Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 48

4-1 Precautions: 

Brakes

Precautions

Precautions

Precautions for Brakes

S5JB0E4000001

Suspension Caution
Refer to “Suspension Caution in Section 00 in related manual”.

Wheels and Tires Caution
Refer to “Wheels and Tires Caution in Section 00 in related manual”.

Brake Caution
Refer to “Brakes Caution and Note in Section 00”.

General Precautions
Refer to “General Precautions in Section 00 in related manual”.

Vehicle Lifting Points
Refer to “Vehicle Lifting Points in Section 0A in related manual”.

Fastener Caution
Refer to “Fastener Caution in Section 00 in related manual”.

Fastener Information
Refer to “Fastener Information in Section 0A in related manual”.

Brake Control System and Diagnosis:  4A-1

Brakes

Brake Control System and Diagnosis

General Description

Brakes Construction

S5JB0E4101001

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

I5JB0A410001-02

1. Brake booster

4. Primary side

7. Parking brake cable

2. Master cylinder

5. ABS (ESP

®) hydraulic unit / control module assembly

8. 4-way joint

3. Secondary side

6. Parking brake lever

A: Forward

4A-2 Brake Control System and Diagnosis: 

Front Brake Hose / Pipe Construction

S5JB0E4101002

I5JB0A410002-03

[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 (ESP

®) 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 (ESP

®) 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 (ESP

®) hydraulic unit to right rear brake

: 11 N

⋅m (1.1 kgf-m, 8.0 lb-ft)

Brake Control System and Diagnosis:  4A-3

Diagnostic Information and Procedures

Brakes Symptom Diagnosis

S5JB0E4104002

Condition

Possible cause

Correction / Reference Item

Not enough braking force Brake fluid leakage from brake lines

Locate leaking point and repair.

Brake disc or pads stained with fluid

Clean or replace.

Overheated brakes

Determine cause and repair.

Poor contact of shoes on brake drum

Repair for proper contact.

Brake shoes linings stained with fluid or 
wet with water

Replace.

Badly worn brake shoe linings

Replace.

Defective wheel cylinders

Repair or replace.

Malfunctioning caliper assembly

Repair or replace.

Air in system

Bleed system.

Malfunctioning ABS (ESP

®), if equipped Check system and replace as necessary.

Brake pull 
(Brakes not working in 
unison)

Pad or shoe linings are wet with water or 
stained with fluid in some brakes

Replace.

Drum-to-shoe clearance out of 
adjustment in some brakes. 
(malfunctioning auto adjusting 
mechanism)

Check for inoperative auto adjusting 
mechanism.

Drum is out of round in some brakes

Replace.

Wheel tires are inflated unequally

Inflate equally.

Malfunctioning wheel cylinders

Repair or replace.

Disturbed front end alignment

Adjust as prescribed.

Unmatched tires on same axle

Tires with approximately the same amount of 
tread should be used on the same axle.

Restricted brake pipes or hoses

Check for soft hoses and damaged lines. 
Replace with new hoses and new brake piping.

Malfunctioning caliper assembly

Check for stuck or sluggish pistons and proper 
lubrication of caliper slide bush.

Loose suspension parts

Caliper should slide. Check all suspension 
mountings.

Loose calipers

Check and torque bolts to specifications.

Brake locked
(For vehicles equipped 
with ABS (ESP

®

))

Malfunctioning ABS (ESP

®), if equipped Check system and replace as necessary.

Excessive pedal travel
(Pedal stroke too large)

Partial brake system failure

Check brake systems and repair as necessary.

Insufficient fluid in master cylinder 
reservoirs

Fill reservoirs with approved brake fluid. Check 
for leaks and air in brake systems. Check 
warning light. Bleed system if required.

Air in system (pedal soft / spongy)

Bleed system.

Rear brake system not adjusted 
(malfunctioning auto adjusting 
mechanism)

Repair auto adjusting mechanism. Adjust rear 
brakes.

Bent brake shoes

Replace brake shoes.

Worn rear brake shoes

Replace brake shoes.

Dragging brakes
(A very light drag is 
present in all disc brakes 
immediately after pedal is 
released)

Master cylinder pistons not returning 
correctly

Replace master cylinder.

Restricted brake pipes or hoses

Check for soft hoses or damaged pipes and 
replace with new hoes and/or new brake pipes.

Incorrect parking brake adjustment on 
rear brakes

Check and adjust to correct specifications.

Weakened or broken return springs in 
the brake

Replace.

Sluggish parking-brake cables or 
linkage

Repair or replace.

Wheel cylinder or caliper piston sticking Repair as necessary.
Malfunctioning ABS (ESP

®), if equipped  Check system and replace as necessary.