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

MASTER CYLINDER

1. Reservoir cap

2. Master cylinder reservoir

3. Reservoir bolt

4. Grommet:

Apply brake fluid.

5. Master cylinder body

6. Secondary piston assembly:

Apply brake fluid.

7. Primary piston assembly:

Apply brake fluid.

8. Piston stopper circlip

9. Master cylinder boot

10. Push rod

: Tightening Torque

MASTER CYLINDER RESERVOIR

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 screw (2).

5) Remove reservoir.

INSTALLATION

1) When using new grommets (3), lubricate them with the same

fluid as the one to fill reservoir (1) with. Then press-fit grommets

to master cylinder.

2) Install reservoir and tighten screws (2) to specified torque.

Tightening Torque

(a) : 2.5 N·m (0.25 kg-m, 2.0 lb-ft)

3) Connect reservoir lead wire at coupler.

4) Fill reservoir with brake fluid.

5) Perform air bleeding, refer to BLEEDING BRAKES in this sec-

tion.

5-32 BRAKES

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 -> Master Cylinder for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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