification.

Tightening torque
Wheel nut (a): 100 N·m (10.0 kgf-m, 72.5 lb-ft)

5) After completing installation, fill reservoir with

specified brake fluid and bleed brake system. Check
each installed part for oil leakage and perform brake
test.

Front Disc Brake Caliper Disassembly and
Assembly

S5JB0A4206006

Disassembly

NOTE
Before disassembly, clean all around caliper
with brake fluid.

1) Remove disc brake piston with air blown into flexible

hose joint bolt installation hole.

WARNING

!

Do not apply too highly compressed air
which will cause piston to jump out of
cylinder. Place a cloth (1) to prevent piston
from damage, it should be taken out
gradually with moderately compressed air.
Do not place your fingers in front of piston
when using compressed air.

2) Remove cylinder boot.

CAUTION

!

Be careful not to damage inside (bore side) of
cylinder.

3) Remove piston seal using a thin blade like a

thickness gauge, etc.

CAUTION

!

Be careful not to damage inside (bore side) of
cylinder.

4) Remove bleeder plug and cap from caliper.

Assembly
Reassemble front brake in reverse order of disassembly,
noting the following points.

CAUTION

!

• Wash each part cleanly before installation

in the same fluid as the one used in master
cylinder reservoir.

• Never use other fluid or thinner.
• Before installing piston and cylinder boot

to cylinder, apply fluid to them.

• After reassembling brake lines, bleed air

from them.

• Before installing piston to cylinder, apply

rubber grease to inside (bore side) of
cylinder.

1,(a)

I5JB0A420009-02

IYSQ01220010-01

I2RH01420011-01

I2RH01420013-01