Suzuki Grand Vitara JB416 / JB420. Manual - part 200

4A-17 Brake Control System and Diagnosis: 

Brake Booster Removal and Installation

S5JB0A4106020

Removal

1) Disconnect brake pipes from ABS actuator if 

equipped.

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.

CAUTION

!

 

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

 

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.
4) Install master cylinder referring to “Master Cylinder 

Assembly Removal and Installation”.

5) After installing, fill reservoir with specified brake fluid 

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

Booster Push Rod Clevis Adjustment

S5JB0A4106023

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

Brake Control System and Diagnosis:  4A-18

Specifications

Tightening Torque Specifications

S5JB0A4107001

NOTE
The specified tightening torque is also described in the following.
“Front Brake Hose / Pipe Construction”
“Master Cylinder Components”
“Brake Booster Components”

 

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Recommended Service Material

S5JB0A4108001

NOTE
Required service material is also described in the following.
“Master Cylinder Components”

 

Special Tool

S5JB0A4108002

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Front brake caliper bleeder plug

7

0.7 

5.0

)

Rear wheel cylinder bleeder plug

7

0.7 

5.0

)

Master cylinder fixing nut

18

1.8 

13.0

)

Brake pipe flare nut

16

1.6 

12.0

)

Booster attaching nut

13

1.3 

9.5

)

Clevis pin lock nut

26

2.6 

19.0

)

09916–44310
Valve guide remover (5 mm)
)

 / )

4B-1 Front Brakes: 

Brakes

Front Brakes

General Description

Front Disc Brake Caliper Assembly Construction

S5JB0A4201001

This caliper is mounted to the brake caliper carrier with two caliper pin bolts. Hydraulic force, created by applying force 
to the brake pedal, is converted by the caliper to friction. The hydraulic force acts equally against the piston and the 
bottom of the caliper bore to move the piston outward and to move (slide) the caliper inward, resulting in a clamping 
action on the disc. This clamping action forces the pads (linings) against the disc, creating friction to stop the vehicle.
For components, refer to “Front Disc Brake Components”.

NOTE
Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber 
components may result. If any component is removed or line disconnected, bleed the brake system.
Replace pads in axle sets only. The torque values specified are for dry, unlubricated fasteners.

 

Front Brakes:  4B-2

Repair Instructions

Front Disc Brake Components

S5JB0A4206010

9

16

17

15

14

4

5

7

7

1

2

3

6

8

8

10

11

12

13

18

19

(b)

(a)

(c)

(d)

F

I5JB0A420001-02

1. Caliper

10. Piston seal

: Apply small amount of brake fluid to all around 
part of piston seal.

19. Brake disc

2.  Caliper pin bolt

11. Cylinder boot

: Apply small amount of brake fluid.

F: Forward

3. Slide pin boot

: Apply rubber grease.

12. Brake caliper carrier

: 36 N

⋅m (3.6 kgf-m, 26.0 lb-ft)

4. Slide pin

: Apply rubber grease.

13. Caliper carrier bolt

: 85 N

⋅m (8.5 kgf-m, 61.5 lb-ft)

5. Brake pad

14. Front caliper bleeder plug

: 7 N

⋅m (0.7 kgf-m, 5.0 lb-ft)

6. Wear indicator

15. Bleeder plug cap

: 23 N

⋅m (2.3 kgf-m, 17.0 lb-ft)

7. Shim

16. Brake flexible hose

: Do not reuse.

8. Pad spring

17. Flexible hose joint bolt

9. Disk brake piston

: Apply brake fluid to contact surface of cylinder.

18. Hose washer