Suzuki Grand Vitara JB416 / JB420. Manual — part 197

4A-5 Brake Control System and Diagnosis:

Substandard or contaminated brake fluid

CAUTION

!

Improper brake fluid, mineral oil or water in
the fluid may cause the brake fluid to boil or
the rubber components in the hydraulic
system to deteriorate.

If primary piston cups are swollen, then rubber parts
have deteriorated. The deterioration may also be
evidenced by swollen wheel cylinder piston cups on the
drum brake wheel.

If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol out
of the system. Replace all rubber parts in the system,
including hoses. Also, when working on the brake
mechanisms, check for fluid on the linings. If excessive
fluid is found, replace the linings.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to
contaminated fluid.

Brakes Symptom Diagnosis

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Condition

Possible cause

Correction / Reference Item

Not enough braking force Brake fluid leakage from brake lines

Locate leaking point and repair.

Brake disc or pads stained with fluid

Clean or replace.

Overheated brakes

Determine cause and repair.

Poor contact of shoes on brake drum

Repair for proper contact.

Brake shoes linings stained with fluid or
wet with water

Replace.

Badly worn brake shoe linings

Replace.

Defective wheel cylinders

Repair or replace.

Malfunctioning caliper assembly

Repair or replace.

Air in system

Bleed system.

Malfunctioning ABS (Antilock brake
system), if equipped

Check system and replace as necessary.

Brake pull
(Brakes not working in
unison)

Pad or shoe linings are wet with water or
stained with fluid in some brakes

Replace.

Drum-to-shoe clearance out of
adjustment in some brakes.
(malfunctioning auto adjusting
mechanism)

Check for inoperative auto adjusting
mechanism.

Drum is out of round in some brakes

Replace.

Wheel tires are inflated unequally

Inflate equally.

Malfunctioning wheel cylinders

Repair or replace.

Disturbed front end alignment

Adjust as prescribed.

Unmatched tires on same axle

Tires with approximately the same amount of
tread should be used on the same axle.

Restricted brake pipes or hoses

Check for soft hoses and damaged lines.
Replace with new hoses and new brake piping.

Malfunctioning caliper assembly

Check for stuck or sluggish pistons and proper
lubrication of caliper slide bush.

Loose suspension parts

Caliper should slide. Check all suspension
mountings.

Loose calipers

Check and torque bolts to specifications.

Brake locked
(For vehicles equipped
with ABS)

Malfunctioning ABS, if equipped

Check system and replace as necessary.

Excessive pedal travel
(Pedal stroke too large)

Partial brake system failure

Check brake systems and repair as necessary.

Insufficient fluid in master cylinder
reservoirs

Fill reservoirs with approved brake fluid. Check
for leaks and air in brake systems. Check
warning light. Bleed system if required.

Air in system (pedal soft / spongy)

Bleed system.

Rear brake system not adjusted
(malfunctioning auto adjusting
mechanism)

Repair auto adjusting mechanism. Adjust rear
brakes.

Bent brake shoes

Replace brake shoes.

Worn rear brake shoes

Replace brake shoes.

Brake Control System and Diagnosis: 4A-6

Dragging brakes
(A very light drag is
present in all disc brakes
immediately after pedal is
released)

Master cylinder pistons not returning
correctly

Replace master cylinder.

Restricted brake pipes or hoses

Check for soft hoses or damaged pipes and
replace with new hoes and/or new brake pipes.

Incorrect parking brake adjustment on
rear brakes

Check and adjust to correct specifications.

Weakened or broken return springs in
the brake

Replace.

Sluggish parking-brake cables or
linkage

Repair or replace.

Wheel cylinder or caliper piston sticking Repair as necessary.
Malfunctioning ABS, if equipped with
ABS

Check system and replace as necessary.

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

Check system referring to “ABS Check 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

Bulb burnt out

Replace bulb.

Brake warning light circuit open

Repair circuit.

ABS warning light does
not turn ON for 2 – 3 sec.
after ignition switch has
turned ON

Bulb burnt out

Replace bulb.

ABS warning light circuit open (including
check relay)

Repair or replace.

Malfunctioning ABS

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

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

Malfunctioning ABS

Check system referring to “ABS Warning Lamp
Comes ON Steady in Section 4E”.

Condition

Possible cause

Correction / Reference Item

4A-7 Brake Control System and Diagnosis:

Repair Instructions

Excessive Pedal Travel Check

S5JB0A4106001

1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 30

kg (66 lbs) load, measure pedal to carpet clearance
“c”.
If clearance “c” is less than specification, the most
possible cause is either rear brake shoes are worn
out beyond limit or air is in lines.
Should clearance “c” remain less than specification
even after replacement of brake shoes and bleeding
of system, other possible but infrequent cause is
malfunction of rear brake shoe adjusters or booster
push rod length out of adjustment.

Brake pedal arm to wall clearance “c”
When pedal is depressed at 300 N (30 kg, 66 lbs):
Over 70 mm (2.75 in.)

Brake Pedal Play Check

S5JB0A4106002

Pedal play should be within specification. If out of
specification, check brake light switch for proper
installation position and adjust if necessary.
Also check pedal shaft bolt and master cylinder pin
installation for looseness and replace if defective.

Brake pedal play “d”
: 1 – 8 mm (0.04 – 0.32 in.)

Brake Fluid Level Check

S5JB0A4106003

Be sure to use particular brake fluid either as indicated
on reservoir cap of that vehicle or recommended in
owner’s manual which comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines
marked on reservoir.
When warning light lights sometimes during driving,
replenish fluid to MAX line.
When fluid decreases quickly, inspect brake system for
leakage. Correct leaky points and then refill to specified
level.

CAUTION

!

Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

IYSQ01410009-01

IYSQ01410010-01

I5JB0A410005-01

Brake Control System and Diagnosis: 4A-8

Air Bleeding of Brake System

S5JB0A4106004

CAUTION

!

Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic rake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.

NOTE
Perform bleeding operation starting with
wheel cylinder farthest from master cylinder
and then at front caliper of the same brake
line. Do the same on the other brake line.

1) Fill master cylinder reservoir with specified brake

fluid and keep at least one-half full of fluid during
bleeding operation.

2) Remove bleeder plug cap.

Attach a vinyl tube (1) to bleeder plug of wheel
cylinder, and insert the other end into container (2).

3) Depress brake pedal several times, and then while

holding it depressed, loosen bleeder plug about one-
third to one half turn.

4) When fluid pressure in the cylinder is almost

depleted, retighten bleeder plug.

5) Repeat this operation until there are no more air

bubbles in hydraulic line.

6) When bubbles stop, depress and hold brake pedal

and tighten bleeder plug.

Tightening torque
Front brake caliper bleeder plug: 7 N·m (0.7 kgf-
m, 5.0 lb-ft)
Rear wheel cylinder bleeder plug: 7 N·m (0.7
kgf-m, 5.0 lb-ft)

7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid

pressure to pipe line and check for leakage.

9) Replenish fluid into reservoir up to “MAX” level.

10) Check brake pedal for “sponginess”. If found spongy,

repeat entire procedure of bleeding.

1. Right brake caliper

4. Left wheel cylinder

2. Left brake caliper

[A]: FRONT

3. Right wheel cylinder

[B]: REAR

I2RH01410013-01

I2RH01410015-01

1. MAX level mark

I2RH01410016-01

I2RH01410017-01

1

I5JB0A410006-01