master cylinder SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 0B-8 Maintenance and Lubrication:
Brake Fluid InspectionS7RS0B0206035
1) Check around master cylinder and reservoir for fluid leakage. If found leaky, correct.
2) Check fluid level. If fluid level is lower than the minimum level of
reservoir, refilling is necessary. Fill reservoir with
specified brake fluid.
For the details, refer to “Brake Fluid Level Inspection
in Section 4A”.
CAUTION!
Since brake system of this vehicle is factory-
filled with brake fluid indicated on reservoir
tank cap, do not use or mix different type of
fluid when refilling; otherwise serious
damage will occur.
Do not use old or used brake fluid, or any
fluid from an unsealed container.

Brake fluid
Refer to reservoir cap of brake master cylinder.
Brake Fluid ReplacementS7RS0B0206017
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill
system with specified fluid and carry out air purge
operation.
For air purging procedure, refer to“Air Bleeding of Brake
System in Section 4A”.
Brake Lever and Cable InspectionS7RS0B0206018
1) Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition. 2) Check tooth tip of each notch for damage or wear. If
any damage or wear is found, replace parking lever.
3) Check parking brake lever for proper operation and stroke, and adjust it if necessary.
For checking and adjusting procedures, refer to
“Parking Brake Inspection and Adjustment in Section
4D”.
Parking brake lever stroke
“a”: 4 – 9 notches (with 200 N (20 kg, 44 lbs) of pull
pressure)
Clutch Fluid InspectionS7RS0B0206019
1) Check clutch system for evidence of fluid leakage. Repair leaky point if any.
2) Check reservoir for fluid level referring to “Clutch
Fluid Level Inspection in Section 5C”.
If fluid is lower than minimum level of reservoir, refill
reservoir with specified brake fluid indicated on
reservoir cap.
I7RW01020002-01
I4RS0A020009-01
I4RS0B020005-01
I4RS0A410006-01

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-13
Brake
Foot brake
Check the following:
• that brake pedal has proper travel,
• that brake works properly,
• that it is free from noise,
• that vehicle does not pull to one side when brake is applied.
• and that brake do not drag.
Parking brake
Check that lever has proper travel.
WARNING!
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property
damage. Be prepared to apply regular brake
quickly even if vehicle should start to move.

Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
Steering
• Check to ensure that steering wheel is free from instability, or abnormally heavy feeling. • Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that ai r comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to “HI” position for this check.
Specifications
Tightening Torque SpecificationsS7RS0B0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS7RS0B0208001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5 )
Oil filter 14 1.4 10.5 for reference )
Engine oilSG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant) “Antifreeze/Antico
rrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1 Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System Construction ...................................................... 4A-2
Front Brake Hose / Pipe Co nstruction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4 Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7 Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-8
Brake Fluid Level Inspection ............................... 4A-8
Stop Light Switch Adjustment ............................. 4A-8
Air Bleeding of Brake System ............................. 4A-9
Front Brake Hose / Pipe Removal and Installation ....................................................... 4A-10
Rear Brake Hose / Pipe Removal and Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-11
Master Cylinder Components............................ 4A-11
Master Cylinder Assembly Removal and Installation ....................................................... 4A-12
Master Cylinder Rese rvoir Removal and
Installation ....................................................... 4A-13
Master Cylinder Assemb ly Disassembly and
Assembly ........................................................ 4A-14
Master Cylinder Assembly Inspection ............... 4A-15
Brake Booster Components .............................. 4A-15
Booster Operation Inspection ........................... 4A-16
Brake Booster Removal and Installation ........... 4A-17
Brake Booster Inspection and Adjustment ........ 4A-18
Specifications ..................................................... 4A-18
Tightening Torque Specifications ...................... 4A-18
Special Tools and Equipmen t ........................... 4A-18 Recommended Service Material ....................... 4A-18
Front Brakes .......
..................................... 4B-1
Repair Instructions ........... ...................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Ca liper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and Assembly........................................................... 4B-4
Front Disc Brake Caliper In spection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .................... ...................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipmen t .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes................... ........................... 4C-1
Repair Instructions ........... ...................................4C-1
Rear Disc Brake Components.............................4C-1
Rear Disc Brake Pad Removal and Installation .........................................................4C-2
Rear Disc Brake Caliper Removal and Installation .........................................................4C-3
Rear Disc Brake Pad Inspection .........................4C-6
Rear Disc Brake Caliper Disassembly and Assembly...........................................................4C-6
Rear Disc Brake Caliper Inspection ....................4C-8
Rear Flexible Hose Remova l and Installation .....4C-8
Rear Brake Disc Removal and Installation..........4C-9
Rear Brake Disc Inspection.................................4C-9
Specifications .................... .................................4C-10
Tightening Torque Specifications ......................4C-10
Special Tools and Equipmen t ...........................4C-11
Recommended Service Material .......................4C-11
Special Tool ......................................................4C-11
Parking Brake ................. ......................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4-iii
ABS Warning Lamp Check ............................... 4F-14
EBD Warning Lamp (Brake Warning Lamp) Check .............................................................. 4F-15
DTC Check ....................................................... 4F-15
DTC Table ......................................................... 4F-15
DTC Clearance ................................................. 4F-18
Fail-Safe Table ................ .................................. 4F-19
Scan Tool Data ................................................. 4F-20
Visual Inspection ............................................... 4F-21
ESP ® Warning Lamp Does Not Come ON at
Ignition Switch ON .......................................... 4F-21
ESP ® Warning Lamp Comes ON Steady......... 4F-22
ABS Warning Lamp Does Not Come ON at Ignition Switch ON .......................................... 4F-23
ABS Warning Lamp Comes ON Steady............ 4F-24
EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady .......................................... 4F-24
Serial Data Link Circuit Check .......................... 4F-26
DTC C1016: Stop Lamp Swit ch Circuit Failure .. 4F-28
DTC C1017 / C1023: Yaw Rate / G Sensor Assembly Failure ............................................ 4F-29
DTC C1018: Brake Fluid Le vel Switch Failure .. 4F-30
DTC 1020: Master Cylinder Pressure Sensor Power Supply Failure ...................................... 4F-31
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Wheel Speed
Sensor Circuit or Encode r Failure ................... 4F-32
DTC C1024: Steering Angle Sensor Circuit
Failure ............................................................. 4F-34
DTC C1027: ESP ® OFF Switch Circuit
Failure ............................................................. 4F-34
DTC C1028: Master Cylinder Pressure Sensor Circuit Failure ....... .............................. 4F-35
DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure ...................................... 4F-36
DTC C1037: Steering Angle Sensor Power Supply Failure ................................................. 4F-37
DTC C1038: Steering Angle Sensor Detect Rolling Counter Fa ilure from ESP® Control
Module ............................................................ 4F-38
DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure .............. .................................. 4F-39
DTC C1040: Stability Control System Function Failure .............................................. 4F-39
DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 /
C1055 / C1056: Solenoid Circuit Failure ......... 4F-40
DTC C1057: ESP ® Control Module Power
Supply Circuit Failure .... .................................. 4F-41
DTC C1061: Pump Motor and/or Motor Driver Circuit Failure .................................................. 4F-42
DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure ....................................... 4F-43
DTC 1071: ESP ® Control Module Internal
Defect.............................................................. 4F-44 DTC C1073: Lost Communication With Yaw
Rate / G Sensor Assembly .............................. 4F-45
DTC C1075 / 1076 / 1078: Sensor Calibration Incomplete.......................... ............................. 4F-46
DTC C1090: Invalid Communication with
ECM ................................................................ 4F-47
DTC C1091 / C1094: ECM Data in CAN Line Failure / Invalid Torque Control
Communication with ECM .. ............................. 4F-48
DTC U1073: Control Module Communication Bus Off ............................................................ 4F-49
DTC U1100: Lost Communication with ECM (Reception Error)............................................. 4F-50
DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error)........ 4F-51
DTC U1140: Lost Communication with BCM (Reception Error)............................................. 4F-52
Repair Instructions ........... ................................. 4F-54
ESP® Hydraulic Unit Operation Check ............. 4F-54
Sensor Calibration............................................. 4F-54
ESP® Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4F-55
ESP ® Hydraulic
Unit / Control Module
Assembly Removal and Inst allation ................ 4F-56
Front / Rear Wheel Speed Sensor On-Vehicle Inspection ........................................................ 4F-57
Front Wheel Speed Sensor Removal and Installation ....................................................... 4F-58
Front Wheel Speed Sensor Inspection ............. 4F-59
Rear Wheel Speed Sensor Removal and Installation ....................................................... 4F-59
Rear Wheel Speed Sensor Inspection .............. 4F-60
Front Wheel Encode r On-Vehicle Inspection .... 4F-61
Front Wheel Encoder Removal and Installation ....................................................... 4F-61
Rear Wheel Encoder On-Veh icle Inspection..... 4F-61
Rear Wheel Encoder Removal and Installation ....................................................... 4F-61
Master Cylinder Pressure Sensor On-Vehicle
Inspection ........................................................ 4F-61
Yaw Rate / G Sensor Assembly On-Vehicle Inspection ........................................................ 4F-62
Yaw Rate / G Sensor Assembly Removal and Installation ....................................................... 4F-63
Yaw Rate / G Sensor Inspection ....................... 4F-64
Steering Angle Sensor On-Vehicle Inspection .. 4F-64
Steering Angle Sensor Removal and Installation ....................................................... 4F-65
Steering Angle Sensor Inspection ..................... 4F-65
ESP® OFF Switch Removal an d Installation .... 4F-65
ESP® OFF Switch Inspection ........................... 4F-65
Specifications .................... ................................. 4F-66
Tightening Torque Specifications ...................... 4F-66
Special Tools and Equipmen t ........................... 4F-66
Special Tool ...................................................... 4F-66

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-1
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS7RS0B4100001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS7RS0B4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and two in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they make two
independent circuits. One connects front right & rear left brakes and the other connects front left & rear right brakes.
In this brake system, the disc brake type is used for the front wheel brake and the rear wheel brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes or pads are used for both parking and foot brakes.
A
5
3
2
1
4
8
8
6
7
I6RS0C410001-01
1. Brake booster 4. Primary side 7. Parking brake lever
2. Master cylinder 5. 4 way joint 8. Parking brake cable
3. Secondary side 6. ABS or ESP® hydraulic unit / control module assembly A: Forward

Downloaded from www.Manualslib.com manuals search engine 4A-4 Brake Control System and Diagnosis:
Rear Brake Hose / Pipe ConstructionS7RS0B4101003
Diagnostic Information and Procedures
Brakes Diagnosis NoteS7RS0B4104001
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both light
and heavy pedal forces at vari ous speeds to determine if
the vehicle stops evenly and effectively. Also drive
vehicle to see if it leads to one side or the other without
brake application. If it does, check the tire pressure, front
wheel alignment and front suspension attachments for
looseness. See diagnosis table for other causes. Brake Fluid Leaks
Check the master cylinder fl
uid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low leve l indicates a leak in the
system. In such a case, chec k the entire brake system
for leakage. If even a slight ev idence of leakage is noted,
the cause should be corrected or defective parts should
be replaced.
Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may
cause the brake fluid to boil or the rubber components in
the hydraulic system to deteriorate.
[A]: ABS model 6. Master cylinder13. ESP® hydraulic unit
[B]: ESP ® model 7. From hydraulic unit to 4-way joint right : 11 N⋅m (11.0 kgf-m, 8.0 lb-ft)
1. From master cylinder primary to hydraulic unit 8. From hydraulic unit to 4-way joint left: 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
2. From master cylinder secondary to hydraulic unit 9. 4-way joint: 16 N⋅m (1.6 kgf-m, 11.5 lb-ft)
3. From hydraulic unit to right front brake 10.4-way joint to left rear brake hose : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft)
4. From hydraulic unit to left front brake 11. 4-way joint to right rear brake hose
5. ABS hydraulic unit 12. Master cylinder fixing nut
I6RS0C410003-01
A: View A4. Right rear brake hose8. Flexible hose joint bolt
1. To left rear brake hose 5. Left rear brake hose to left brake9. Caliper
2. To right rear brake hose 6. Right rear brake hose to right brake: 16 N⋅m (1.6 kgf-m, 12.0 lb-ft)
3. Left rear brake hose 7. Brake flexible hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-5
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol out
of the system. Replace all rubber parts in the system,
including hoses. Also, when working on the brake
mechanisms, check for fluid on the linings.
If excessive fluid is found, replace the pads. If master cylinder piston seals
are satisfactory, check for
leakage or excessive heat co nditions. If leakage is not
found, drain fluid, flush with brake fluid, refill and bleed
system.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to
contaminated fluid.
Brakes Symptom DiagnosisS7RS0B4104002
Condition Possible cause Correction / Reference Item
Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair.
Brake disc or brake pad stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Badly worn brake pad Replace.
Malfunctioning caliper assembly Repair or replace.
Malfunctioning brake booster Check system and replace assembly.
Malfunctioning brake master cylinder Check system and replace as necessary.
Air in system Bleed system.
Malfunctioning ABS (ESP ®). Check system and replace as necessary.
Brake pull (Brakes not
working in unison) Brake pad and disc are wet with water or
stained with oil in some brakes Clean or replace.
Disc is out of round in some brakes Replace.
Tires are inflated unequally Inflate equally.
Disturbed front wheel alignment Adjust as prescribed.
Unmatched tires on same axle Tires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hoses Check for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assembly Caliper should slide.
Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifications.
Noise (High pitched
squeak without brake
applied) Contact wear indicator to brake disc
Replace brake pads.
Worn brake pad Replace brake pads.
Excessive pedal travel
(Pedal stroke too large) Partial brake system failure
Check brake systems and repair as necessary.
Brake fluid leaking Repair the leaking point and bleed air.
Air in system (soft / spongy pedal) Bleed system.
Brake locked Malfunctioning ABS (ESP®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
Dragging brakes (A very
light drag is present in all
brakes immediately after
pedal is released.) Master cylinder pistons not returning
correctly
Replace master cylinder.
Restricted brake pipes or hoses Check for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakes Check and adjust to correct specifications.
Weakened or broken return springs in
rear brakes. Replace.
Sluggish parking brake cables or linkage Repair or replace.
Brake caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Improper brake pedal free height Check brake pedal free height.

Downloaded from www.Manualslib.com manuals search engine 4A-8 Brake Control System and Diagnosis:
Excessive Pedal Travel InspectionS7RS0B4106003
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 300 N (30 kg, 66 lbs) load, measure brake pedal to wall
(dash panel silencer) clearance “a”. If clearance “a”
is less than specification, the most possible cause is
air in lines. Should clearance “a” remain less than
specification even after bleeding of system, other
possible infrequent cause is booster push rod length
out of adjustment.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
Brake arm pedal to wall clearance “a”
When pedal depressed at 300 N (30 kg, 66 lbs):
over 75 mm (2.95 in.)
Brake Fluid Level InspectionS7RS0B4106004
1) Check master cylinder, reservoir and reservoir hose (if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX and MIN marks on reservoir.
NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning lamp lights sometimes
during driving, replenis h fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

Stop Light Switch AdjustmentS7RS0B4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clea rance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and stop light switch
“a”: 1.2 – 2.2 mm (0.05 – 0.08 in.)
I6RS0C410005-02
I4RS0B410006-01
I4RS0A410007-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-9
Air Bleeding of Brake SystemS7RS0B4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper farthest from master cylinder
and then at front caliper of the same brake
line. Do the same on the other brake line.

1) Fill master cylinder rese rvoir with brake fluid and
keep at least one-half full of fluid during bleeding
operation.
Brake fluid
: Refer to reservoir cap (1) 2) Remove bleeder plug cap. Attach a vinyl tube (1) to
bleeder plug, and insert the other end into container
(2).
3) Depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one-
third to one-half turn.
4) When fluid pressure in cy linder is almost depleted,
retighten bleeder plug.
5) Repeat this operation until there are no more air bubbles in hydraulic line.
6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug referring to “Front Disc
Brake Components in Section 4B” and “Rear Disc
Brake Components in Section 4C”.
1. Right front brake caliper 3. Right rear brake caliper
2. Left front brake caliper 4. Left rear brake caliper
I6RS0C410007-01
1
I6RS0C410009-01
I2RH01410015-01
I2RH01410016-01
I2RH01410017-01

Downloaded from www.Manualslib.com manuals search engine 4A-10 Brake Control System and Diagnosis:
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
9) Replenish fluid into reserv oir up to specified level.
10) Check brake pedal for sponginess. If found spongy, repeat entire procedure of bleeding.
Front Brake Hose / Pipe Removal and
Installation
S7RS0B4106007
“Front Brake Hose / Pipe Construction”
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Raise and support vehicle properly. Remove tire and wheel.
NOTE
This operation is not necessary when
removing pipes connecting master cylinder.

2) Clean dirt and foreign mate rial from both flexible
hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Make sure that steering wh eel is in straight-forward
position and flexible hose has not twist or kink.
• Check to make sure that flexible hose doesn’t contact any part of suspension, both in extreme right and
extreme left turn conditions. If it does at any point,
remove and correct. Fill and maintain brake fluid level
in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
• Perform brake test and check installed part for fluid leakage.
Rear Brake Hose / Pipe Removal and
Installation
S7RS0B4106008
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Raise and support vehicle properly. Remove tire and wheel.
2) Clean dirt and foreign material from both flexible hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Fill and maintain brake fluid level in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
• Perform brake test and check each installed part for fluid leakage.
• Never reuse protector nut once removed. Be sure to use a new one.
• Install clamps properly referring to the figure and tighten bolts.
• When installing hose, make sure that it has no twist or
kink.
I4RS0B410006-01