2006 SUZUKI SX4 PPL

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-12
3) Drain brake fluid in reservoir.
4) Disconnect clutch reservoir hose from reservoir (M/T
model).
5) Remove reservoir connector pin (1) by using special
tool and then reservoir.
Special tool
(A): 09916–44310
Installation
1) When using new grommets (2), lubricate them with
the same fluid as the one to fill reservoir with.
Then press-fit grommets (2) to master cylinder (3).
2) Install reservoir (1) to master cylinder.
3) Drive in reservoir connector pin (2) by using special
tool (A). Till both of its ends at the right and left of
reservoir (1) becomes the same length.
Special tool
(A): 09916–44310 4) Connect clutch reservoir hose to reservoir (M/T
model).
5) Connect fluid level switch coupler (1) and clamp (3)
to reservoir (2).
6) Fill reservoir with specified brake fluid up to its MAX
level.
7) After completing the work, bleed air from brake
system referring to “Air Bleeding of Brake System”
and bleed air from clutch system referring to“Air
Bleeding of Clutch System in Section 5C” (M/T
model).
8) Check each installed parts for fluid leakage.
9) Perform brake test and check fluid leakage.
Master Cylinder Removal and InstallationS6RW0D4106012
Removal
CAUTION!
• Never disassemble master cylinder since
the master cylinder is supplied as
assembly parts.
If faulty condition is found, replace it with
new one.
• 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.

1) Clean outside of master cylinder.
2) Disconnect fluid level switch coupler (1) and clamp
(3) from reservoir (2).
1 (A)I5JB0A410013-02
1
2
2
3
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I7RW01410011-01
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13
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Downloaded from www.Manualslib.com manuals search engine 4A-13 Brake Control System and Diagnosis:
3) Drain brake fluid in reservoir.
4) Disconnect clutch reservoir hose from reservoir (M/T
model).
5) Disconnect brake pipes (1) connected to master
cylinder.
6) Remove master cylinder fixing nuts (2).
7) Remove master cylinder (3) and O-ring.
Installation
1) Install new O-ring (2) to master cylinder assembly
(1).
2) Apply grease to piston rod “A”.
Use specified grease in spare to master cylinder or
brake booster as supply parts.
3) Install master cylinder assembly (1) to brake booster
(3) and tighten master cylinder fixing nuts to
specified torque.
Tightening torque
Master cylinder fixing nut (a): 18 N·m (1.8 kgf-
m, 13.0 lb-ft)4) Connect brake pipe to master cylinder and tighten
flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
5) Connect clutch reservoir hose to reservoir and install
reservoir hose clamp (M/T model).
6) Connect fluid level switch connector and clamp.
7) Fill reservoir with specified brake fluid up to its MAX
level.
8) After completing the work, bleed air from brake and
clutch system referring to “Air Bleeding of Brake
System” and bleed air from clutch system referring to
“Air Bleeding of Clutch System in Section 5C” (M/T
model).
9) Check each installed parts for fluid leakage.
10) Check brake pedal for play referring to “Brake Pedal
Play Inspection”.
11) Perform brake test and check fluid leakage.
Master Cylinder InspectionS6RW0D4106013
• Depress brake pedal a few times and retain brake
pedal. If pedal gone down, replace the brake master
cylinder assembly.
• Check master cylinder for leakage, corrosion and
smooth operation.
• Inspect distance “a” to be the following.
If measurement is out of specification, replace master
cylinder assembly.
Distance
“a”: 72.0 mm (2.83 in.) or more
2
1
3I7RW01410012-01
(a)3
2
1
"A"
I7RW01410019-01
(a)I7RW01410013-01
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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
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I7RW01420003-01
42
3
1
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"a"
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I7RW01420012-01

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.

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

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-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
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A
A
I6JB0A430002-01
I4RS0A430016-01
1
2
3
I7RW01431004-01