Grand Vitara 4WD V6-2.5L (2003)
1. Install secondary piston assembly into cylinder.
2. Install primary piston assembly in cylinder.
3. Install plate, cylinder cup and piston stopper (piston stopper, piston guide and plate for G16 engine model without ABS) in that order.
4. Depress primary piston assembly by rod (1), and install circlip (2).
5. Install piston stopper bolt with pistons pushed in all the way and tighten it to specified torque (for vehicle without ABS).
Tightening torque
Piston stopper bolt for J20/H25 engine models (a): 10 Nm (1.0 kgf-m, 7.5 ft. lbs.) J20, H25
Piston stopper bolt for G16 engine model (b): 8.5 Nm (0.85 kgf-m, 6.5 ft. lbs.) G16
6. Apply thin coat of brake fluid to all around new grommets (2 pcs.) and install them to cylinder body, then install reservoir (2) to master cylinder
(3).
7. Set a new pin (1) in reservoir hole and drive it in. At this time, make end of pin and end face margin of reservoir equal. Or tighten connector screw
to specified torque.
