Suzuki Grand Vitara JB416 / JB420. Manual - part 199

4A-13 Brake Control System and Diagnosis: 

Master Cylinder Reservoir Removal and 
Installation

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CAUTION

!

 

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 reservoir (2) and master cylinder 

(3).

3) Take out fluid with syringe or such.
4) Disconnect clutch reservoir hose (1) from reservoir 

(2) for M/T vehicle.

5) Remove reservoir connector pin (1) by using special 

tool and then reservoir.

Special tool
(A):  09916–44310

Installation

1) When using new grommets (3), lubricate them with 

the same fluid as the one to fill reservoir (1) with. 
Then press-fit grommets (3) to master cylinder (2). 
Grommets (3) must be seated in place.

2) Install reservoir (1) and drive in reservoir connector 

pin (2) by using special tool (A). till both of its ends at 
the right and left of reservoir becomes the same 
length.

Special tool
(A):  09916–44310

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

M/T vehicle.

3

2

1

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2

1

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1

(A)

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1

2

3

3

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2

1

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Brake Control System and Diagnosis:  4A-14

4) Connect reservoir lead wire at coupler.
5) Fill reservoir with specified fluid.
6) 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” for M/T 
vehicle.

7) Upon completion of installation, check for fluid 

leakage.

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) for M/T vehicle.

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) 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

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4A-15 Brake Control System and Diagnosis: 

3) 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)

4) Connect brake pipes to master cylinder and tighten 

brake pipe flare nuts (1) to specified torque.

Tightening torque
Brake pipe flare nut (a):  16 N·m (1.6 kgf-m, 12.0 
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” and at the same 
time bleed air from clutch system referring to “Air 
Bleeding of Clutch System in Section 5C” for M/T 
vehicle.

9) 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.) or more

1,(a)

1,(a)

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1,(a)

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2

1

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Brake Control System and Diagnosis:  4A-16

Brake Booster Components

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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

9

10

(a)

(b)

(c)

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1. Brake master cylinder assembly

5. Clevis pin lock nut 

9. Brake vacuum hose

: 26 N

⋅m (2.6 kgf-m, 19.0 lb-ft)

2. Brake booster assembly

6. Clevis pin

10. Master cylinder fixing nut

3. Gasket

7. Clip

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

4. Push rod clevis

8. Booster attaching nut

: 13 N

⋅m (1.3 kgf-m, 9.5 lb-ft)