Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Master Cylinder

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WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.


CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

REMOVAL & INSTALLATION



Samurai Models

See Figures 1, 2, 3 and 4

  1. If necessary, remove the air cleaner case.
  2.  
  3. Disconnect the reservoir lead wire.
  4.  
  5. Clean the outside of the reservoir, and use a siphon to remove the fluid from the reservoir.
  6.  
  7. Disconnect and plug the two brake fluid lines at the master cylinder.
  8.  



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Fig. Fig. 1: The fluid reservoir is attached to the master cylinder with a retaining screw-1986-89 models



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Fig. Fig. 2: For 1990-95 models, separate the reservoir from the master cylinder by driving the retaining pin out


WARNING
Do not allow brake fluid to sit on painted surfaces; the brake fluid will eat away the paint finish.

  1. Remove the two master cylinder to booster mounting bolts and remove the master cylinder.
  2.  
  3. At this point, the reservoir can be separated from the master cylinder by either removing the reservoir retaining screw (1986-89 models), or by driving the retaining pin out with a thin punch. Remove the reservoir from the master cylinder.
  4.  

To install:
  1. If the reservoir was separated from the master cylinder, position the reservoir on the master cylinder and either install the retaining screw (1986-89 models), or drive the retaining pin (1990-95 models) through the reservoir and master cylinder holes.
  2.  
  3. Bleed the master cylinder.
  4.  
  5. Install the new master cylinder and tighten the mounting bolts to 88-141 inch lbs. (10-16 Nm).
  6.  



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Fig. Fig. 3: When driving a new retaining pin into the reservoir and master cylinder, ensure that it is positioned so that both protruding ends of the pin are even



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Fig. Fig. 4: When installing the master cylinder, tighten the mounting nuts and brake line fittings to the specified values

  1. Install the hydraulic brake lines to the master cylinder and tighten and tighten the flare nuts to 124-159 inch lbs. (14-18 Nm).
  2.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Fill the reservoir with the specified brake fluid.
  2.  
  3. Connect the reservoir lead wire. Install the air cleaner case, if removed.
  4.  
  5. Bleed the air from the brake hydraulic system and check the brake pedal play.
  6.  

Sidekick, Tracker and X-90 Models

1989-93 MODELS

See Figures 5 and 6


WARNING
Do not allow brake fluid to come in contact with painted surfaces; the brake fluid can damage paint.

  1. If necessary for added clearance, remove the air cleaner case assembly.
  2.  
  3. If equipped, detach the wiring harness connectors from the fluid reservoir, from the Proportioning and Differential (P+D) valve and the pressure limit valve.
  4.  



Click image to see an enlarged view

Fig. Fig. 5: The 1989-93 models equipped with the RWAL ABS system are designed with the P+D and pressure limit valves mounted on the master cylinder, while models without ABS have the proportioning valve mounted on a frame rail

  1. Clean the outside of the reservoir, then siphon the brake fluid from the reservoir.
  2.  
  3. Disconnect and plug brake fluid lines A, B, and C from the master cylinder, 2-way joint and the P+D valve.
  4.  
  5. Remove the heat shield from the master cylinder bracket.
  6.  
  7. Remove the master cylinder mounting nuts, then remove the master cylinder, 2-way joint and P+D valve together from the booster.
  8.  



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Fig. Fig. 6: To remove the master cylinder, first siphon all of the brake fluid out of the reservoir ...



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Fig. Fig. 7: ... then detach the wiring harness connector(s) from the master cylinder



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Fig. Fig. 8: For models equipped with P+D and pressure limit valves mounted on the master cylinder, detach and plug brake fluid lines A, B and C only-On models not equipped with these two valves ...



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Fig. Fig. 9: ... detach the brake fluid lines from the master cylinder, then plug them to prevent fluid loss or contamination



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Fig. Fig. 10: Loosen the master cylinder-to-brake booster retaining nuts ...



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Fig. Fig. 11: ... then separate the master cylinder (A) from the brake booster (B). Be sure to wipe up all spilled brake fluid

To install:
  1. Adjust the booster piston rod-to-master cylinder clearance.
  2.  
  3. Bleed the master cylinder.
  4.  
  5. Install the master cylinder, along with the 2-way joint and P+D valve.
  6.  
  7. Install and tighten the mounting nuts to 88-141 inch lbs. (10-16 Nm).
  8.  
  9. Reattach all of the hydraulic brake lines to the master cylinder, 2-way joint and P+D valve, then tighten the fittings to 124-159 inch lbs. (14-18 Nm).
  10.  
  11. Install the heat shield on the master cylinder bracket.
  12.  
  13. Reattach all of the wiring harness connectors.
  14.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Fill the reservoir with the specified brake fluid.
  2.  
  3. Bleed the air from the brake hydraulic system, check the brake pedal play, and inspect the master cylinder fittings for fluid leaks.
  4.  
  5. Install the air cleaner case assembly.
  6.  
  7. Road test the vehicle and verify proper brake system operation.
  8.  

1994-95 MODELS

See Figure 7


WARNING
Do not allow brake fluid to come in contact with painted surfaces; the brake fluid can damage paint.

  1. If necessary for added clearance, detach the wiring harness connector from the air flow meter, then remove the air intake hose, air flow meter and air cleaner case assembly lid.
  2.  
  3. Detach the wiring harness connector from the fluid reservoir.
  4.  
  5. Clean the outside of the reservoir, then siphon the brake fluid from the reservoir.
  6.  
  7. Depress the brake pedal a few times, which will make removal easier.
  8.  



Click image to see an enlarged view

Fig. Fig. 12: Identification of common master cylinder and related components

  1. Disconnect and plug the three brake fluid lines from the master cylinder.
  2.  
  3. Remove the master cylinder mounting nuts, then remove the master cylinder from the booster.
  4.  


WARNING
The brake master cylinder should not be disassembled. If the master cylinder is faulty, replace the entire unit with a new one.

To install:
  1. Adjust the booster piston rod-to-master cylinder clearance.
  2.  
  3. Bleed the master cylinder.
  4.  
  5. Position the master cylinder against the booster, then install and tighten the mounting nuts to 88-141 inch lbs. (10-16 Nm).
  6.  
  7. Reattach all of the hydraulic brake lines to the master cylinder, then tighten the fittings to 124-159 inch lbs. (14-18 Nm).
  8.  
  9. Reattach all of the wiring harness connectors.
  10.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Fill the reservoir with the specified brake fluid.
  2.  
  3. Bleed the air from the brake hydraulic system, check the brake pedal play, and inspect the master cylinder fittings for fluid leaks.
  4.  
  5. Install the air cleaner case assembly lid, the air flow meter, and the air intake hose, then reattach the wiring harness connector to the air flow meter.
  6.  
  7. Road test the vehicle and verify proper brake system operation.
  8.  

1996-98 MODELS

1996-98 Sidekick, Tracker and X-90 models equipped with the Anti-Lock Brake System (ABS) require a scan tool to properly bleed the brake system. If you are servicing such a vehicle, please refer to the applicable ABS information located at the end of this information BEFORE you perform any brake procedures.

  1. If necessary for added clearance, remove the air cleaner case assembly.
  2.  
  3. If equipped, detach the wiring harness connectors from the fluid reservoir, from the Proportioning and Differential (P+D) valve, and the pressure limit valve.
  4.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.


CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance

  1. Clean the outside of the reservoir, then siphon the brake fluid from the reservoir.
  2.  
  3. For vehicles without ABS, disconnect and plug the brake fluid lines from the master cylinder.
  4.  
  5. For vehicles with ABS, disconnect pipes 1 and 2 from the master cylinder and ABS actuator, and pipe 3 from the ABS actuator.
  6.  
  7. Remove the master cylinder mounting nuts, then remove the master cylinder from the booster.
  8.  

To install:
  1. Bleed the master cylinder.
  2.  
  3. Install the new master cylinder. Tighten the mounting nuts to 9.5 ft. lbs. (13 Nm).
  4.  
  5. Install the hydraulic brake lines to the master cylinder and tighten and tighten the flare nuts to 11 ft. lbs. (15 Nm).
  6.  
  7. Reconnect the reservoir lead wire.
  8.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Fill the reservoir with the specified brake fluid.
  2.  
  3. Bleed the air from the brake hydraulic system and check the brake pedal play.
  4.  
  5. Road test the vehicle and verify proper brake system operation.
  6.  

Sidekick Sport Models


WARNING
Do not allow brake fluid to come in contact with painted surfaces; the brake fluid can damage paint.

  1. Clean the outside of the master cylinder and reservoir, then siphon all of the brake fluid out of the reservoir.
  2.  
  3. Remove the brake fluid pressure proportioning valve switch electrical connection.
  4.  
  5. Disconnect the brake lines from the proportioning valve.
  6.  
  7. Remove the one bolt securing both the 2-way joint and the proportioning valve to the retaining bracket.
  8.  
  9. Remove the master cylinder level switch electrical connector.
  10.  
  11. Disconnect the brake lines from the master cylinder.
  12.  
  13. Remove the attaching nuts and washers from the master cylinder.
  14.  
  15. Loosen the brake booster attaching nuts to allow enough room to remove the master cylinder.
  16.  
  17. Turn the master cylinder and brake booster slightly and remove the master cylinder from the vehicle.
  18.  

To install:
  1. Adjust the clearance between the booster piston and the primary piston.
  2.  
  3. Bleed the master cylinder.
  4.  
  5. Turn the brake booster slightly and install the master cylinder to the brake booster.
  6.  
  7. Tighten the brake booster nuts to 115 inch lbs. (13 Nm).
  8.  
  9. Install and tighten the master cylinder attaching bolts to 115 inch lbs. (13 Nm).
  10.  
  11. Install the brake lines to the master cylinder, then tighten the fittings to 141 inch lbs. (16 Nm).
  12.  
  13. Connect the master cylinder electrical connector.
  14.  
  15. Install the proportioning valve to the master cylinder, then install and tighten the bolt to 88 inch lbs. (10 Nm).
  16.  
  17. Connect and tighten the four brake lines to the proportioning valve to 141 inch lbs. (16 Nm).
  18.  
  19. Reattach all wiring harness connectors.
  20.  


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded.

  1. Refill the brake fluid reservoir with DOT approved brake fluid.
  2.  
  3. Bleed the brake system.
  4.  

ADJUSTMENT



Piston Rod Clearance

See Figures 8, 9 and 10

This procedure applies to all models.

The length of the booster piston rod is adjusted to provide the specified clearance between the piston rod end and the master cylinder piston. The specified clearance is designed to allow optimum operation of the master cylinder, but to prevent master cylinder damage from excessive booster rod pressure.



Click image to see an enlarged view

Fig. Fig. 13: To properly measure and adjust the master cylinder-to-brake booster piston rod clearance, this tool is necessary



Click image to see an enlarged view

Fig. Fig. 14: Position the measuring tool on the master cylinder as shown ...



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Fig. Fig. 15: ... then turn the tool around and position it against the booster-there should be zero clearance between the tool pin head and the booster rod

  1. Remove the master cylinder from the booster.
  2.  
  3. Push the piston rod several times to ensure that the reaction disc inside the booster is in the proper position.
  4.  
  5. Install a new gasket on the master cylinder.
  6.  

The inside of the booster should be kept at atmospheric pressure for an accurate measurement.

  1. Position the Booster Piston Rod Gauge 09950-9610, or equivalent, on the master cylinder. Depress the tool pin until it contacts the master cylinder piston.
  2.  
  3. Turn the tool around and position it against the brake power booster. The pin head of the tool should just contact the booster piston rod. If the pin head does not touch, or is moved by the piston rod, adjust the piston rod position by turning it with the Suzuki Booster Piston Rod Adjuster 09952-1610, or equivalent. There should be no clearance (0 in./0mm) between the pin head and the piston rod.
  4.  
  5. Install the master cylinder on the booster.
  6.  

BLEEDING THE MASTER CYLINDER




CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance

If the master cylinder has been removed or disconnected, it must be bled before any brake unit is bled. To bleed the master cylinder:

  1. Disconnect the front brake line from the master cylinder and allow fluid to flow from the front connector port.
  2.  
  3. Reconnect the line to the master cylinder and tighten it until it is fluid tight.
  4.  
  5. Have a helper press the brake pedal down one time and hold it down.
  6.  
  7. Loosen the front brake line connection at the master cylinder. This will allow trapped air to escape, along with some fluid.
  8.  
  9. Again tighten the line, release the pedal slowly and repeat the sequence (Sub-steps 3, 4 and 5) until only fluid runs from the port. No air bubbles should be present in the fluid.
  10.  
  11. Final tighten the line fitting at the master cylinder to 11 ft. lbs.
  12.  
  13. After all the air has been bled from the front connection, bleed the master cylinder at the rear connection by repeating Steps 1 through 6.
  14.  

 
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