Suzuki Grand Vitara JB416 / JB420. Manual - part 198

4A-9 Brake Control System and Diagnosis: 

Brake Pedal Free Height Adjustment

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Measure brake pedal free height between pedal and 
carpet installed on dash panel.
If the measurement is not within the specification, check 
the position of booster push rod clevis and/or brake light 
switch, referring to, “Master Cylinder Assembly 
Inspection”, “Booster Push Rod Clevis Adjustment” and/
or “Brake Light Switch Adjustment”. The free height 
varies depending on installation position of booster push 
rod clevis and stop light switch.

Brake pedal free height “a” from carpet
“a”: 131 – 141 mm (5.16 – 5.55 in.)

Brake Light Switch Adjustment

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CAUTION

!

 

Do not apply any oil or grease (including rust 
preventives, lubricant, etc.) to following 
sections.
* Stop light switch (1) (including its tip end)
* Switch (1) contacting section of brake pedal 
stay (3)
Oil or grease, if applied, will enter the contact 
point in the switch, causing contact failure. 
Also, when checking, adjusting or replacing 
brake switch, check that no oil or grease is 
attached to switch contacting section on 
brake pedal side or tip end of switch.
Wipe off oil or grease being attached.

 

Adjustment should be made as follows when installing 
switch (1). Pull up brake pedal toward you and while 
holding it there, adjust switch position so that clearance 
between end of switch thread (2) and brake pedal stay 
(3).

Clearance “b” between end of thread and brake 
pedal stay 
“b”: 1.5 – 2.5 mm (0.06 – 0.10 in.)

Brake Flexible Hose and Pipe Check

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The brake hose assembly should be checked for road 
hazard damage, for cracks and chafing of the flexible 
hose, for leaks and blisters. A light and mirror may be 
needed for an adequate inspection. If any of the above 
conditions are observed on the brake flexible hose, it is 
necessary to replace it.
Inspect the pipe for damage, cracks, dents and 
corrosion. If any defect is found, replace it.

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3

2

1

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Brake Control System and Diagnosis:  4A-10

Master Cylinder Check

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Check for a cracked master cylinder casting or brake 
fluid around the master cylinder. Leaks are indicated 
only if there is at least a drop of fluid. A damp condition is 
not abnormal.

Flushing Brake Hydraulic System

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It is recommended that entire hydraulic system be 
thoroughly flushed with clean brake fluid whenever new 
parts are installed in hydraulic system.
Periodical change of brake fluid is also recommended.

Booster Operation Check

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There are two ways to perform this inspection, with and 
without a tester. Ordinarily, it is possible to roughly 
determine its condition without using a tester.

NOTE
For this check, make sure that no air is in 
hydraulic line.

 

Inspection without Tester
Check air tightness

1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same 

load as in ordinary braking and observe pedal travel. 
If pedal goes down deep the first time but its travel 
decreases as it is depressed the second and more 
times, air tightness is obtained.

4) If pedal travel doesn’t change, air tightness isn’t 

obtained.

NOTE
If defective, inspect vacuum lines and sealing 
parts, and replace any faulty part.
When this has been done, repeat the entire 
test.

 

Check operation

1) With engine stopped, depress brake pedal several 

times with the same load and make sure that pedal 
travel doesn’t change.

2) Start engine while depressing brake pedal. If pedal 

travel increases a little, operation is satisfactory. But 
no change in pedal travel indicates malfunction.

[A]: Good

2. 2nd

1. 1st

3. 3rd

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[B]: No Good

1. 1st, 2nd, 3rd

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4A-11 Brake Control System and Diagnosis: 

Check air tightness under load

1) With engine running, depress brake pedal. Then 

stop engine while holding brake pedal depressed.

2) Hold brake pedal depressed for 30 seconds. If pedal 

height does not change, condition is good. But it isn’t 
if pedal rises.

Front Brake Hose / Pipe Removal and 
Installation

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CAUTION

!

 

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) Raise and support vehicle properly. Remove tire and 

wheel.

NOTE
This operation is not necessary when 
removing pipes connecting master cylinder.

 

2) Clean dirt and foreign material from both flexible 

hose end and pipe end fittings.

3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.

Installation
Reverse brake flexible hose removal procedure, noting 
the following.
• Make sure that steering wheel is in straight-forward 

position and flexible hose has not twist or kink.

• Check to make sure that flexible hose doesn’t contact 

any part of suspension, both in extreme right and 
extreme left turn conditions. 
If it does at any point, remove and correct. Fill and 
maintain brake fluid level in reservoir.

• Bleed brake system. Refer to “Air Bleeding of Brake 

System”.

• Perform brake test and check installed part for fluid 

leakage.

Rear Brake Hose / Pipe Removal and 
Installation

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CAUTION

!

 

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) Raise and support vehicle properly. Remove tire and 

wheel. 

2) Clean dirt and foreign material from both flexible 

hose end and pipe end fittings.

3) Drain brake fluid in reservoir. 
4) Remove brake flexible hose or pipe.

Installation
Reverse brake flexible hose removal procedure, noting 
the following.
• Fill and maintain brake fluid level in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake 

System”.

• Perform brake test and check each installed part for 

fluid leakage.

• Install clamps properly referring to the figure and 

tighten bolts.

• When installing hose, make sure that it has no twist or 

kink.

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Brake Control System and Diagnosis:  4A-12

Master Cylinder Components

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CAUTION

!

 

Never disassemble master cylinder. Disassembly will spoil its original function. If faulty condition is 
found, replace it with new one as an assembly.

 

[A]

[B]

4

5

3

3

2

2

1

7

6

8

(a)

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[A]: A/T vehicle

2. Grommet

: Apply brake fluid.

5. Filter

8. Master cylinder fixing nut

[B]: M/T vehicle

3. Reservoir

6. Reservoir connector pin

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

1. Master cylinder body

4. Reservoir cap

7. O-ring

: Do not reuse.