Suzuki Grand Vitara JB627. Manual - part 173

4A-11 Brake Control System and Diagnosis: 

Booster Operation Check

S6JB0B4106010

There are two ways to perform this inspection, with and 
without a tester. Ordinarily, it is possible to roughly 
determine its condition without using a tester.

NOTE
For this check, make sure that no air is in 
hydraulic line.

 

Inspection without Tester
Check air tightness

1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same 

load as in ordinary braking and observe pedal travel. 
If pedal goes down deep the first time but its travel 
decreases as it is depressed the second and more 
times, air tightness is obtained.

4) If pedal travel doesn’t change, air tightness isn’t 

obtained.

NOTE
If defective, inspect vacuum lines and sealing 
parts, and replace any faulty part.
When this has been done, repeat the entire 
test.

 

Check operation

1) With engine stopped, depress brake pedal several 

times with the same load and make sure that pedal 
travel doesn’t change.

2) Start engine while depressing brake pedal. If pedal 

travel increases a little, operation is satisfactory. But 
no change in pedal travel indicates malfunction.

Check air tightness under load

1) With engine running, depress brake pedal. Then 

stop engine while holding brake pedal depressed.

[A]: Good

2. 2nd

1. 1st

3. 3rd

[B]: No Good

1. 1st, 2nd, 3rd

I5JB0A410008-01

I5JB0A410009-01

IYSQ01410018-01

IYSQ01410019-01

IYSQ01410020-01

Brake Control System and Diagnosis:  4A-12

2) Hold brake pedal depressed for 30 seconds. If pedal 

height does not change, condition is good. But it isn’t 
if pedal rises.

Front Brake Hose / Pipe Removal and 
Installation

S6JB0B4106011

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) Raise and support vehicle properly. Remove tire and 

wheel.

NOTE
This operation is not necessary when 
removing pipes connecting master cylinder.

 

2) Clean dirt and foreign material from both flexible 

hose end and pipe end fittings.

3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.

Installation
Reverse brake flexible hose removal procedure, noting 
the following.

• Tighten brake pipe flare nut to specified torque.

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

• Make sure that steering wheel is in straight-forward 

position and flexible hose has not twist or kink.

• Check to make sure that flexible hose doesn’t contact 

any part of suspension, both in extreme right and 
extreme left turn conditions. 
If it does at any point, remove and correct. Fill and 
maintain brake fluid level in reservoir.

• Bleed brake system. Refer to “Air Bleeding of Brake 

System”.

• Perform brake test and check installed part for fluid 

leakage.

Rear Brake Hose / Pipe Removal and 
Installation

S6JB0B4106012

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) Raise and support vehicle properly. Remove tire and 

wheel. 

2) Clean dirt and foreign material from both flexible 

hose end and pipe end fittings.

3) Drain brake fluid in reservoir. 
4) Remove brake flexible hose or pipe.

Installation
Reverse brake flexible hose removal procedure, noting 
the following.
• Fill and maintain brake fluid level in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake 

System”.

• Perform brake test and check each installed part for 

fluid leakage.

• Install clamps properly referring to the figure and 

tighten bolts.

• When installing hose, make sure that it has no twist or 

kink.

IYSQ01410021-01

4A-13 Brake Control System and Diagnosis: 

Master Cylinder Components

S6JB0B4106013

CAUTION

!

 

Never disassemble master cylinder. Disassembly will spoil its original function. If faulty condition is 
found, replace it with new one as an assembly.

 

[A]

[B]

4

5

3

3

2

2

1

7

6

8

(a)

I6JB0B410002-01

[A]: A/T model

3. Reservoir

7. O-ring

: Apply grease to piston rod

(Grease included in spare parts)

[B]: M/T model

4. Reservoir cap

8. Master cylinder fixing nut

1. Master cylinder body

5. Filter

: 18 N

⋅m (1.8 kgf-m, 13.0 lb-ft)

2. Grommet

: Apply brake fluid.

6. Reservoir connector pin

: Do not reuse.

Brake Control System and Diagnosis:  4A-14

Master Cylinder Reservoir Removal and 
Installation

S6JB0B4106014

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) (M/T model).

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) (M/

T model).

3

2

1

I5JB0A410011-02

2

1

I5JB0A410012-02

1

(A)

I5JB0A410013-02

1

2

3

3

I5JB0A410014-01

I5JB0A410015-01

2

1

I5JB0A410012-02