Suzuki Aerio, Verona 2002-06

Brake Pads

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Removal & Installation



  1. Remove the wheels on both sides.
  2.  
  3. Remove the pad retaining spring carefully so as not to deform it.
  4.  
  5. Remove:

    The protective caps (1) from the two locating pins (2)
     
    The locating pins, use hex socket 7mm.
     
    The brake caliper from the holder
     
    Brake pads.
     

  6.  
  7. Hang brake caliper from a steel wire from the front spring so as not to damage brake hose.
    NOTE
    Do not depress the brake pedal while the brake pads are removed.

  8.  
  9. Clean and check the brake caliper and dust cover.
  10.  
  11. Clean and check the brake pad mating surfaces in the brake caliper and caliper holder.
  12.  
  13. Check piston dust boot.
    NOTE
    If the dust boot is damaged dirt may have penetrated the cylinder. If this is the case the caliper must be replaced.

  14.  
  15. Check brake disc friction surfaces.
    NOTE
    Minimum recommended disc thickness/replacement limit is 0.984 inch (25.0mm). Minimum recommended disc thickness when installing new brake pads is 0.984 inch (25.8mm).

  16.  

To install:

  1. Press piston back into cylinder on brake caliper.
  2.  
  3. Check that the dust cover is correctly positioned.
  4.  
  5. Install:

    New brake pads
     
    The brake caliper.
     

  6.  
  7. Lubricate the locating pins using caliper grease. Insert the locating pins into the rubber sleeves. The pins should slide into the sleeves easily.
  8.  
  9. Tighten the locating pins to 20 ft. lbs. (28 Nm).
  10.  
  11. Install the protective caps.
  12.  
  13. Install the securing spring.
  14.  
  15. Check the brake fluid level in the reservoir.
  16.  
  17. Depress the brake pedal a few times. Check the level of the brake fluid reservoir.
  18.  
  19. Install the wheels.
  20.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the brake caliper.
  6.  
  7. Remove the brake pads.
  8.  

To install:

  1. Before installing brake pad shim, apply small amount of grease (included in spare parts) to mating surfaces of brake pad and pad shim.
  2.  
  3. Set brake pad springs and shim and install brake pads.
  4.  
  5. Install brake caliper.
  6.  
  7. Tighten wheel temporarily and lower lift.
  8.  
  9. Tighten wheel nuts to 61.5 ft. lbs. (85 Nm).
  10.  
  11. After completion of installation, check for brake effectiveness.
  12.  

  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 lower caliper mounting bolt.
    NOTE
    Caliper removal is not necessary to service the brake pads.

  10.  
  11. Pivot the caliper upward.
  12.  
  13. Remove the brake shoes.
  14.  

To install:

  1. Install the brake shoes.
  2.  
  3. Push the caliper piston inward, if needed.
  4.  
  5. Pivot the caliper downward and install the mounting bolt. Tighten the caliper mounting bolt to 19 ft. lbs. (27 Nm).
  6.  
  7. Tighten the pushrod clevis to 13 ft. lbs. (18 Nm).
  8.  
  9. Align the marks that were made when removing the front wheel, and install the wheel.
  10.  
  11. Lower the vehicle.
  12.  

 
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