Removal & Installation (Vitara)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2004 Suzuki XL-7, 2004 Suzuki Vitara, 2004 Suzuki Grand Vitara, 2003 Suzuki XL-7, and 2003 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect fluid level switch lead wire at wire harness connector. Clean around master cylinder reservoir cap. Using a syringe, remove brake fluid from reservoir.
On models without ABS, remove and cap brake lines from master cylinder and plug master cylinder ports. On models with ABS, remove and cap brake lines from master cylinder and proportioning valve. Remove proportioning valve mounting bolt, and remove proportioning valve from master cylinder. See Fig 1. On all models, remove mounting nuts attaching master cylinder to brake booster, and remove master cylinder.
To install, reverse removal procedure. Adjust clearance between brake booster piston rod and master cylinder piston. See BRAKE BOOSTER PISTON ROD under ADJUSTMENTS. Fill master cylinder reservoir and bleed brake system. See BLEEDING BRAKE SYSTEM . Check brake pedal for play. See BRAKE PEDAL CLEARANCE under ADJUSTMENTS.

Fig 1: Identifying Proportioning Valve (Vitara With ABS)

Courtesy of SUZUKI OF AMERICA CORP.