Suzuki Aerio, Verona 2002-06

Bleeding the Brake System

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WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.


CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

  1. Remove the reservoir cap and fill the brake reservoir with brake fluid.
  2.  
  3. Connect a vinyl tube to the wheel cylinder bleeder screw and insert the other end of the tube in a clear container.
  4.  
  5. Slowly depress the brake pedal several times.
  6.  
  7. While depressing the brake pedal fully, loosen the bleeder screw until fluid runs out. Then close the bleeder screw and release the brake pedal.
  8.  
  9. Repeat these steps until there are no more bubbles in the fluid escaping to the clear container.
  10.  
  11. Tighten the bleeder screw to 80 inch lbs. (9 Nm).
  12.  
  13. Repeat the above procedure for each wheel.
  14.  


CAUTION
Brake fluid is extremely damaging to paint. If fluid should accidentally touch painted surface, immediately wipe fluid from paint and clean painted surface.

Bleeding operation is necessary to remove air whenever it entered hydraulic brake system. Hydraulic lines of 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 farthest from master cylinder and then at front caliper of the same brake line. Do the same on the other brake line.



Click image to see an enlarged view

Fig. Identifying brake system bleeding order

  1. Fill master cylinder reservoir with brake fluid (DOT 3) and keep at least one-half full of fluid during bleeding operation.

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    Fig. Fill master cylinder reservoir with brake fluid

  2.  
  3. Remove bleeder plug cap. Attach a vinyl tube (1) to bleeder plug, and insert the other end into container (2).

    Click image to see an enlarged view

    Fig. Remove bleeder plug cap and attach a vinyl tube to bleeder plug

  4.  
  5. Depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one-third to one-half turn.
  6.  
  7. When fluid pressure in cylinder is almost depleted, retighten bleeder plug.
  8.  
  9. Repeat this operation until there are no more air bubbles in hydraulic line.

    Click image to see an enlarged view

    Fig. Bleeding brakes

  10.  
  11. When bubbles stop, depress and hold brake pedal and tighten the front brake caliper bleeder plug to 8.0 ft. lbs. (11 Nm) and the rear wheel cylinder bleeder plug to 6.0 ft. lbs. (8 Nm).

    Click image to see an enlarged view

    Fig. Tighten bleeder plugs

  12.  
  13. Then attach bleeder plug cap.
  14.  
  15. After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
  16.  
  17. Replenish fluid into reservoir up to specified level.

    Click image to see an enlarged view

    Fig. Apply fluid pressure to pipe line and check for leakage

  18.  
  19. Check brake pedal for sponginess. If found spongy, repeat entire procedure of bleeding.
  20.  

 
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