Get Brakes -> On-Vehicle Service Guide for Suzuki Alto 4 Door Fifth Generation (1998-2003)

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

Brakes -> On-Vehicle Service for Your Suzuki Alto 4 Door Fifth Generation (1998-2003)

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