Brake bleeding SUZUKI SX4 2006 1.G Service User Guide

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
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3
3 1 2
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3,(a)
3,(a) 1 2
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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.
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Downloaded from www.Manualslib.com manuals search engine 4C-5 Rear Brakes:
Installation
1) Take off bleeder plug cap from brake pipe and
connect pipe to wheel cylinder (1) just enough to
prevent fluid from leaking.
2) Install wheel cylinder (1) to brake back plate (2), and
tighten wheel cylinder mounting bolt to specified
torque.
Tightening torque
Wheel cylinder mounting bolt (a): 12 N·m (1.2
kgf-m, 9.0 lb-ft)
3) Tighten flare nut of brake pipe (3) to specified torque.
Tightening torque
Rear brake pipe flare nut (b): 16 N·m (1.6 kgf-m,
11.5 lb-ft)
4) Install bleeder plug cap (4) taken off from pipe back
to bleeder plug.
5) Install brake shoes. Refer to “Rear Brake Shoe
Removal and Installation”.
6) Install brake drum. Refer to “Rear Brake Drum
Removal and Installation”.
7) Fill reservoir with brake fluid and bleed brake
system. For bleeding operation refer to “Air Bleeding
of Brake System in Section 4A”.
8) Upon completion of all jobs, depress brake pedal
with about 300 N (30 kg, 66 lbs) load at least 15
times until adjuster actuator clicking sound from
drum brake can not be heard so as to obtain proper
drum-to-shoe clearance.
Adjust parking brake cable referring to “Parking
Brake Inspection and Adjustment in Section 4D”.
9) Install rear wheel.
10) Check to ensure that brake drum is free from
dragging and proper braking is obtained. Remove
vehicle from hoist and perform brake test (foot brake
and parking brake).Wheel Cylinder InspectionS6RW0D4306008
Inspect wheel cylinder disassembled parts for wear,
cracks, corrosion or damage.
NOTE
Clean wheel cylinder components with brake
fluid.

Brake Back Plate Removal and InstallationS6RW0D4306009
Removal
1) Remove rear wheel hub referring to “Rear Wheel
Hub Assembly Removal and Installation in Section
2C”.
2) Remove parking brake cable (1) from brake back
plate.
3) Remove wheel cylinder from brake back plate
referring to “Wheel Cylinder Removal and
Installation”.
(b)3
4(a)
(a)
1
2
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1
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Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-6
Installation
Install brake back plate by reversing removal procedure,
noting the instructions.
CAUTION!
Never reuse rear wheel hub mounting bolts.

• Install rear wheel hub and brake back plate, and then
tighten mounting bolt. Refer to “Rear Drum Brake
Components”.
• Install parking brake cable (1) to brake back plate.
Tightening torque
Parking cable cap nut (a): 11 N·m (1.1 kgf-m, 8.0
lb-ft)• After installing all removed parts, bleed air from brake
system referring to “Air Bleeding of Brake System in
Section 4A”. and then adjust parking brake cable
referring to “Parking Brake Inspection and Adjustment
in Section 4D”.
Specifications
Tightening Torque SpecificationsS6RW0D4307001
NOTE
The specified tightening torque is also described in the following.
“Rear Drum Brake 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 MaterialS6RW0D4308001
NOTE
Required service material is also described in the following.
“Rear Drum Brake Components”

1
(a)
I4RS0A430024-01
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Wheel cylinder mounting bolt 12 1.2 9.0)
Rear brake pipe flare nut 16 1.6 11.5)
Parking cable cap nut 11 1.1 8.0)

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-34
Installation
1) Install hydraulic unit / control module assembly by
reversing removal procedure noting the following.
Install ABS hydraulic unit / control module assembly
bracket bolt as follows.
a) Tighten bracket bolt (1) and (2) by hand.
b) Then tighten bracket bolt to specified torque.
Tightening order (1) → (2)
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
ABS hydraulic unit / control module assembly
bolt (b): 9 N·m (0.9 kgf-m, 6.5 lb-ft)
ABS hydraulic unit / control module assembly
bracket bolt (c): 26 N·m (2.6 kgf-m, 19.0 lb-ft)2) Bleed air from brake system referring to “Air
Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage and
perform “ABS Hydraulic Unit Operation Check”.
NOTE
For new ABS hydraulic unit / control module
assembly, if “ABS Hydraulic Unit Operation
Check” has not been performed, ABS
warning light may flash when ignition switch
is turned ON position.
Accordingly preform “ABS Hydraulic Unit
Operation Check” to stop flashing of ABS
warning light.

Front and Rear Wheel Speed Sensor On-Vehicle
Inspection
S6RW0D4506005
Output Voltage Inspection
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Set up measuring device as shown in figure, the
resistance to 115 Ω and the power supply voltage to
12 V.
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

I6RW0C450011-01
1. Wheel speed sensor connector 4. “BLK” wire terminal
2. Resistance (115Ω) 5. Power supply (12 V)
3. “WHT” wire terminal
V
41
3
2
5
I5JB0A450026-03

Downloaded from www.Manualslib.com manuals search engine 5C-3 Clutch:
Repair Instructions
Clutch Pedal InspectionS6RW0D5306001
Cylinder Push Rod Play “a”
1) Press clutch pedal (1) gradually with finger, stop
when slight increase of resistance is felt and
measure how much pedal has moved (push rod
play) as represented by “a” as shown.
Push rod play
“a”: Max. 3 mm (0.12 in.)
2) If “a” is not within specification, replace master
cylinder (3) or pedal arm (2).
Clutch Pedal Free Travel “b”
1) Depress clutch pedal (1), stop the moment clutch
resistance is felt, and measure how much pedal has
moved (clutch pedal free travel) as represented by
“b” in the figure.
Clutch pedal free travel
“b”
: 2 – 8 mm (0.08 – 0.31 in.)
2) If “b” is not within specification, check pedal arm (2)
and master cylinder (3) and replace defective part.
Clutch Release Margin “c”
1) Pull up parking brake fully and block wheels.
2) Start engine and keep engine at idle with neutral
gear position.
3) Without clutch pedal (1) depressed, slightly push the
shift lever to reverse position until transaxle emits
gear contact noise. Do not shift the lever to reverse
position.
4) With emitting gear contact noise, be slow to depress
clutch pedal (1), and at gear contact noise died
position (release point) stop depressing.
5) Measure distance between release point (4) and full
stroke point (5) on clutch pedal (1) which is shown by
“c” in the figure.
Clutch release margin
“c”: 25 – 55 mm (0.98 – 2.17 in.)6) If “c” is not within specification, it is possible that air
is trapped in this system. If suspected so, bleed air
referring to “Air Bleeding of Clutch System”.Upon
completion of above inspection, start engine and
check clutch for proper operation.
Clutch Fluid Level InspectionS6RW0D5306002
Refer to “Brake Fluid Level Inspection in Section 4A”.
Clutch fluid specification
: Refer to the reservoir cap of the brake master
cylinder.
Air Bleeding of Clutch SystemS6RW0D5306003
CAUTION!
When operating the pedal stroke for air
bleeding of clutch system, after releasing the
clutch pedal, be sure to wait 1 second or
more before depressing it again. Otherwise,
the oil seal of operating cylinder will be
damaged, resulting in oil leakage.

Bleed air from clutch system.
Refer to “Air Bleeding of Brake System in Section 4A”.
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Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-4
Clutch Fluid Pipe and Hose LocationS6RW0D5306004
Clutch Fluid Pipe Removal and InstallationS6RW0D5306005
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be
disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master
cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and pull
clamp (5) of fluid pipe joint (4), and then disconnect
clutch fluid pipe (2).
4) Pull clamp (6) of damper (7), and then disconnect
damper (7) from clutch fluid pipe (2).Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted
surface.
• Do not allow pipe to contact hard against
vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and
bleed air from clutch system referring to “Clutch Pedal
Inspection” and “Air Bleeding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS6RW0D5306006
Check pipe (1) for damage, dirt and leak. Replace if
check result is not satisfactory.
4 [A]
3131
22
4
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[A]: RH steering vehicle 3. Clutch reservoir hose
1. Clutch master cylinder 4. Brake master cylinder reservoir
2. Clutch fluid pipe
2
6
5 74
3
1
2
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[A]: LH steering vehicle
[B]: RH steering vehicle
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Downloaded from www.Manualslib.com manuals search engine Body Structure: 9K-5
Side Body
Hole to hole distance
o
dek
fl
im
n
g
j
h
o
ac
b
dek
fl
im
n
g
j
h
ac
b
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a. Instrumental panel upper mounting bolt hole f. Front shoulder adjuster bracket installation
upper holek. Curtain-air bag module installation hole
b. Front door lower hinge installation upper hole g. Front door switch mounting screw hole l. Rear seat belt upper anchor installation hole
c. Front pillar inner trim installation hole h. Bleeding hole (φ 15 mm) m. Rear door switch mounting screw hole
d. Curtain-air bag module installation hole i. Rear door upper hinge installation upper hole n. Side sill scuff installation rear hole (φ 7 mm)
e. Curtain-air bag module installation hole j. Rear door lower hinge installation front hole o. Parking brake cable bracket installation front hole
a-f: 1,144 mm (45.039 in.) f-h: 1,242 mm (48.898 in.) d-o: 1,236 mm (48.661 in.)
a-g: 862 mm (33.937 in.) f-l: 864 mm (34.016 in.) e-o: 1,221 mm (48.071 in.)
a-i: 938 mm (36.929 in.) i-l: 1,020 mm (40.157 in.) f-o: 1,139 mm (44.843 in.)
b-g: 965 mm (37.992 in.) i-m: 885 mm (34.843 in.) g-o: 784 mm (30.866 in.)
b-j: 1,001 mm (39.409 in.) j-m: 1,022 mm (40.236 in.) h-o: 978 mm (38.504 in.)
c-h: 959 mm (37.756 in.) k-n: 1,089 mm (42.874 in.) k-o: 1,315 mm (51.772 in.)
d-f: 415 mm (16.339 in.) l-n: 910 mm (35.827 in.) l-o: 1,445 mm (56.890 in.)
d-g: 848 mm (33.386 in.) a-o: 1,285 mm (50.591 in.) m-o: 1,276 mm (50.236 in.)
d-h: 1,195 mm (47.047 in.) b-o: 1,278 mm (50.315 in.) n-o: 913 mm (35.945 in.)
e-h: 1,334 mm (52.520 in.) c-o: 1,303 mm (51.299 in.)