Suzuki Grand Vitara JB416 / JB420. Manual - part 196

4A-1 Brake Control System and Diagnosis: 

Brakes

Brake Control System and Diagnosis

General Description

Brakes Construction

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When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder (2) to actuate pistons 
(two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two 
independent circuits. One connects front right and rear left brakes and the other connects front left and rear right 
brakes.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading / trailing 
shoes) for the rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and 
mechanical linkage system. The same brake shoes are used for both parking and foot brakes.

NOTE
The difference between RH steering vehicle and LH steering vehicle is the location of the brake master 
and the brake booster only.

 

A

2

8

1

5

3

4

6

7

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1. Brake booster

4. Primary side

7. Parking brake cable

2. Master cylinder

5. ABS hydraulic unit / control module assembly

8. 4-way joint

3. Secondary side

6. Parking brake lever

A: Forward

Brake Control System and Diagnosis:  4A-2

Front Brake Hose / Pipe Construction

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[A]: For LH steering vehicle

4. From ABS hydraulic unit to left front brake

9. Master cylinder fixing nut

[B]: For RH steering vehicle

5. ABS hydraulic unit / control module assembly

10. Brake joint bolt

1. From master cylinder primary to ABS hydraulic unit

6. Master cylinder

11. 4-way joint

2. From master cylinder secondary to ABS hydraulic unit

7. From ABS hydraulic unit to left rear brake

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

3. From ABS hydraulic unit to right front brake

8. From ABS hydraulic unit to right rear brake

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

4A-3 Brake Control System and Diagnosis: 

Rear Brake Hose / Pipe Construction

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Master Cylinder Assembly Construction

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The master cylinder has two pistons, two pressure seal (3) and two separating seal (4). Its hydraulic pressure is 
produced in the primary (A in the figure) and secondary (B) chambers. The hydraulic pressure produced in the primary 
chamber (A) acts on the front right and rear left brakes.
Also, the hydraulic pressure produced in the secondary chamber (B) acts on the front left and rear right brakes.

WARNING

!

 

Brake master cylinder cannot be disassembled. When anything faulty is found in it, it must be replaced 
as an assembly.

 

CAUTION

!

 

Brake master cylinder cannot be disassembled in principle. Should primary piston (1) have come off 
from cylinder while dismounting or handling it, wash it in the same specified fluid as that in reservoir 
and place it back in cylinder.

 

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1. To left rear brake hose

3. Left rear brake hose

2. To right rear brake hose

4. Right rear brake hose

Brake Control System and Diagnosis:  4A-4

Booster Assembly Construction

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The booster is located between the master cylinder and the brake pedal. It is so designed that the force created when 
the brake pedal is depressed is mechanically increased combined with the engine vacuum.

CAUTION

!

 

• Never disassemble brake booster assembly. If it is found faulty, replace it with new assembly.
• The torque values specified are for dry, unlubricated fasteners. If any hydraulic component is 

removed or brake line disconnected, bleed the brake system.

 

Diagnostic Information and Procedures

Brake Diagnosis Note

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Road Test for Brakes
Brakes should be tested on dry, clean, smooth and 
reasonably level roadway which is not crowned. 
Road test brakes by making brake applications with both 
light and heavy pedal forces at various speeds to 
determine if the vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the 
other without brake application. If it does, check the tire 
pressure, front end alignment and front suspension 
attachments for looseness. 
See diagnosis flow table for other causes.

Brake Fluid Inspection
Brake fluid leaks
Check the master cylinder fluid levels. While a slight 
drop in reservoir level does result from normal lining 
wear, an abnormally low level indicates a leak in the 
system. In such a case, check the entire brake system 

for leakage. If even a slight evidence of leakage is noted, 
the cause should be corrected or defective parts should 
be replaced.
If fluid level is lower than the minimum level of reservoir, 
refilling is necessary. 
Fill reservoir with specified brake fluid.

Brake fluid
: Refer to reservoir cap.

CAUTION

!

 

Since brake system of this vehicle is factory 
filled with brake fluid indicated on reservoir 
cap, do not use or mix different type of fluid 
when refilling; otherwise serious damage will 
occur.
Do not use old or used brake fluid, or any 
fluid from a unsealed container.

 

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2. Secondary piston

6. Secondary piston return spring

8. O-ring

5. Primary piston return spring

7. Grommet

9. Master cylinder body