brake SUZUKI SX4 2006 1.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-14
Booster Operation InspectionS6RW0D4106014
There are two ways to perform this inspection, with and
without a tester. Ordinarily, it is possible to roughly
determine its condition without using a tester.
NOTE
For this check, make sure that no air is in
hydraulic line.

Check Air Tightness
1) Start engine.
2) Stop engine after running for 1 – 2 minutes.
3) Depress brake pedal several times with the same
load as in ordinary braking and observe pedal travel.
If pedal goes down deep the first time but its travel
decreases as it is depressed the second and more
times, air tightness is obtained.
4) If pedal travel doesn’t change, air tightness isn’t
obtained.
NOTE
If defective, inspect vacuum lines and sealing
parts, and replace any faulty part. When this
has been done, repeat the entire test.

Check Operation
1) With engine stopped, depress brake pedal several
times with the same load and make sure that pedal
travel doesn’t change.
2) Start engine while depressing brake pedal. If pedal
travel increases a little, operation is satisfactory. But
no change in pedal travel indicates malfunction.
Check Air Tightness Under Load
1) With engine running, depress brake pedal. Then
stop engine while holding brake pedal depressed.
1. 1st 2. 2nd 3. 3rd
1. 1st, 2nd, 3rd
I2RH01410005-01
I2RH01410006-01
H: Hold
I2RH01410007-01
I2RH01410008-01
I2RH01410009-01

Downloaded from www.Manualslib.com manuals search engine 4A-15 Brake Control System and Diagnosis:
2) Hold brake pedal depressed for 30 seconds. If pedal
height does not change, condition is good. But it isn’t
if pedal rises.
Brake Booster Removal and InstallationS6RW0D4106015
Removal
1) Remove master cylinder assembly from booster
referring to “Master Cylinder Removal and
Installation”.
2) Disconnect vacuum hose from booster referring to
“Master Cylinder and Brake Booster Components”.
3) Remove front brake pipe (from master cylinder
primary and secondary to ABS hydraulic unit pipe)
referring to “Front Brake Hose / Pipe Removal and
Installation”.
4) Remove clip (1) and then remove push rod clevis pin
(2).
5) Loosen booster mounting nuts (3) and then remove
booster.Installation
1) Install booster to dash panel. Then connect push rod
clevis pin (2) and clip (1).
2) Tighten booster mounting nuts (3) to specified
torque.
Tightening torque
Booster mounting nut (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
3) Connect vacuum hose to booster referring to
“Master Cylinder and Brake Booster Components”.
4) Install front brake pipe (from master cylinder primary
and secondary to ABS hydraulic unit pipe) referring
to “Front Brake Hose / Pipe Removal and
Installation”.
5) Install master cylinder assembly to booster referring
to “Master Cylinder Removal and Installation”.
6) Fill reservoir with specified fluid.
7) Bleed air from brake system referring to “Air
Bleeding of Brake System” and at the same time
bleed air from clutch system referring to “Air
Bleeding of Clutch System in Section 5C” (M/T
model).
8) Check pedal height and play referring to “Brake
Pedal Free Height Inspection” and “Brake Pedal
Play Inspection”.
9) Check each installed part for fluid leakage and
perform brake test.
Brake Booster InspectionS6RW0D4106016
• Check brake booster for damage and operation.
• Check boot for damage and deterioration.
• Check for push clevis rod distance.
If any malfunction is found, replace brake booster.
H: Hold
T: 30 seconds
I2RH01410010-01
3
3 1 2
I5RW0A410019-02
3,(a)
3,(a) 1 2
I5RW0A410021-02

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Booster Push Clevis Rod AdjustmentS6RW0D4106017
Install push clevis rod (1) so that measurement “a” is
obtained and torque nut (2) to specification.
Tightening torque
Clevis pin lock nut (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
Clevis installing position (length “a”)
“a”: 129.5 - 130.5 mm (5.10 - 5.13 in.)
Specifications
Tightening Torque SpecificationsS6RW0D4107001
NOTE
The specified tightening torque is also described in the following.
“Front Brake Hose / Pipe Construction”
“Rear Brake Hose / Pipe Construction”
“Brake Pedal Components”
“Master Cylinder and Brake Booster Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS6RW0D4108001
NOTE
Required service material is also described in the following.
“Master Cylinder and Brake Booster Components”

Special ToolS6RW0D4108002
IYSQ01410050-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Front brake caliper bleeder plug 9 0.9 6.5)
Rear wheel cylinder bleeder plug 8 0.8 6.0)
Flexible hose joint bolt 23 2.3 17.0)
Master cylinder fixing nut 18 1.8 13.0)
Brake pipe flare nut 16 1.6 11.5)
Booster mounting nut 13 1.3 9.5)
Clevis pin lock nut 26 2.6 19.0)
09916–44310
Valve guide remover (5 mm)
) / )

Downloaded from www.Manualslib.com manuals search engine 4B-1 Front Brakes:
Brakes
Front Brakes
Repair Instructions
Front Disc Brake ComponentsS6RW0D4206001
I7RW01420001-05
1. Caliper 9. Disk brake piston
: Apply rubber grease included in piston
seal set or brake fluid to contact surface of
cylinder.17. Brake flexible hose
: Be sure to direct mark (18) to
inside of vehicle “I” as shown in
figure.
2. Caliper pin bolt 10. Pad spring
: Apply grease included in brake pad spare
parts to inside.: 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)
3. Boot 11. Brake disc : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Slide pin No.1
: Apply rubber grease included in slide pin / boot
set.12. Brake caliper carrier : 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
5. Brake pad 13. Caliper carrier bolt : 85 N⋅m (8.5kgf-m, 61.5 lb-ft)
6. Shim 14. Bleeder plug : Do not reuse.
7. Cylinder boot
: Apply small amount of rubber grease included
in piston seal set or brake fluid.15. Flexible hose joint bolt
8. Piston seal
: Apply small amount of rubber grease included
in piston seal set or brake fluid.16. Hose washer

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-2
Front Disc Brake Pad On-Vehicle InspectionS6RW0D4206002
Inspect pad linings (1) periodically according to
maintenance schedule whenever wheels are removed
(for tire rotation or other reason). Take a look through
each end and inspection hole of caliper and check lining
thickness of outside and inside pads.
If lining is worn and its thickness (“a” in figure) is less
than limit, all pads must be replaced at the same time.
Front brake pad thickness “a” (lining thickness)
Standard: 10 mm (0.39 in.)
Limit: 2 mm (0.08 in.)
Front Disc Brake Pad Removal and InstallationS6RW0D4206003
NOTE
When replacing brake pad, replace it on the
right and left.

Removal
1) Hoist vehicle and remove front wheel.
2) Remove caliper pin bolts (1).
3) Remove caliper (1) from caliper carrier (2).
NOTE
Hang removed caliper (1) with a wire hook (4)
or the like so as to prevent brake hose from
bending and twisting excessively or being
pulled.
Don’t operate brake pedal with brake pads
removed.

4) Remove brake pads (3).
5) Remove brake pad spring (1) as show in figure.
Installation
1) Apply small amount of pad grease “a” (included in
spare parts) to pad spring and set brake pad spring
as shown in figure.
2) Set brake pad springs (1), and install brake pads (2)
and shim (4).
NOTE
Install the brake pad with wear indicator (3) to
the vehicle center side of front right brake
pad.

I7RW01420009-01
1
I7RW01420003-01
42
3
1
I7RW01420010-01
1
I7RW01420014-01
"a"
I7RW01420011-01
I7RW01420012-01

Downloaded from www.Manualslib.com manuals search engine 4B-3 Front Brakes:
3) Install caliper and tighten caliper pin bolts to
specified torque.
Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
4) Install front wheel referring to “Wheel (with Tire)
Removal and Installation in Section 2D”.
5) Check brake effectiveness.
Front Disc Brake Pad InspectionS6RW0D4206004
Check pad lining for wear. When the wear exceeds limit,
replace with new one.
CAUTION!
Never polish pad lining with sandpaper. If
lining is polished with sandpaper, hard
particles of sandpaper will be deposited in
lining and may damage disc. When pad lining
requires correction, replace it with a new one.

Front disc brake pad thickness (lining thickness)
Standard: 10 mm (0.39 in.)
Limit: 10 mm (0.39 in.)
NOTE
When pads are removed, visually inspect
caliper for brake fluid leak. Correct leaky
point, if any.

Front Disc Brake Caliper Removal and
Installation
S6RW0D4206005
Removal
1) Hoist vehicle and remove front wheel.
2) Remove brake flexible hose joint bolt (1) from caliper
(2). As this will allow fluid to flow out of hose (3),
have a container ready beforehand.
3) Remove caliper pin bolts (1).
4) Remove caliper from caliper carrier.
Installation
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts to specification.
NOTE
Make sure that boots are fit into groove
securely.

Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
(a)
I7RW01420005-02
I2RH01420005-01
I7RW01420006-01
1
I7RW01420003-01
(a)
I7RW01420005-02

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-4
3) Connect flexible hose (3) to caliper as shown in
figure.
4) Torque flexible hose joint bolt to specification.
Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
WARNING!
• Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.
• Be sure to direct mark (1) to inside of
vehicle (2) as shown in figure.

5) Tighten bleeder plug to specified torque.
Tightening torque
Bleeder plug (b): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
6) Install front wheel referring to “Wheel (with Tire)
Removal and Installation in Section 2D”.
7) After completing the installation, fill reservoir with
brake fluid and bleed air from brake system referring
to “Air Bleeding of Brake System in Section 4A”.
8) Check every installed part for fluid leakage.
9) Perform brake test and check fluid leakage.
Front Disc Brake Caliper Disassembly and
Assembly
S6RW0D4206006
Disassembly
CAUTION!
Clean around caliper with brake fluid before
disassembly.

1) Remove disc brake piston with air blown into flexible
hose joint bolt installation hole.
WARNING!
Do not apply too highly compressed air
which will cause piston to jump out of
cylinder. Place a cloth (1) to prevent piston
from damage. It should be taken out
gradually with moderately compressed air.
Do not place your fingers in front of piston
when using compressed air.

2) Remove cylinder boot.
3) Remove piston seal using a thin blade like a
thickness gauge, etc.
CAUTION!
Be careful not to damage inside (bore side) of
cylinder.

4) Remove bleeder plug and cap from caliper.
I7RW01420007-02
I2RH01420011-01
I2RH01420013-01

Downloaded from www.Manualslib.com manuals search engine 4B-5 Front Brakes:
Assembly
Assemble parts in reverse order of disassembly,
observing the following instructions.
CAUTION!
• Wash each part cleanly before installation
in the same fluid as the one used in master
cylinder reservoir.
• Never use other fluid or thinner.
• Before installing piston seal and cylinder
boot to cylinder, apply rubber grease
included in piston seal set or brake fluid to
them.
• Install a new piston seal into groove in
cylinder securely making sure that it is not
twisted.
• After reassembling brake lines, bleed air
from them.

Before installing caliper to carrier, install slide pins with
rubber grease included in slide pin / boot set applied into
caliper carrier hole and check for its smooth movement
in thrust direction.
• Install piston seal, boot and piston to caliper referring
to the following instructions.
1) Replace with a new piston seal (1) at every overhaul.
After applying rubber grease included in piston seal
set or brake fluid, fit piston seal (1) into groove in
cylinder taking care not to twist it.2) Before inserting piston (1) into cylinder, apply rubber
grease included in piston seal set or brake fluid to
new boot (a) and install it onto piston as shown.
3) Fit boot as it is in figure into boot groove in cylinder
with fingers.
4) Insert piston into cylinder by hand and fit boot in boot
groove in piston.
NOTE
Check that boot is fitted in boot groove
securely all around piston and cylinder.

IYSQ01420021-01
1
I2RH01420017-01
A: 1 grooved side directed cylinder side
B: 2 grooved side directed pad side
I4RS0B420015-01
I2RH01420019-01
I2RH01420020-01

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-6
5) To confirm that boot is fitted in its groove in cylinder
properly, pull piston out of cylinder a little but do not
take it all out.
NOTE
Boot’s face (1) should be at the same level
from cylinder’s face (2) all around.

6) Insert piston into cylinder by hand.
Front Disc Brake Caliper InspectionS6RW0D4206007
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage.
If defective, replace boots.
Piston Seal
Excessive or uneven wear of pad lining may indicate
unsmooth return of piston.
In such case, replace rubber seal.
Front Brake Disc Removal and InstallationS6RW0D4206008
CAUTION!
During removal, be careful not to damage
brake flexible hose and not to depress brake
pedal.

Removal
1) Hoist vehicle and remove front wheel.
2) Remove caliper assembly by removing caliper
carrier bolts (2 pcs).
NOTE
Hang removed caliper with a wire hook or the
like so as to prevent brake hose from
bending and twisting excessively or being
pulled.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
I4RS0A420004-01
I2RH01420014-01
I2RH01420015-01
I4RS0B420010-01
I5RW0A420003-01

Downloaded from www.Manualslib.com manuals search engine 4B-7 Front Brakes:
Installation
1) Install caliper assembly to steering knuckle.
CAUTION!
Make sure that flexible hose is not twisted
when installing caliper assembly. If it is
twisted, reinstall it using care not to twist it.

2) Torque caliper carrier bolts to specification.
Tightening torque
Caliper carrier bolt (a): 85 N·m (8.5 kgf-m, 61.5
lb-ft)
3) Install front wheel referring to “Wheel (with Tire)
Removal and Installation in Section 2D”.
4) Perform brake test.
Front Brake Disc InspectionS6RW0D4206009
• Using magnetic stand and with dial gauge positioned
at about 10 mm (0.39 in.) inward from periphery of
disc, measure deflection of disc.
If it exceeds the limit, correct or replace the brake
disc.
Front brake disc deflection
Limit: 0.10 mm (0.004 in.) max.
Special tool
(A): 09900–20607
(B): 09900-20701
• Using micrometer, measure thickness of brake disc.
If it is less than limit, replace brake disc.
Front brake disc thickness
Standard: 22.0 mm (0.87 in.)
Limit: 20.0 mm (0.79 in.)
I4RS0B420012-01I4RS0B420013-01
I4RS0B420014-01