2006 SUZUKI SX4 torque

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

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-16
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-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-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

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-8
Specifications
Tightening Torque SpecificationsS6RW0D4207001
NOTE
The specified tightening torque is also described in the following.
“Front Disc 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 MaterialS6RW0D4208001
NOTE
Required service material is also described in the following.
“Front Disc Brake Components”

Special ToolS6RW0D4208002
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Caliper pin bolt 26 2.6 19.0) / )
Flexible hose joint bolt 23 2.3 17.0)
Bleeder plug 9 0.9 6.5)
Caliper carrier bolt 85 8.5 61.5)
09900–20607 09900–20701
Dial gauge Magnetic stand
))

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)