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    2003 Suzuki Truck Vitara 4WD 2.0L SFI DOHC 4cyl

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    Master Cylinder

    Inspect/Service/Replace

    • Remove the master cylinder from the vehicle.
    • Be sure to use fender covers to protect the paint from accidental spills. Loosen and remove the two flared metal lines using a flare-nut wrench.
    • If there is no vacuum power brake, unhook the pedal pushrod from under the dash. This is not necessary on power brake cars.
    • Remove the nuts that hold the master cylinder in place.
    • Remove the master cylinder and dump the brake fluid in a suitable container for disposal.
    • Install and bench bleed the new master cylinder according to the manufacturer's direction.

    Adjusting Brake Pedal Free Travel

    Adjustment of pedal free travel is not usually required, but should be checked when the master cylinder is replaced. There should be less than 1/8 inch of free play between the brake pushrod and the back of the primary master cylinder piston or power booster. This translates to free pedal travel of about 1/4 to 1/2 inch.

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