Suzuki Grand Vitara JB416 / JB420. Manual - part 202

4B-7 Front Brakes: 

Piston seal
Piston seal is used to seal piston and cylinder and to 
adjust clearance between pad and disc. Replace with a 
new one at every overhaul. Fit piston seal into groove in 
cylinder taking care not to twist it.

Piston and boot

1) Before inserting piston (1) into cylinder, apply brake 

fluid to new cylinder boot (a) and piston (1). Install 
cylinder boot onto piston as shown in the figure.

2) Fit boot as it is in above figure into boot groove in 

cylinder with fingers.

3) Insert piston into cylinder by hand and fit boot in boot 

groove in piston.

4) To confirm that boot is fitted in its groove in cylinder 

properly, pull piston out of cylinder a little but do not 
take it all out.

NOTE
Boot’s face (1) should be at the same level 
from cylinder’s face (2) all around.

 

5) Install piston into cylinder by hand.

Caliper
Before installing caliper (cylinder body) to carrier, check 
to ensure that guide pin (pin bolt) inserted in each caliper 
carrier hole can be moved smoothly in thrust direction.

NOTE
Where temperature gets as low as –30 

°C in 

cold weather, use rubber grease whose 
viscosity varies very little even at –40 

°C (–40 

°F).

 

Front Disc Brake Caliper Inspection

S5JB0A4206007

Cylinder Boot
Check boots for breakage, crack and damage. If 
defective, replace.

A: 1 grooved side directed cylinder side
B: 2 grooved side directed cylinder pad side

I4RS0B420015-01

I2RH01420019-01

I2RH01420020-01

I4RS0A420004-01

IYSQ01420021-01

IYSQ01420022-01

Front Brakes:  4B-8

Piston Seal
Excessive or uneven wear of pad lining may indicate 
unsmooth return of the piston. In such a case, replace 
rubber seal.

Front Brake Disc Removal and Installation

S5JB0A4206008

Removal

1) Hoist vehicle and remove front wheel.
2) Remove caliper assembly (2) by loosening caliper 

carrier bolts (1) (2 pcs).

CAUTION

!

 

During removal, be careful not to damage 
brake flexible hose and not to depress brake 
pedal.

 

NOTE
Hang removed caliper with a wire hook or the 
like so as to prevent brake hose from 
bending and twisting excessively or being 
pulled.

 

3) Remove disc by using 8 mm bolts (1) (2 pcs).

Installation

1) Install disc to wheel hub.
2) Install caliper assembly to steering knuckle.
3) Tighten caliper carrier bolts (1) to specification.

Tightening torque
Caliper carrier bolt (a):  85 N·m (8.5 kgf-m, 61.5 
lb-ft)

4) Tighten front wheel nuts to specifications.

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

5) Upon completion of installation, perform brake test.

Front Brake Disc Inspection

S5JB0A4206009

Inspect front brake disc, referring to “Front Brake Disc 
and Pad Inspection”.

IYSQ01420023-01

1

2

I5JB0A420010-01

IYSQ01420025-01

1,(a)

I5JB0A420011-01

IYSQ01220010-01

4B-9 Front Brakes: 

Specifications

Tightening Torque Specifications

S5JB0A4207001

NOTE
The specified tightening torque is also described in the following.
“Front Disc Brake 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

S5JB0A4208001

NOTE
Required service material is also described in the following.
“Front Disc Brake Components”

 

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Caliper pin bolt

36

3.6 

26.0

)

 / )

Wheel nut

100

10.0 

72.5

)

 / ) / )

Flexible hose joint bolt

23

2.3 

17.0

)

Caliper carrier bolt

85

8.5 

61.5

)

Rear Brakes:  4C-1

Brakes

Rear Brakes

General Description

Rear Drum Brake Assembly Construction

S5JB0A4301001

The drum brake assembly has a self shoe clearance adjusting system so that drum-to-shoe clearance is maintained 
appropriate at all times. Rear brake is a drum type. It uses leading trailing operation when brake pedal is depressed 
and when parking brake is applied on level road.
For components, refer to “Rear Drum Brake Assembly Components”.

NOTE
Replace all components included in repair kits to service this drum brake. Lubricate parts as specified.

 

WARNING

!

 

If any hydraulic component is removed or brake line disconnected, bleed the brake system. The torque 
values specified are for dry, unlubricated fasteners.