Suzuki Aerio, Verona 2002-06

Brake Caliper

Print

Removal & Installation



  1. Remove the wheel.
  2.  
  3. If the caliper is being replaced:
    1. Secure the pedal in the depressed position. Use a pedal jack.
    2.  
    3. Clean the brake caliper thoroughly.
    4.  
    5. Remove the protective cap from the bleed nipple.
    6.  
    7. Install a plastic hose on the nipple.
    8.  
    9. Open the bleed nipple. Collect the brake fluid in a container. Shut the bleed nipple.
    10.  
    11. Slacken the off brake hose approximately half a turn.
    12.  

  4.  
  5. Remove the retaining spring carefully so as not to deform it.
  6.  
  7. Remove:

    The protective caps from the two locating pins
     
    The locating pins
     
    The brake caliper from the holder
     
    The brake pads.
     

  8.  
  9. Unscrew the brake caliper from the brake hose.
  10.  
  11. Drain the remaining brake fluid.
  12.  
  13. Insert the brake caliper on brake hose (Do not tighten)

    Click image to see an enlarged view

    Fig. Front brake exploded view

  14.  

To install:

  1. Install:

    brake pads
     
    brake caliper in the holder.
     

  2.  
  3. Lubricate the locating pins using grease caliper grease.
  4.  
  5. Insert the locating pins into the rubber sleeves. The pins should slide into the sleeves easily.
  6.  
  7. Tighten the locating pins to 20 ft. lbs. (28 Nm).
  8.  
  9. Install the protective caps.
  10.  
  11. Install the securing spring.
  12.  
  13. Tighten the brake hose to 13 ft. lbs. (18 Nm).
    NOTE
    The brake hose must not be twisted.

  14.  
  15. Fill and bleed the brake system.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the wheels.
  4.  
  5. Loosen flexible hose joint bolt a little at caliper.
    NOTE
    Be careful not to twist flexible hose while loosening the bolt.

  6.  
  7. Remove caliper pin bolts.
  8.  
  9. Remove caliper from caliper carrier.
  10.  
  11. Disconnect flexible hose from caliper using care not to twist it. As this will allow brake fluid to flow out of flexible hose, have a container ready beforehand.

    Click image to see an enlarged view

    Fig. Front caliper and related components-Aerio

  12.  

To install:

  1. Apply grease to slide pin, then install caliper to caliper carrier.
  2.  
  3. Torque caliper pin bolts to 16 ft. lbs. (22 Nm).
  4.  
  5. Connect caliper to flexible hose.
  6.  
  7. Torque flexible hose joint bolt to 17 ft. lbs. (23 Nm).
    WARNING
    Make sure that flexible hose is not twisted when tightening joint bolt. If it is twisted, reconnect it using care not to twist it.

  8.  
  9. Tighten bleeder plug.
  10.  
  11. Tighten wheel temporarily and lower lift.
  12.  
  13. Tighten wheel nuts to 61.5 ft. lbs. (85 Nm).
  14.  
  15. After completing installation, fill reservoir with brake fluid and bleed air from brake system. Perform brake test and check each installed part for oil leakage.
  16.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and safely support the rear of the vehicle.
  4.  
  5. To preserve wheel balance, mark the position of the front wheel relative to the wheel hub.
  6.  
  7. Remove the wheel.
  8.  
  9. Remove the caliper brake hose inlet bolt. Remove the ring seals.
  10.  
  11. To prevent fluid loss or contamination, plug openings at the caliper inlet and the brake hose.
  12.  
  13. Remove the caliper mounting bolts.
  14.  
  15. Remove the caliper.
  16.  

To install:

  1. Install the caliper
  2.  
  3. Install the caliper mounting bolts. Tighten the caliper mounting bolts to 19 ft. lbs. (27 Nm).
  4.  
  5. Install the brake hose to the caliper with the bolt and the ring seals. Tighten the caliper brake hose inlet bolt to 30 ft. lbs. (40 Nm).
  6.  
  7. Align the marks that were made when removing the front wheel, and install the wheel.
  8.  
  9. Lower the vehicle.
  10.  
  11. Fill the master cylinder reservoir to the proper level with clean brake fluid.
  12.  
  13. Bleed the air out of the brake system.
  14.  

 
label.common.footer.alt.autozoneLogo