parking brake SUZUKI SX4 2006 1.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 4A-1 Brake Control System and Diagnosis:
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS6RW0D4100001
Air Bag Warning
Refer to“Air Bag Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS6RW0D4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and four 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 is used for the front wheel brake and drum brake (leading / trailing shoes) for the
rear 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 of rear drum brake are used for both parking and foot brakes.
NOTE
• The figures show LH steering vehicle.
• The difference between RH steering vehicle and LH steering vehicle is the location of the brake
master cylinder, the brake booster and ABS hydraulic unit / control module assembly.

A
421
37
7
658
I7RW01410001-01
1. Brake booster 4. Primary side 7. Parking brake cable
2. Master cylinder 5. ABS hydraulic unit / control module assembly 8. 4-way joint
3. Secondary side 6. Parking brake lever A: Forward

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-6
Dragging brakes (Without
a very light drag is
present in all brakes
immediately after pedal is
released)Master cylinder pistons not returning
correctlyReplace master cylinder.
Restricted brake pipes or hosesCheck for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakesCheck and adjust to correct specifications.
Weakened or broken return springs in
the drum brakeReplace.
Sluggish parking brake cables or linkageRepair or replace.
Wheel cylinder or caliper piston stickingRepair as necessary.
Badly worn piston seal in caliperReplace piston seal.
Improper brake pedal free heightCheck brake pedal free height.
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged wheel bearingsReplace wheel bearings.
Distorted steering knuckle or rear wheel
spindle or rear axle shaftReplace knuckle or rear wheel spindle or rear
axle shaft.
Excessive disc lateral runoutCheck per instructions. If not within
specifications, replace or machine disc.
Rear drums out of roundCheck runout.
Repair or replace drum as necessary.
Braking noiseGlazed brake pad and/or brake shoeRepair or replace brake pad and/or brake
shoe.
Worn or distorted brake shoeReplace brake shoe.
Loose front wheel bearingsReplace wheel hub.
Distorted backing plates or loose
mounting boltsReplace or retighten securing bolts.
Contact wear indicator to brake discReplace brake pads.
Brake warning light lights
after engine startParking brake appliedRelease parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faultyRepair circuit.
Malfunctioning EBD systemCheck system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is appliedBrake fluid leakingInvestigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluidInvestigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is appliedBrake warning light circuit faultyReplace bulb or repair circuit.
ABS warning light turns
on after engine startMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light turns
on when brake is appliedMalfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light after
ignition switch has turned
ON Bulb burnt outReplace bulb.
Malfunctioning ABSCheck system referring to “ABS Check in
Section 4E”.
ABS warning light flashesNew ABS hydraulic unit / control module
assembly installed.Perform “ABS Hydraulic Unit Operation Check
in Section 4E”. Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine 4C-1 Rear Brakes:
Brakes
Rear Brakes
Repair Instructions
Rear Drum Brake ComponentsS6RW0D4306001
11
2
3
4
5
6 7
12
1411310 16
19 15
17
98
18
F
(a)
(b)
(c)
(d)
I6RW0D430001-01
1. Brake drum 10. Wheel cylinder 19. Bleeder plug
2. Brake shoe 11. Brake back plate : 73 N⋅m (7.3 kgf-m, 53 lb-ft)
3. Shoe return spring 12. Rear wheel hub : 12 N⋅m (1.2 kgf-m, 9.0 lb-ft)
4. Brake adjuster 13. Nut (4WD model) : 7 N⋅m (0.7 kgf-m, 5.0 lb-ft)
5. Antirattle spring 14. Parking cable : 175 N⋅m (17.5 kgf-m, 127.0 lb-ft)
6. Hold down spring 15. Rear wheel hub mounting bolt : Heat-resistant brake grease
7. Shoe hold down pin 16. Wheel cylinder mounting bolt : Do not reuse.
8. Push nut 17. Rear axle : Apply brake fluid
9. Brake shoe lever 18. Plug

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-2
Rear Brake Drum Removal and InstallationS6RW0D4306002
Removal
1) Hoist vehicle and remove rear wheel.
2) Release parking brake lever.
3) Remove brake drum (1) by using 8 mm bolts (2) (2
pcs).
Installation
1) Before installing brake drum, to maximize brake
shoe-to-drum clearance, put screwdriver between
rod and ratchet and push down ratchet.
NOTE
The figure show ratchet position where brake
shoe-to-drum clearance is maximum.

2) Confirm that inside of brake drum and brake shoes
are free from dirt and oil. And then install brake
drum.
3) Start engine and then depress brake pedal with
about 300 N (30 kg, 66 lbs) load at least 3 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”.
4) Install rear wheel.
5) Check to ensure that brake drum is free from
dragging and proper braking is obtained. Perform
brake test (foot brake and parking brake).
Rear Brake Drum and Shoe InspectionS6RW0D4306003
Brake Drum
Inspect brake drum for wear.
If drum inner diameter is exceeds the limit or uneven or
stepped wear is excessive, replace the drum.
Rear brake drum inner diameter
“a”
Standard: 220 mm (8.66 in.)
Limit: 222 mm (8.74 in.)
1. Rod 2. Ratchet
I7RW01431002-01
I2RH01430009-01
IYSQ01430007-01

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-4
3) Remove return springs, brake shoes and adjuster.
4) Disconnect parking brake shoe lever (1) from
parking brake cable (2).
5) Remove push nut (1).
6) Remove parking brake shoe lever (2) from shoe rim
(3).
Installation
Install parts in reverse order of removal, noting the
following.
• Before installing rear brake shoe to brake back plate,
clean brake back plate and apply heat-resistance
brake grease to A on which shoe rims rest.
• Push and rotate 90° hold down pin and install hold
down pin and hold down spring.
• Install brake drum referring to “Rear Brake Drum
Removal and Installation”.Rear Brake Shoe InspectionS6RW0D4306006
• Check ratchet of brake adjuster (1) assembly for wear
or damage.
• Check shoe return spring, antirattle spring, quadrant
spring and shoe hold down spring for damage,
corrosion and weakening.
• Check for smooth movement of brake shoe lever (2)
along shoe rim.
If any defective or malfunction is found, repair or replace.
Wheel Cylinder Removal and InstallationS6RW0D4306007
Removal
1) Remove brake drum referring to “Rear Brake Drum
Removal and Installation”.
2) Remove brake shoe referring to “Rear Brake Shoe
Removal and Installation”.
3) Loosen brake pipe flare nut (1) but only within the
extent that fluid does not leak.
4) Remove wheel cylinder mounting bolt (3).
Disconnect brake pipe from wheel cylinder and put
bleeder plug cap (2) onto pipe to prevent fluid from
spilling.
I2RH01430013-01
1
2 3
I4RS0A430014-01
A
A
I6JB0A430002-01
I4RS0A430016-01
1
2
3
I7RW01431004-01

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
I7RW01431005-01
I6RW0D430002-02
1
I4RS0A430020-01

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 4D-1 Parking Brake:
Brakes
Parking Brake
General Description
Parking Brake Cable ConstructionS6RW0D4401001
46
FT
T
F F R 3[A]
F9
(a)2
(a)5
1
3
4 [A]
(a)10
(a)10
(b)11(b)
(b)10 10
11
11(a)
(a)
11
7
8
(b)
I6RW0D440001-01
T: Top side 3. Equalizer 8. Parking brake cable left : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)
F: Front side 4. Parking cable bracket 9. Brake back plate : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
R: Right side 5. Parking cable bracket bolt 10. Parking cable clamp bolt
1. Parking brake lever assembly 6. Grommet 11. Parking cable clamp nut
2. Parking brake lever bolt 7. Parking brake cable right [A]: View [A]

Downloaded from www.Manualslib.com manuals search engine Parking Brake: 4D-2
Repair Instructions
Parking Brake Inspection and AdjustmentS6RW0D4406001
Inspection
Hold center of parking brake lever grip and pull it up with
200 N (20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count
ratchet notches. There should be 4 – 9 notches.
Also, check if both right and left rear wheels are locked
firmly.
To count number of notches easily, listen to click sounds
that ratchet makes while pulling parking brake lever
without pressing its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable
referring to adjustment procedure so as to obtain
specified parking brake stroke.
NOTE
Check tooth tip of each notch for damage or
wear.
If any damage or wear is found, replace
parking brake lever.

Adjustment
NOTE
Make sure for the following conditions before
cable adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Start engine and then brake pedal has
been depressed at least 3 times with about
300 N (30 kg, 66 lbs) load.
• Parking brake lever has been pulled up a
few times with about 200 N (20 kg, 44 lbs)
load.
If parking brake cable is replaced with new
one, pull up parking brake lever a few
times with about 500 N⋅m (50 kg, 110 lbs)
force.

After confirming that the conditions are all satisfied,
adjust parking brake lever stroke by loosening or
tightening adjust nut (1).
NOTE
Check brake drum for dragging after
adjustment.

Parking brake stroke
When lever is pulled up at 200 N (20 kg, 44 lbs): 4 to
9 notches
Parking Brake Cable Removal and InstallationS6RW0D4406002
Removal
NOTE
When it is necessary to remove both right
and left parking brake cables, repeat below
steps 2) and 6) on right and left wheels.

1) Hoist vehicle.
2) Remove wheel.
3) Disconnect parking brake cable from equalizer
(parking brake lever) and clamps.
4) Remove brake drum. Refer to “Rear Brake Drum
Removal and Installation in Section 4C”.
5) Disconnect parking brake cable from brake shoe
lever referring to “Rear Brake Shoe Removal and
Installation in Section 4C”.
6) Remove parking brake cable and parking cable
bracket.
Installation
Install it by reversing removal procedure, noting the
following points.
• Install clamps properly referring to “Parking Brake
Cable Construction”.
• Tighten bolts and nuts to specified torque referring to
“Parking Brake Cable Construction”.
• Adjust parking brake cable. Refer to “Parking Brake
Inspection and Adjustment”.
• Check brake drum for dragging and brake system for
proper performance. Brake test should be performed.
I4RS0B440002-01
1
I6RW0C440002-01

Downloaded from www.Manualslib.com manuals search engine 4D-3 Parking Brake:
Parking Brake Lever Removal and InstallationS6RW0D4406003
Removal
1) Remove console box.
2) Block vehicle wheels and release parking brake
lever.
3) Disconnect lead wire of parking brake switch at
coupler.
4) Loosen parking brake cable adjusting nut (1).
5) Remove parking brake lever bolts (1) and then
remove parking brake lever assembly (2) with
equalizer (3).
NOTE
Don’t disassemble parking brake lever
switch. It must be removed and installed as a
complete switch assembly.

Installation
1) Install in reverse order of removal procedure.
Check equalizer inclined angle.
Tightening torque
Parking brake lever bolt (a): 26 N·m (2.6 kgf-m,
19.0 lb-ft)
2) After all parts are installed, parking brake lever
needs to be adjusted. Refer to “Parking Brake
Inspection and Adjustment”.
3) Check brake drum for dragging and brake system for
proper performance. After removing vehicle from
hoist, brake test should be performed.
I4RS0A440004-01
I5RW0A440002-01
I5RW0A440003-01