Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 51

 

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Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 51

 

 

4B-1 Front Brakes: 

Brakes

Front Brakes

Repair Instructions

Front Disc Brake Pad Removal and Installation

S5JB0E4206003

Removal

1) Hoist vehicle and remove front wheel.
2) Remove caliper pin bolts (2).

3) Remove caliper (1) from caliper carrier.

NOTE
Hang removed caliper (1) with a wire hook (2) 
or the like so as to prevent brake hose from 
bending and twisting excessively or being 
pulled. Don’t operate brake pedal with pads 
removed.

 

4) Remove pads (3).

Installation

1) Install pad spring (1) and pads (2).

NOTE
Install brake pad with wear indicator (5) to 
vehicle center side on right wheel brake.

 

2) Install caliper and tighten caliper (slide) pin bolts (1) 

to specified torque.

NOTE
Make sure that boots are fit into groove 
securely.

 

Tightening torque
Caliper pin bolt (a):  36 N·m (3.6 kgf-m, 26.0 lb-ft)

1. Caliper
3. Disc

3

1

2

I5JB0A420003-01

I1SQ01420004-01

3. Disc

6. Shim

4. Caliper carrier

5

2

2

1

3

4

6

6

6

I5JB0A420004-01

1,(a)

I5JB0A420005-01

Front Brakes:  4B-2

3) Install wheel and lower vehicle.
4) Tighten wheel nuts to specified torque.

Tightening torque
Wheel nut:  100 N·m (10.0 kgf-m, 72.5 lb-ft)

5) Upon completion of installation, perform brake test.

Front Disc Brake Caliper Removal and 
Installation

S5JB0E4206005

Removal

1) Hoist vehicle and remove front wheel.
2) Remove brake flexible hose mounting bolt (1) from 

caliper (2). As this will allow fluid to flow out of hose 
(3), have a container ready beforehand.

CAUTION

!

 

Be careful not to twist flexible hose while 
loosening the bolt.

 

3) Remove caliper pin bolts.
4) Remove caliper.

Installation

1) Apply rubber grease to slide pin, then install caliper 

to caliper carrier.

NOTE
Use rubber grease whose viscosity varies 
very little even at –40 

°C (–40 °F) if applied.

 

2) Tighten caliper pin bolts to specified torque.

NOTE
Make sure that boots are fit into groove 
securely.

 

Tightening torque
Caliper pin bolt:  36 N·m (3.6 kgf-m, 26.0 lb-ft)

3) Install brake flexible hose as shown and tighten 

flexible hose joint bolt (1) to specified torque.

Tightening torque
Flexible hose joint bolt (a):  23 N·m (2.3 kgf-m, 
17.0 lb-ft)

4) Install wheel and lower vehicle.
5) Tighten wheel nuts to specified torque.

Tightening torque
Wheel nut:  100 N·m (10.0 kgf-m, 72.5 lb-ft)

6) After completing installation, fill reservoir with 

specified brake fluid and bleed brake system. Check 
each installed part for oil leakage and perform brake 
test.

Front Brake Disc Removal and Installation

S5JB0E4206008

Removal

1) Hoist vehicle and remove front wheel.
2) Remove caliper assembly (2) by loosening caliper 

carrier bolts (1) (2 pcs).

CAUTION

!

 

During removal, be careful not to damage 
brake flexible hose and not to depress brake 
pedal.

 

NOTE
Hang removed caliper with a wire hook or the 
like so as to prevent brake hose from 
bending and twisting excessively or being 
pulled.

 

1

2

3

I5JB0A420006-01

1,(a)

I5JB0A420009-02

1

2

I5JB0A420010-01

4B-3 Front Brakes: 

3) Remove disc by using 8 mm bolts (1) (2 pcs).

Installation

1) Install disc to wheel hub.
2) Install caliper assembly to steering knuckle.
3) Tighten caliper carrier bolts (1) to specification.

Tightening torque
Caliper carrier bolt (a):  85 N·m (8.5 kgf-m, 61.5 
lb-ft)

4) Install wheel and lower vehicle.
5) Tighten wheel nuts to specified torque.

Tightening torque
Wheel nut:  100 N·m (10.0 kgf-m, 72.5 lb-ft)

6) Upon completion of installation, perform brake test.

Specifications

Tightening Torque Specifications

S5JB0E4207001

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

IYSQ01420025-01

1,(a)

I5JB0A420011-01

Fastening part

Tightening torque

Note

N

m

kgf-m

lb-ft

Caliper pin bolt

36

3.6 

26.0

)

 / )

Wheel nut

100

10.0 

72.5

)

 / ) / )

Flexible hose joint bolt

23

2.3 

17.0

)

Caliper carrier bolt

85

8.5 

61.5

)

ABS: 4E-1

Brakes

ABS

Precautions

Precautions in Diagnosing Troubles

S5JB0E4500001

To ensure that the trouble diagnosis is done accurately 
and smoothly, observe the following and follow “ABS 
Check”.
• Diagnostic information stored in ABS (ESP

®) control 

module memory can be cleared as well as checked by 
using SUZUKI scan tool. Before using scan tool, read 
its Operator’s (Instruction) Manual carefully to have 
good understanding as to what functions are available 
and how to use it.

• If the vehicles was operated in any of the following 

ways, ABS warning lamp may light momentarily but 
this does not indicate anything abnormal in ABS.
– The vehicle was driven with parking brake pulled.
– The vehicle was driven with brake dragging.
– The vehicle was stuck in mud, sand, etc.
– Wheel spin occurred while driving.
– Wheel(s) was rotated while the vehicle was jacked 

up.

• Be sure to read “Precaution for CAN Communication 

System in Section 00 in related manual” before 
inspection and observe what is written there.

• Be sure to use the trouble diagnosis procedure as 

described in “ABS Check”. Failure to follow it may 
result in incorrect diagnosis. (Some other diagnosis 
trouble code may be stored by mistake in the memory 
of ABS (ESP

®) control module during inspection.)

• When disconnecting ABS hydraulic unit / control 

module connector (1), pull down lock lever (2) of 
connector.
When connecting, set the connector on ABS hydraulic 
unit / control module assembly and pull up the lock 
lever (2) until it locks.

• When disconnecting ESP

® hydraulic unit / control 

module connector (1), pull up lock lever (2) of 
connector.
When connecting, set the connector on ESP

® 

hydraulic unit / control module assembly and pull 
down the lock lever (2) until it locks.

• Communication of ECM, TCM (for A/T model), BCM, 

ABS (ESP

®) control module (if equipped), 4WD 

control module (if equipped), keyless start control 
module (if equipped), steering angle sensor (if 
equipped) and combination meter is established by 
CAN (Controller Area Network).
Therefore, be sure to read “Precautions for Installing 
Mobile Communication Equipment in Section 00 in 
related manual” before inspection and handle CAN 
communication line.

Precautions in On-Vehicle Service

S5JB0E4500002

When connector is connected to ABS (ESP

®) hydraulic 

unit / control module assembly, do not disconnect 
connectors of sensors with ignition switch ON. 
Otherwise, DTC will be set in ABS (ESP

®) control 

module.

Precautions in Hydraulic Unit Operation Check

S5JB0E4500003

ABS (ESP

®) hydraulic unit / control module assembly 

function is checked by correct wheel lock / release 
condition when brake pressure is pressurized / 
depressurized using SUZUKI scan tool. The hydraulic 
unit operation check referring to “Hydraulic Unit 
Operation Check” shou
ld be performed to confirm the 
correct brake pipe connection in the following cases.
• ABS (ESP

®) hydraulic unit / control module assembly 

was replaced.

• Brake pipe and/or hose were replaced.

[A]: Disconnect

C: Pull down to disconnect

[B]: Connect

D: Pull up to connect

2

1

C

D

[A]

[B]

I4RH01450001-01

A: Disconnect

C: Pull up to disconnect

B: Connect

D: Pull down to connect

2

1

[A]

[B]

C

D

I6JB01450001-02

 

 

 

 

 

 

 

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