Suzuki Grand Vitara JB416 / JB420 / JB419. Manual - part 271

4A-15 Brake Control System and Diagnosis: 

Master Cylinder Assembly Removal and 
Installation

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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.

• 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) Disconnect reservoir lead wire at coupler (1).

2) Clean outside of master cylinder and take out fluid 

with syringe or such.

3) Disconnect clutch reservoir hose (1) from reservoir 

(2) (M/T model).

4) Loosen brake pipe flare nuts (2) for master cylinder 

(1).

5) Disconnect brake pipes (3) from master cylinder (1).

6) Loosen master cylinder fixing nuts (1) and then 

remove master cylinder (2) with reservoir (3) from 
brake booster (4).

Installation

1) Install new master cylinder O-ring (1) to master 

cylinder.

2) Apply grease to piston rod “A”.

Use specified grease to spare parts.

3) Install master cylinder (2) with reservoir (3) to brake 

booster (4).

1

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2

1

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2

3

3

1

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1

2

1

3

4

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1

2

3

4

“A”

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Brake Control System and Diagnosis:  4A-16

4) Tighten master cylinder fixing nuts (1) to specified 

torque.

Tightening torque
Master cylinder fixing nut (a):  18 N·m (1.8 kgf-
m, 13.0 lb-ft)

5) Connect brake pipes to master cylinder and tighten 

brake pipe flare nuts (1) to specified torque.

Tightening torque
Brake pipe flare nut for M10 (a):  16 N·m (1.6 kgf-
m, 12.0 lb-ft)
Brake pipe flare nut for M12 (a):  19 N·m (1.9 kgf-
m, 14.0 lb-ft)

6) Connect clutch reservoir hose (1) to reservoir (2) (M/

T model).

7) Connect reservoir lead wire at coupler.
8) Fill reservoir with specified brake fluid.
9) After installing, bleed air from brake system referring 

to “Air Bleeding of Brake System” and at the same 
time bleed air from clutch system referring to “Air 
Bleeding of Clutch System in Section 5C” (M/T 
model).

10) Perform brake test and check each installed part for 

fluid leakage.

Master Cylinder Assembly Inspection

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• Check master cylinder for corrosion and smooth 

operation.

• Inspect distance “a” to be the following.

If measurement is out of specification, replace master 
cylinder assembly.

Distance 
“a”: 72.0 mm (2.83 in.)

1,(a)

1,(a)

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1,(a)

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2

1

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4A-17 Brake Control System and Diagnosis: 

Brake Booster Components

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NOTE
The difference between RHD model and LHD model booster components is the location of vacuum 
hose.

 

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[A]: RHD model

1. Brake master cylinder 

assembly

6. Clevis pin

11. To brake vacuum hose

[B]: LHD model

2. Brake booster assembly

7. Clip

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

[C]: M16A engine model

3. Gasket

8. Booster attaching nut

: 13 N

⋅m (1.3 kgf-m, 9.5 lb-ft)

[D]: J20A engine model

4. Push rod clevis

9. Brake vacuum hose

: Be sure to direct arrow mark to engine 
side, and location mark (12) to upward.

: 26  N

⋅m (2.6 kgf-m, 19.0 lb-ft)

[E]: F9Q engine model

5. Clevis pin lock nut 

10. Master cylinder fixing nut

: Do not reuse.

Brake Control System and Diagnosis:  4A-18

Brake Booster Removal and Installation

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CAUTION

!

 

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

 

Removal

1) Disconnect brake pipes from ABS (ESP

®) hydraulic 

unit / control module assembly.

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.

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 

referring to “Brake Booster Components”.

4) Install master cylinder referring to “Master Cylinder 

Assembly Removal and Installation”.

5) Connect brake pipes to ABS (ESP

®) hydraulic unit / 

control module assembly referring to “ABS (ESP

®) 

Hydraulic Unit / Control Module Assembly Removal 
and Installation in Section 4E”.

6) Fill reservoir with specified brake fluid.
7) After installing, bleed air from brake system referring 

to “Air Bleeding of Brake System” and at the same 
time bleed air from clutch system referring to “Air 
Bleeding of Clutch System in Section 5C” (M/T 
model).

8) Perform brake test and check each installed part for 

fluid leakage.

Booster Push Rod Clevis Adjustment

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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

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1. Steering column

3

5

6,(a)

1

4

6,(a)

2

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