Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 50

4A-8 Brake Control System and Diagnosis: 

4) Connect brake pipes to master cylinder and 

tightenbrake 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)

5) Connect clutch reservoir hose (1) to reservoir (2) for 

M/T vehicle.

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

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

9) Perform brake test and check each installed part for 

fluid leakage.

Master Cylinder Assembly Inspection

S5JB0E4106016

• 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)

I5JB0A410020-01

2

1

I5JB0A410012-02

I5JB0A410022-01

Brake Control System and Diagnosis:  4A-9

Brake Booster Components

S5JB0E4106017

NOTE
The difference between RH steering vehicle and LH steering vehicle booster components is the 
location of vacuum hose.

 

1

2

3

4

5

6

7

8

10

(a)

(b)

(c)

9

11

I5JB0D410001-01

1. Brake master cylinder assembly

5. Clevis pin lock nut 

9. Brake vacuum hose

: 13 N

⋅m (1.3 kgf-m, 9.5 lb-ft)

2. Brake booster assembly

6. Clevis pin

10. Master cylinder fixing nut

: 26 N

⋅m (2.6 kgf-m, 19.0 lb-ft)

3. Gasket

7. Clip

11. To intake manifold

4. Push rod clevis

8. Booster attaching nut

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

4A-10 Brake Control System and Diagnosis: 

Brake Booster Removal and Installation

S5JB0E4106018

Removal

1) Disconnect brake pipes from ABS (ESP

®) hydraulic 

unit / control module assembly 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 
in related manual”.

 

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) Connect brake pipes to ABS (ESP

®) hydraulic unit / 

control module assembly (if equipped) 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 in related manual” 
and at the same time bleed air from clutch system 
referring to “Air Bleeding of Clutch System in Section 
5C in related manual” for M/T vehicle.

8) Perform brake test and check each installed part for 

fluid leakage.

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

Brake Control System and Diagnosis:  4A-11

Specifications

Tightening Torque Specifications

S5JB0E4107001

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

 

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

Special Tools and Equipment

Special Tool

S5JB0E4108001

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Brake pipe flare nut for M10

16

1.6 

12.0

)

 / ) / )

Brake pipe flare nut for M12

19

1.9 

14.0

)

 / )

Master cylinder fixing nut

18

1.8 

13.0

)

Booster attaching nut

13

1.3 

9.5

)

09916–44310
Valve guide remover (5 mm)
)

 / )