Suzuki Vitara, Grand Vitara, XL7 2000-06

Master Cylinder

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Removal & Installation




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.

  1. Clean around reservoir cap and take out fluid with syringe or such.
  2.  
  3. Remove clip and push rod clevis pin.
  4.  
  5. Disconnect fluid pipe from master cylinder assembly.
  6.  
  7. Remove master cylinder attaching nut and bolt.
  8.  
  9. Remove master cylinder assembly and gasket.
  10.  
  11. Bleed air from master cylinder itself.
  12.  

To install:

  1. Install master cylinder assembly and new gasket to body, attaching bolt, nuts and push rod clevis pin.
  2.  
  3. Torque attaching bolt and nut to 10 ft. lbs. (13 Nm).
  4.  
  5. Connect fluid line and torque flare nut to 12 ft. lbs. (16 Nm).
  6.  
  7. Apply grease to clevis pin and install it.
  8.  
  9. Fill reservoir with specified brake fluid and check fluid leakage.
  10.  
  11. After installation, bleed air from system and check clutch pedal free travel.
  12.  
  13. Adjust clutch pedal height to 0.79 inch. (20 mm) by loosening clevis lock nut and turning push rod.
  14.  

 
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