Get Brakes Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

BRAKES 5-1

SECTION 5

BRAKES

NOTE:

All brake fasteners are important attaching parts in that they could affect the performance of vital parts

and systems, and/or could result in major repair expense. They must be replaced with one of same part

number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of

lesser quality or substitute design. Torque values must be used as specified during reassembly to assure

proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening

of the metal.

CONTENTS

GENERAL DESCRIPTION 5- 2. . . . . . . . . . . . . . . .

Front Disc Brake Caliper Assembly 5- 3. . . . . . .

Rear Drum Brake Assembly 5- 3. . . . . . . . . . . . .

Master Cylinder Assembly 5- 3. . . . . . . . . . . . . .

DIAGNOSIS 5- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagnosis Table 5- 5. . . . . . . . . . . . . . . . . . . . . . . .

ON-VEHICLE SERVICE 5- 7. . . . . . . . . . . . . . . . . .

Brake pedal Free Height Adjustment 5- 7. . . . .

Brake Pedal Play Inspection 5- 7. . . . . . . . . . . . .

Stop Light Switch Adjustment 5- 7. . . . . . . . . . . .

Excessive Pedal Travel Check 5- 7. . . . . . . . . . .

Front Brake Pad Inspection 5- 8. . . . . . . . . . . . .

Brake Disc Inspection 5- 8. . . . . . . . . . . . . . . . . .

Rear Drum Brake Shoe Adjustment 5- 8. . . . . .

Parking Brake Inspection and

Adjustment 5- 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

Flushing Brake Hydraulic System 5- 9. . . . . . . .

Master Cylinder and Brake Fluid

Level Inspection 5-10. . . . . . . . . . . . . . . . . . . . . .

Brake Hose and Pipe Inspection 5-10. . . . . . . . .

Bleeding Brakes 5-11. . . . . . . . . . . . . . . . . . . . . . .

Brake Hose/Pipe and Parking Brake

Cable 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT DISC BRAKE 5-15. . . . . . . . . . . . . . . . . . . .

Brake Pad 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caliper Assembly 5-18. . . . . . . . . . . . . . . . . . . . . .

Brake Disc 5-22. . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR DRUM BRAKE 5-23. . . . . . . . . . . . . . . . . . . . .

Brake Drum 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Shoe 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Cylinder 5-28. . . . . . . . . . . . . . . . . . . . . . . .

Brake Back Plate 5-30. . . . . . . . . . . . . . . . . . . . . .

MASTER CYLINDER 5-32. . . . . . . . . . . . . . . . . . . . .

Master Cylinder Reservoir 5-32. . . . . . . . . . . . . . .

Master Cylinder Assembly 5-33. . . . . . . . . . . . . .

REQUIRED SERVICE MATERIALS 5-37. . . . . . . .

SPECIAL TOOLS 5-37. . . . . . . . . . . . . . . . . . . . . . . .

GENERAL DESCRIPTION

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. Four brake pipes are connected to the master cylinder and they

make two independent circuits. One connects the front right & rear left brakes and the other connects the front left

& rear right brakes.

The proportioning valve (P valve) is included in these circuits between the master cylinder and rear wheels.

In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading/trailing

shoes) for the rear wheel brake.

The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and me-

chanical linkage system. The same brake shoes are used for both parking and foot brakes.

1. Master cylinder

2. Proportioning valve

3. Parking brake lever

4. Disc brake

5. Drum brake

5-2 BRAKES

BRAKES 5-3

FRONT DISC BRAKE CALIPER ASSEMBLY

This caliper has a single 51.1 mm (2.012 in.) bore and is mounted to the brake caliper holder with two mounting

bolts. Hydraulic force, created by applying force to the brake pedal, is converted by the caliper to friction. The hy-

draulic force acts equally against the piston and the bottom of the caliper bore to move the piston outward and to

move (slide) the caliper inward, resulting in a clamping action on the disc. This clamping action forces the pads

(linings) against the disc, creating friction to stop the vehicle.

NOTE:

Lubricate parts as specified. Do not use lubricated shop air on brake parts as damage to rubber compo-

nents may result. If any component is removed or line disconnected, bleed the brake system. Replace pads

in axle sets only. The torque values specified are for dry, unlubricated fasteners.

REAR DRUM BRAKE ASSEMBLY

The drum brake assembly has a self shoe clearance adjusting system so that drum- to-shoe clearance is main-

tained appropriate at all times.

NOTE:

Replace all components included in repair kits used to service this drum brake. Lubricate parts as speci-

fied.

WARNING:

When servicing wheel brake parts, do not create dust by grinding or sanding brake linings or by

cleaning wheel brake parts with a dry brush or with compressed air. (A water dampened cloth should

be used.) Many wheel brake parts contain asbestos fibers which can become airborne if dust is

created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm.

If any hydraulic component is removed or brake line disconnected, bleed the brake system. The

torque values specified are for dry, unlubricated fasteners.

MASTER CYLINDER ASSEMBLY

The tandem master cylinder is similar in construction to an ordinary master cylinder, the principal differences being

that it has two pistons and that hydraulic pressure is developed in two chambers, one for front left & rear right brakes

and the other for front right & rear left brakes.

1. Master cylinder body

2. Master primary piston

3. Master secondary piston

4. Piston stopper bolt

5. Stopper bolt seal ring

6. Push rod

7. Piston stopper circlip

8. Master cylinder boot

“A” : Primary piston (For front left & rear right brakes)

“B” : Secondary piston (For front right & rear left brakes)

5-4 BRAKES

DIAGNOSIS

ROAD TESTING BRAKES

Brakes should be tested on dry, clean, smooth and

reasonably level roadway which is not crowned. Road

test brakes by making brake applications with both

light and heavy pedal forces at various speeds to de-

termine if the vehicle stops evenly and effectively.

Also drive vehicle to see if it leads to one side or the

other without brake application. If it does, check the

tire pressure, front end alignment and front suspen-

sion attachments for looseness. See diagnosis table

for other causes.

BRAKE FLUID LEAKS

Check the master cylinder fluid levels. While a slight

drop in reservoir level does result from normal lining

wear, an abnormally low level indicates a leak in the

system. In such a case, check the entire brake system

for leakage. If even a slight evidence of leakage is

noted, the cause should be corrected or defective

parts should be replaced.

SUBSTANDARD OR CONTAMINATED BRAKE

FLUID

Improper brake fluid, mineral oil or water in the fluid

may cause brake fluid to boil or rubber components

in the hydraulic system to deteriorate.

If primary piston cups are swollen, then rubber parts

have deteriorated. This deterioration may also be evi-

denced by swollen wheel cylinder piston cups on the

drum brake wheels.

If deterioration of rubber is evident, disassemble all

hydraulic parts and wash with alcohol. Dry these parts

with compressed air before assembly to keep alcohol

out of the system. Replace all rubber parts in the sys-

tem, including hoses. Also, when working on the

brake mechanisms, check for fluid on the linings. If ex-

cessive fluid is found, replace the pads or linings.

If master cylinder piston seals are satisfactory, check

for leakage or excessive heat conditions. If leakage

is not found, drain fluid, flush with brake fluid, refill and

bleed system.

The system must be flushed if there is any doubt as

to the grade of fluid in the system or if fluid has been

used which contained parts that have been subjected

to contaminated fluid.

BRAKES 5-5

DIAGNOSIS TABLE

Condition

Possible Cause Correction

Not enough

braking force

D Brake oil leakage from brake lines.

D Brake disc or pads stained with oil.

D Overheated brakes.

D Poor contact of shoes on brake drum.

D Brake shoes linings stained with oil or wet with

water.

D Badly worn brake pad linings.

D Defective wheel cylinders.

D Malfunctioning caliper assembly.

D Air in system.

Locate leaking point and repair.

Clean or replace.

Determine cause and repair.

Repair for proper contact.

Replace.

Repair or replace.

Bleed system.

Brake pull

(Brakes not

working in

unison)

D Pad linings and/or shoe linings are wet with wa-

ter or stained with oil in some brakes.

D Drum-to-shoe clearance out of adjustment in

some brakes.

(Malfunctioning auto adjusting mechanism)

D Disc and/or drum is out of round in some

brakes.

D Wheel tires are inflated unequally.

D Malfunction in wheel cylinders.

D Disturbed front end alignment.

D Unmatched tires on same axle.

D Restricted brake pipes or hoses.

D Malfunctioning caliper assembly.

D Loose suspension parts.

D Loose calipers.

Replace.

Check for inoperative auto adjusting

mechanism.

Replace.

Inflate equally.

Repair or replace.

Adjust as prescribed.

Tires with approximately the same

amount of tread should be used on the

same axle.

Check for soft hoses and damaged lines.

Replace with new hoses and new brake

piping.

Check for stuck or sluggish pistons and

proper lubrication of caliper slide bush.

Caliper should slide.

Check all suspension mountings.

Check and torque bolts to specifications.

Noise (high

pitched squeak

without brake

applied)

D Front lining worn out. Replace linings.

Excessive

pedal travel

(Pedal stroke

too large)

D Partial brake system failure.

D Insufficient fluid in master cylinder reservoirs.

D Air in system (soft/spongy pedal).

D Rear brake system not adjusted

(malfunctioning auto adjusting mechanism).

D Bent brake shoes.

D Worn rear brake shoes.

Check brake systems and repair as nec-

essary.

Fill reservoirs with approved brake fluid.

Check for leaks and air in brake system.

Check warning light. Bleed system if re-

quired.

Bleed system.

Repair auto adjusting mechanism.

Adjust rear brakes.

Replace brake shoes.

5-6 BRAKES

Condition Possible Cause Correction

Dragging

brakes

(A very light

drag is present

in all brakes

immediately

after pedal is

released)

D Master cylinder pistons not returning correctly.

D Restricted brake pipes or hoses.

D Incorrect parking brake adjustment on rear

brakes.

D Weakened or broken return springs in the

brake.

D Sluggish parking brake cables or linkage.

D Wheel cylinder or caliper piston sticking.

D Badly worn piston seal in caliper.

Repair master cylinder.

Check for soft hoses or damaged pipes

and replace with new hoses and/or new

brake piping.

Check and adjust to correct specifications.

Replace.

Repair or replace.

Repair as necessary.

Replace piston seal.

Pedal pulsation

(Pedal pulsates

when

depressed for

braking)

D Damaged or loose wheel bearings.

D Distorted steering knuckle or rear wheel

spindle.

D Excessive disc lateral runout.

D Parallelism not within specifications.

D Rear drums out of round.

Replace wheel bearings.

Replace knuckle or rear wheel spindle.

Check per instructions. If not within speci-

fications, replace or machine disc.

Check per instructions. If not within speci-

fications, replace or machine disc.

Check runout.

Repair or replace drum as necessary.

Braking noise D Glazed shoe linings, or foreign matters stuck to

linings.

D Worn or distorted shoe linings.

D Loose front wheel bearings.

D Distorted backing plates or loose mounting

bolts.

Repair or replace shoe linings.

Replace shoe linings (or pads).

Replace wheel bearing.

Replace or retighten securing bolts.

ON-VEHICLE SERVICE

BRAKE PEDAL FREE HEIGHT ADJUSTMENT

Brake pedal height is normal if brake pedal is as high as clutch ped-

al.

When stop light switch has been removed, refer to the following

STOP LIGHT SWITCH ADJUSTMENT for proper installation.

BRAKE PEDAL PLAY INSPECTION

Pedal play should be within below specification.

If out of specification, check stop light switch for proper installation

position and adjust if necessary.

Also check pedal shaft bolt and master cylinder pin installation for

looseness and replace if defective.

Pedal play “a”: 1 – 8 mm (0.04 – 0.31 in.)

STOP LIGHT SWITCH ADJUSTMENT

Adjustment should be made as follows when installing switch (3).

Pull up brake pedal (1) toward you and while holding it there, adjust

switch position so that clearance between the end of thread and

brake pedal contact plate (2) (shown as “b” in figure) is within 0.5

– 1.0 mm (0.02 – 0.04 in.). Then tighten lock nut (4) to specified

torque.

Clearance “b”: 0.5 – 1.0 mm (0.02 – 0.04 in.)

Tightening Torque

(a) : 13 N·m (1.3 kg-m, 9.5 lb-ft)

EXCESSIVE PEDAL TRAVEL CHECK

1) With brake pedal depressed with approximately 30 kg (66 lbs)

load, measure pedal arm to wall clearance “c”. It mustn’t be less

than 85 mm (3.35 in.).

Clearance “c”: Over 85 mm (3.35 in.)

2) If clearance “c” is less than 85 mm (3.35 in.), the most possible

cause is either rear brake shoes are worn out beyond limit or air

is in lines.

Should clearance “c” remain less than 85 mm (3.35 in.) even af-

ter replacement of brake shoes and bleeding of system, other

possible but infrequent cause is malfunction of rear brake shoe

adjusters.

D Bleed brake system. (Refer to BLEEDING BRAKES in this

section.)

D Remove brake drums for adjuster inspection. (Refer to

BRAKE DRUM in this section.) If defective, correct or re-

place.

BRAKES 5-7

FRONT BRAKE PAD INSPECTION

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 (or hole) of caliper and

check lining thickness of outside and inside pads.

If lining is worn and its thickness (“d”) in figure is less than limit, all

pads must be replaced at the same time.

Pad thickness “d” (Lining thickness)

Standard : 10.0 mm (0.394 in.)

Limit : 1.0 mm (0.039 in.) for pad rim is painted black

3.0 mm (0.118 in.) for pad rim is painted brown

BRAKE DISC INSPECTION

Refer to BRAKE DISC of this section for inspection point and pro-

cedure.

REAR DRUM BRAKE SHOE ADJUSTMENT

Rear brake has self-adjusting mechanism but it does require ad-

justment for proper drum-to-shoe clearance when brake shoe has

been replaced or brake drum has been removed for some other

service.

Adjustment is automatically accomplished by depressing brake

pedal 2 to 3 times with approximately 30 kg (66 lbs) load after all

parts are installed.

Then check brake drum for dragging and brake system for proper

performance. After lowering vehicle from lift, brake test should be

performed.

5-8 BRAKES

PARKING BRAKE INSPECTION AND AD-

JUSTMENT

INSPECTION

Hold center or parking brake lever grip and pull it up with 20 to 25

kg (44 to 55f lbs) force.

With parking brake lever pulled up as above, count ratchet notches

in “A” as shown in figure.

There should be 3 to 6 notches.

Also, check if both right and left rear wheels are locked firmly.

To count number of notches easily, listen to click sounds that ratch-

et makes while pulling parking brake lever without pressing its but-

ton. One click sound corresponds to one notch.

If number of notches is out of specification, adjust cable by referring

to adjustment procedure described on the following so as to obtain

specified parking brake stroke.

NOTE:

Check tooth tip of each notch for damage or wear. If any dam-

age or wear is found, replace parking brake lever.

ADJUSTMENT

NOTE:

Make sure for following conditions before cable (2) adjust-

ment.

D No air is trapped in brake system.

D Brake pedal travel is proper.

D Brake pedal has been depressed a few times with about 30

kg (66 lbs) load.

D Parking brake lever has been pulled up a few times with

about 20 kg force.

D Rear brake pads are not worn beyond limit.

After confirming that above conditions are all satisfied, adjust park-

ing brake lever (1) stroke by loosening or tightening adjusting nuts

(3). Right and left outer cables should be adjusted equal.

NOTE:

Check brake drum for dragging after adjustment.

FLUSHING BRAKE HYDRAULIC SYSTEM

It is recommended that entire hydraulic system be thoroughly

flushed with clean brake fluid whenever new parts are installed in

hydraulic system.

It is also recommended that brake fluid be changed every two

years periodically.

BRAKES 5-9

Parking brake stroke; when lever is

pulled up at 20 kg (44 lbs)

Within 3 – 6 notches

MASTER CYLINDER AND BRAKE FLUID

LEVEL INSPECTION

1) Check master cylinder and reservoir tank for crack, damage

and brake fluid leakage. If any faulty condition exists, correct or

replace.

2) Check that brake fluid level is between MAX and MIN marks on

reservoir tank.

NOTE:

Be sure to use particular brake fluid either as indicated on res-

ervoir cap of that vehicle or recommended in owner’s manual

which comes along with that vehicle. Use of any other fluid is

strictly prohibited.

Fluid level should be between MIN and MAX lines marked on

reservoir.

When brake warning light lights sometimes during driving, re-

plenish fluid to MAX level.

When fluid decreases quickly, inspect brake system for leak-

age. Correct leaky points and then refill to specified level.

CAUTION:

Do not use shock absorber fluid or any other fluid which

contains mineral oil. Do not use a container which has

been used for mineral oil or a container which is wet from

water. Mineral oil will cause swelling and distortion of

rubber parts in hydraulic brake system and water mixed

into brake fluid will lower fluid boiling point. Keep all fluid

containers capped to prevent contamination.

BRAKE HOSE AND PIPE INSPECTION

HOSE

The flexible hydraulic brake hose, which transmits hydraulic pres-

sure from steel brake line on the body to rear cylinders and to front

calipers, should be inspected at least twice a year. The brake hose

assembly should be checked for road hazard damage, for cracks

and chafing of outer cover, for leaks and blisters. A light and mirror

may be needed for an adequate inspection. If any of the above

conditions are observed on brake hose, it will be necessary to re-

place it.

PIPE

Inspect the pipe for damage, cracks, dents and corrosion. If any de-

fect is found, replace it.

5-10 BRAKES

BLEEDING BRAKES

A bleeding operation is necessary to remove air whenever it is

introduced into the hydraulic brake system.

The hydraulic lines of this brake system are based on the diagonal

split system. When a brake pipe or hose was disconnected at the

wheel, bleeding operation must be performed at both ends of the

line of the removed pipe or hose. When any joint part of the master

cylinder of other joint part between the master cylinder and each

brake (wheel) was removed, the hydraulic brake system must be

bled at all 4 wheel brakes.

NOTE:

Perform bleeding operation starting with wheel cylinder far-

thest from master cylinder and then at front caliper of the

same brake line. Do the same on the other brake line.

CAUTION:

Brake fluid is extremely damaging to paint. If fluid should

accidentally touch painted surface, immediately wipe

fluid from paint and clean painted surface.

Left wheel cylinder Left brake caliper

Right wheel cylinder Right brake caliper

REAR FRONT

1) Fill master cylinder reservoir with brake fluid and keep at least

one-half full of fluid during bleeding operation.

2) Remove bleeder plug cap.

Attach a vinyl tube (1) to the bleeder plug of wheel cylinder, and

insert the other end into a container (2).

3) Depress brake pedal several times, and then while holding it de-

pressed, loosen bleeder plug about one-third to one-half turn.

BRAKES 5-11

4) When the fluid pressure in the cylinder is almost depleted, re-

tighten bleeder plug.

5) Repeat this operation until there are no more air bubbles in hy-

draulic line.

6) When bubbles stop, depress and hold brake pedal and tighten

bleeder plug.

Tightening torque for bleeder plug

FRONT: 8.5 N·m (0.85 kg-m, 6.5 lb-ft)

REAR: 8.5 N·m (0.85 kg-m, 6.5 lb-ft)

7) Then attach bleeder plug cap.

8) After completing bleeding operation, apply fluid pressure to

pipe line and check for leakage.

9) Replenish fluid into reservoir up to specified level.

10) Check brake pedal for “sponginess”. If found spongy, repeat

entire procedure of bleeding.

5-12 BRAKES

BRAKE HOSE/PIPE AND PARKING BRAKE CABLE

REMOVAL

1) Raise and support vehicle properly. Remove tire and wheel.

2) Clean dirt and foreign material from both flexible hose end and pipe end fittings. Remove brake flexible hose

or pipe.

3) Remove parking brake cable.

INSTALLATION

1) Install it by reversing removal procedure, noting the following points.

D Install clamps properly referring to figure below.

D Tighten bolts and nuts to specified torque.

2) Upon completion if installation, adjust cable. (Refer to PARKING BRAKE INSPECTION AND ADJUSTMENT

of this section.) Then check brake drum for dragging and brake system for proper performance. After removing

vehicle from hoist, perform brake test and check each installed part for fluid leakage.

1. Parking brake cable:

Apply water tight sealant 366E

99000-31090 where plate and

cable contact.

2. Proportioning valve (P-valve)

3. E-ring

4. From master cylinder primary

to P-valve.

5. From master cylinder second-

ary to P-valve.

6. Brake back plate:

Apply water tight sealant 366E

99000-31090 to mating sur-

faces of brake back plate and

rear axle.

7. Clamp A

8. Clamp B

9. Clamp C

10. Clamp D

11. Clamp E

12. Clamp F

: Tightening Torque

Rear suspension for I.T.L. type

BRAKES 5-13

Rear suspension for DEAD AXLE type

1. Primary side

2. Secondary side

3. For right hand steering vehicle

4. For left hand steering vehicle

5. To right front flexible hose

6. To left front flexible hose

7. 4-way joint (right hand steering vehicle only)

8. 4-way joint (left hand steering vehicle only)

9. proportioning valve (P-valve)

10. White mark

11. E-ring

12. Washer

13. Clamp A

14. Clamp B

15. Clamp C

16. Clamp D

17. Clamp E

18. Clamp F

19. Clamp G

20. Clamp H

21. Clamp I

22. Clamp J

23. Clamp K

24. Clamp K (right hand steering vehicle)

25. Clamp K (left hand steering vehicle)

26. Clamp L

27. Parking brake cable:

Apply water tight sealant 366E

99000-31090 where plate and cable contact.

28. Brake back plate:

Apply water tight sealant 366E 99000-31090

to mating surfaces of brake back and rear

axle.

5-14 BRAKES

FRONT DISC BRAKE

1. Caliper pin bolt

2. Caliper pin:

Apply rubber grease

to sliding surface of caliper pin.

3. Boot

4. Disc brake pad

5. Bleeder plug cap

6. Bleeder plug

7. Disc brake caliper (Disc brake cylinder)

8. Piston seal:

Apply brake fluid.

9. Disc brake piston:

Apply brake fluid.

10. Cylinder boot

11. Brake disc

12. Disc bolt

13. Caliper bolt

: Tightening Torque

: Do not reuse

BRAKES 5-15

BRAKE PAD

REMOVAL

1) Loosen wheel nuts and with vehicle lifted up, remove wheels.

2) Remove caliper pin bolt (1).

3) Remove caliper (1) from caliper carrier (2).

NOTE:

Hang removed caliper (1) with a wire hook or the like so as

to prevent brake hose from bending and twisting exces-

sively or being pulled.

Don’t operate brake pedal with brake pads removed.

4) Remove brake pads (3).

CAUTION:

Never polish pad lining with sandpaper. If lining is pol-

ished with sandpaper, hard particles of sandpaper will be

deposited in lining and may damage disc. When pad lin-

ing requires correction, replace it with a new one.

INSPECTION

Check the pad lining for wear. When the wear exceeds its limit, re-

place with a new one. Timing for pad replacement can be deter-

mined with the line of the groove which is provided on each pad

lining. When it has disappeared, replace with a new one.

Data marked with “B” is applicable to only European market.

Distinction

“A” marked brake pad rim is painted black.

“B” marked brake pad rim is painted brown.

NOTE:

When pads are removed, visually inspect caliper for brake

fluid leak. Correct leaky point, if any.

5-16 BRAKES

Standard Limit

Pad thickness

(lining +

15.5 mm

“A”

6.5 mm

(0.256 in.)

pad rim)

(0.610 in.)

“B”

8.5 mm

(0.335 in.)

INSTALLATION

1) Set brake pad springs (1) and install brake pads (2).

2) Install caliper and tighten caliper pin bolt (1) to specified torque.

Tightening Torque

(a): 27 N·m (2.7 kg-m, 19.5 lb-ft)

3) Tighten wheel temporarily and lower lift.

4) Tighten wheel nuts (1) to specified torque.

Tightening Torque

(b): 55 N·m (5.5 kg-m, 40.0 lb-ft)

5) After completion of installation, check for brake effectiveness.

BRAKES 5-17

CALIPER ASSEMBLY

REMOVAL

1) Loosen wheel nuts and with vehicle lifted up, remove wheels.

2) Remove flexible hose bolt (1) and washer.

CAUTION:

Keep end or disconnected hose in a container (2) so that

brake fluid will not get on vehicle body or floor.

3) Remove caliper pin bolt (1) and remove caliper (2) from caliper

carrier (3).

DISASSEMBLY

1) Remove piston with air blown into flexible hose bolt installation

hole.

CAUTION:

Clean around caliper with brake fluid before disassem-

bly.

WARNING:

Do not apply too highly compressed air which will

cause piston to jump out of cylinder. It should be tak-

en out gradually with moderately compressed air. Do

not place your fingers in front of piston when using

compressed air.

1. Cloth

5-18 BRAKES

2) Remove piston seal using a thin blade like a thickness gauge,

etc.

CAUTION:

Be careful not to damage inside (bore side) of cylin-

der.

INSPECTION

Pin Boot and Cylinder Boot

Check boots for breakage, crack and damage. If defective, re-

place.

Piston Seal

Excessive or uneven wear of pad lining may indicate unsmooth re-

turn of piston. In such case, replace rubber seal.

BRAKES 5-19

ASSEMBLY

Assemble parts in reverse order of disassembly, observing follow-

ing instructions.

NOTE:

Where temperature gets as low as –30 C in cold weather,

use rubber grease whose viscosity varies very little event

at –40 C (–40 F).

CAUTION:

D Wash each part cleanly before installation in the same

fluid as the one used in master cylinder reservoir.

D Never use other fluid or thinner.

D Before installing piston and piston seal to cylinder, ap-

ply fluid to them.

D After reassembling brake lines, bleed air from them.

D Install a new piston seal into groove in cylinder se-

curely making sure that it is not twisted.

D Before installing caliper to carrier, install caliper pin (1)

with rubber grease applied into caliper carrier hole

and check for its smooth movement in thrust direc-

tion.

Piston Seal

Piston seal is used to seal piston and cylinder and to adjust clear-

ance between pad and disc.

Replace with a new one at every overhaul. Fit piston seal into

groove in cylinder taking care not to twist it.

Piston and Boot

D Before inserting piston (1) into cylinder, install new boot (2) onto

piston as shown.

5-20 BRAKES

D Fit boot as it is in figure into boot groove in cylinder with fingers.

D Insert piston into cylinder by hand and fit boot in boot groove in

piston.

D 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.

D Insert piston into cylinder by hand.

INSTALLATION

1) Install caliper to caliper carrier.

2) Tighten caliper pin bolt (1) to specified torque.

Tightening Torque

(a): 27 N·m (2.7 kg-m, 19.5 lb-ft)

CAUTION:

Check that pin boot is installed securely.

3) Connect flexible hose and tighten flexible hose bolt to specified

torque.

Tightening Torque

(a): 23 N·m (2.3 kg-m, 17.0 lb-ft)

CAUTION:

D Connect hose without twisting.

D Use new washers.

D After installation, perform air bleeding and check

for brake effectiveness and fluid leakage.

BRAKES 5-21

BRAKE DISC

REMOVAL

Refer to WHEEL HUB, KNUCKLE AND BEARING in Section 3D.

INSPECTION

Check disc surface for scratches in wearing parts. Scratches on

disc surface noticed at the time of specified inspection or replace-

ment are normal and the disc is not defective if these are not seri-

ous. But when there are deep scratches or scratches all over the

surface, replace disc.

When only one side is scratched, polish and correct that side.

Brake disc thickness

Standard : 10.0 mm (0.394 in.)

Limit : 8.0 mm (0.315 in.)

To check disc deflection, measure at 2 points on its periphery and

center with a dial gauge, while rotating the disc.

Limit on disc deflection : 0.15 mm (0.006 in.)

Special Tool

(A) : 09900-20606

(B) : 09900-20701

INSTALLATION

Refer to WHEEL HUB, KNUCKLE AND BEARING in Section 3D.

5-22 BRAKES

REAR DRUM BRAKE

1. Brake back plate:

Apply water tight sealant 366E 99000-31090

to mating surfaces of brake back plate and rear axle.

2. Brake shoe

3. Shoe return spring

4. Brake strut

5. Shoe return spring

6. Rod spring

7. Shoe hold down spring

8. Shoe hold down pin

9. Wheel cylinder:

Apply brake fluid to wheel cylinder components.

Apply water tight sealant 366E 99000-31090 to

contact surface of wheel cylinder.

10. Rubber plug

11. Wheel cylinder bolt

: Tightening Torque

: Do not reuse

BRAKES 5-23

BRAKE DRUM

REMOVAL

1) With parking brake pulled up, hoist vehicle and remove wheels.

2) Remove spindle cap (1). When removing cap with a chisel, tap

it lightly at about 3 locations using care not to damage seat face

of cap.

3) Remove split pin (1), castle nut (2) and washer (3).

4) Release parking brake lever (1) to cancel rear brake.

5) Loosen parking brake cable lock nuts (2).

FRONT

6) Pull brake drum (1) off by using special tools.

Special Tool

(A) : 09942-15510

(B) : 09943-17912

7) Remove wheel stud bolt (1) by using hydraulic press (2) and

general rod (3).

5-24 BRAKES

8) Insert new stud in drum hole and rotate it slowly to assure serra-

tions are aligned with those made by replaced bolt.

INSPECTION

Inspect drum for cleanliness. Check its braking surface for wear by

measuring its inside diameter.

Drum inside diameter “a”

Standard : 180 mm (7.09 in.)

Limit : 182 mm (7.17 in.)

Whenever brake drums are removed, they should be thoroughly

cleaned and inspected for cracks, scores, deep grooves.

Cracked, Scored, or Grooved Drum

A cracked drum is unsafe for further service and must be replaced.

Do not attempt to weld a cracked drum. Smooth up any slight

scores. Heavy or extensive scoring will cause excessive brake lin-

ing wear and it will probably be necessary to resurface drum brak-

ing surface.

If brake linings are slightly worn and drum is grooved, drum should

be polished with fine emery cloth but should not be cut.

NOTE:

When drum is removed, visually inspect wheel cylinder for

brake fluid leak. Correct leaky point, if any.

INSTALLATION

1) Before installing brake drum, check that outer diameter of brake

shoes is shorter than 180 mm (7.08 in.). If it is not so, adjust it

to shorter than 180 mm (7.08 in.) by turning adjuster.

2) Install brake drum (1) after making sure that inside of brake

drum and brake shoes are free from dirt and oil.

3) Install washer and axle castle nut.

4) Tighten castle nut (2) to specified torque.

Tightening Torque

(a) : 100 N·m (10.0 kg-m, 72.5 lb-ft)

BRAKES 5-25

5) Bend split pin (1) securely as shown.

6) Install spindle cap (when installing spindle cap, hammer lightly

several locations on the collar of cap until the collar comes

closely into contact with brake drum) and tighten wheel nuts (1)

to specified torque.

Tightening Torque

(b) : 55 N·m (5.5 kg-m, 40.0 lb-ft)

NOTE:

If fitting part of cap is deformed or damaged or if it is fitted

loosely, replace with new one.

7) Upon completion of all jobs, depress brake pedal with about 30

kg (66 lbs) load several times so as to obtain proper drum-to-

shoe clearance.

Adjust parking brake cable (For adjustment, refer to PARKING

BRAKE INSPECTION AND ADJUSTMENT in this section).

8) Check to ensure that brake drum is free from dragging and

proper braking is obtained. Then remove vehicle from hoist and

perform brake test.

5-26 BRAKES

BRAKE SHOE

REMOVAL

1) Remove brake drum, refer to BRAKE DRUM in this section.

2) Remove shoe hold down springs by turning shoe hold down

pins as shown.

3) Disconnect parking brake cable (1) from parking brake shoe le-

ver (2) and remove brake shoes.

INSPECTION

Brake Shoe

If lining is worn out beyond service limit, replace shoe.

Brake shoe thickness

Standard : 6.0 mm (0.24 in.)

Limit : 2.6 mm (0.10 in.)

If one of brake linings is worn to or beyond service limit, all linings

must be replaced at the same time.

CAUTION:

Never polish lining with sandpaper. If lining is polished

with sandpaper, hard particles of sandpaper will be de-

posited in lining and may damage drum. When it is re-

quired to correct lining, replace it with a new one.

Parking Shoe Lever

Inspect brake shoe lever for smooth movement along shoe rim. If

defective, correct or replace.

BRAKES 5-27

Springs

Inspect for damage, corrosion or weakening. Inspect each part

with arrow for rust. If found defective, replace.

INSTALLATION

Install parts in reverse other of removal.

D Install shoe hold down springs by pushing down them in place

and turning hold down pins.

D For procedure hereafter, refer to BRAKE DRUM in this section.

WHEEL CYLINDER

REMOVAL

1) Remove brake drum, refer to BRAKE DRUM in this section.

2) Remove brake shoe, refer to BRAKE SHOE in this section.

3) Take out fluid with a syringe or such and disconnect brake pipe

flare nut (1) from wheel cylinder.

4) Remove E-ring (2).

5) Remove wheel cylinder mounting bolts.

And put wheel cylinder breeder plug cap onto pipe to prevent

fluid from spilling.

INSPECTION

When removing brake drum, check wheel cylinder for oil leakage.

If any leakage is found, replace wheel cylinder inner parts.

Inspect wheel cylinder disassembled parts for wear, cracks, corro-

sion or damage.

NOTE:

Clean wheel cylinder components with brake fluid.

5-28 BRAKES

INSTALLATION

1) Before installing wheel cylinder to back plate, apply water tight

sealant to contact surface of wheel cylinder.

“A”: Sealant 366E 99000-31090

2) Take off breeder plug cap from brake pipe and connect pipe to

wheel cylinder just enough to prevent fluid from leaking.

3) Tighten wheel cylinder to brake back plate (1) to specified

torque.

Tightening Torque

(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)

4) Torque flare nut (2) of brake pipe which was connected in step

3) to specification.

Tightening Torque

(b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)

5) Install breeder plug cap taken off pipe back to breather plug.

6) Install E-ring (3) to bracket securely.

7) Install brake shoes, refer to BRAKE SHOE in this section.

8) Install brake drum, refer to BRAKE DRUM in this section.

9) Fill reservoir with brake fluid and bleed brake system, refer to

BLEEDING BRAKES in this section.

10) Upon completion of all jobs, depress brake pedal with about

30kg load two to three times so as to obtain proper drum-to-

shoe clearance.

Adjust parking brake cable, refer to PARKING BRAKE IN-

SPECTION AND ADJUSTMENT in this section.

11) Install wheel and tighten wheel nuts to specified torque.

Tightening torque for wheel nut

55 N·m (5.5 kg-m, 42.0 lb-ft)

12) Check to ensure that brake drum is free from dragging and

proper braking is obtained. Then remove vehicle from hoist

and perform brake test (foot brake and parking brake).

13) Check each installed part for oil leakage.

BRAKES 5-29

BRAKE BACK PLATE

REMOVAL

1) Remove brake drum, refer to BRAKE DRUM in this section.

2) Remove brake shoe, refer to BRAKE SHOE in this section.

3) Remove wheel cylinder, refer to WHEEL CYLINDER in this sec-

tion.

4) Remove parking brake cable securing clip (1) and disconnect

brake cable (2) from brake back plate (3).

5) Remove brake back plate (1) by removing bolts (2).

INSTALLATION

1) Apply water tight sealant to mating surfaces of brake back plate

(1) and rear axle.

“A”: Sealant 366E 99000-31090

2) Install brake back plate to rear axle and tighten back plate bolts

(1) to specified torque.

Tightening Torque

(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)

5-30 BRAKES

3) Apply water tight sealant where plate and cable contact, and run

parking cable (1) through brake back plate (2) and secure it with

clip (3).

“A” : Sealant 366E 99000-31090

4) Install wheel cylinder, refer to WHEEL CYLINDER in this sec-

tion.

5) For procedure hereafter, refer to WHEEL CYLINDER in this

section.

BRAKES 5-31

MASTER CYLINDER ASSEMBLY

REMOVAL

1) Disconnect reservoir lead wire at coupler.

2) Clean outside of reservoir (1).

3) Take out fluid with a syringe or such.

4) Remove reservoir connector screws (2).

5) Remove reservoir.

6) Disconnect brake pipes (4) from master cylinder (3).

CAUTION:

Do not allow brake fluid to get on painted surfaces.

7) Remove master cylinder push rod split pin and rod pin from

brake pedal arm.

8) Remove attaching nuts (5) and washers.

9) Remove master cylinder.

DISASSEMBLY

1) Remove circlip (1).

2) Remove primary piston by removing piston stopper bolt (1). Be

cautions during removal as primary piston will jump out.

3) Pull out secondary piston by tapping flange with a piece of wood

or something soft.

NOTE:

D Do not drop piston.

D Do not cause any damage to inside of cylinder wall.

BRAKES 5-33

NOTE:

Do not loosen lock nut (1) of push rod. Should it be loosened,

be sure to adjust and secure lock nut at the position within the

measurement “a”. Data in figure does not include gasket

thickness.

Length “a”: 102.0 – 103.0 mm (4.016 – 4.055 in.)

INSPECTION

Inspection all disassembled parts for wear or damage, and replace

parts if necessary.

NOTE:

D Wash disassembled parts with brake fluid.

D Do not reuse piston assembly.

Inspect master cylinder bore for scoring or corrosion. It is best to

replace corroded cylinder. Corrosion can be identified as pits or ex-

cessive roughness.

NOTE:

Polishing bore of master cylinder with cast aluminum body

with anything abrasive is prohibited, as damage to cylinder

bore may occur.

Rinse cylinder in clean brake fluid. Shake excess rinsing fluid from

cylinder. Do not use a cloth to dry cylinder, as lint from cloth cannot

be kept from cylinder bore surfaces.

ASSEMBLY

CAUTION:

D Never use any mineral oil such as kerosene and gaso-

line when washing and assembling parts.

D Check inside of cylinder wall, pistons and cup seals

are free from any foreign objects such as dust and dirt

and use case not to cause any damage with a tool dur-

ing assembly.

D Do not drop parts. Do not use any part which has been

dropped.

5-34 BRAKES

1) Assemble secondary piston as shown in figure.

1. Secondary piston return spring

2. Return spring seat

3. Piston cup

4. Secondary piston

5. Piston pressure cap

2) Install secondary piston assembly into cylinder.

3) Install primary piston in cylinder.

4) Depress using a rod (1), and install circlip (2).

5) Install piston stopper bolt (1) with pistons pushed in all the way

and tighten it to specified torque.

Tightening Torque

(a) : 3 N·m (0.3 kg-m, 2.5 lb-ft)

BRAKES 5-35

INSTALLATION

1) Install master cylinder (3) as shown and tighten attaching nuts

(1) to specified torque.

Tightening Torque

(a) : 13 N·m (1.3 kg-m, 9.5 lb-ft)

2) Install master cylinder push rod to brake pedal and bend split

pin securely.

3) Connect 4 hydraulic lines and tighten flare nuts (4) to specified

torque.

Tightening Torque

(b) : 12 N·m (1.2 kg-m, 9.0 lb-ft)

4) When using new grommets, lubricate them with the same fluid

as the one to fill reservoir (2) with. Then press-fit grommets to

master cylinder.

5) Install reservoir and tighten screws (5) to specified torque.

Tightening Torque

6) Fill reservoir with specified fluid.

After installing, check brake pedal height, bleed air from system

(Refer to BRAKE PEDAL FREE HEIGHT ADJUSTMENT and

BLEEDING BRAKES in this section.

CAUTION:

D Never use any mineral oil such as kerosene and gaso-

line when washing and assembling parts.

D Check inside of cylinder wall, pistons and cup seals

are free from any foreign objects such as dust and dirt

and use case not to cause any damage with a tool dur-

ing assembly.

D Do not drop parts. Do not use any part which has been

dropped.

Fluid to fill reservoir with is indicated on reservoir cap of the vehicle

with embossed letters or in owner’s manual supplied with the ve-

hicle.

Add fluid up to MAX line.

5-36 BRAKES

BRAKES 5-37

REQUIRED SERVICE MATERIALS

MATERIALS

RECOMMENDED

SUZUKI PRODUCT

USE

Brake fluid DOT 3

D To fill master cylinder reservoir.

D To clean and apply to inner parts of master cylinder

caliper and wheel cylinder when they are disassembled.

Water tight sealant

SEALING COMPOUND 366E

(99000-31090)

D To apply to mating surfaces of brake back plate and

rear axle.

D To apply to mating surfaces of brake back plate and

parking brake cable.

D To apply to mating surface of wheel cylinder and brake

back plate.

rubber grease D To apply to sliding surfaces of caliper pin

SPECIAL TOOLS

09942-15510

Sliding hammer

09943-17912

Brake drum remover

(Front wheel hub remover)

09900-20606

Dial gauge

09900-20701

Magnetic stand

Brakes for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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