Get Brakes -> Front Disc Brake Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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

Brakes -> Front Disc Brake for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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