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 brake caliper and brake pads. See Brake Pads removal and installation.
  6.  
  7. Unscrew the brake caliper from the brake hose.
  8.  
  9. Drain the remaining brake fluid.

    Click image to see an enlarged view

    Fig. Rear brake exploded view

  10.  

To install:

  1. Insert the brake caliper on the hose and hand tighten.
  2.  
  3. Clean and install the brake pads and brake calipers.
  4.  
  5. Tighten the locating pins to 20 ft. lbs. (28 Nm) plus 60°.
  6.  
  7. Tighten the brake hose to 13 ft. lbs. (18 Nm).
    NOTE
    The brake hose must not be twisted.

  8.  
  9. Fill and bleed the brake system.
  10.  
  11. Depress the brake pedal a few times. Check the level of the brake fluid reservoir.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and safely support the rear of the vehicle.
  4.  
  5. Remove the wheels.
  6.  
  7. Remove the bolt and the ring seals that attach the brake hose inlet fitting to the caliper.
  8.  
  9. Disconnect the brake hose. Plug the openings in the caliper and the brake hose to prevent fluid loss or contamination.
  10.  
  11. Remove the caliper mounting bolts from the steering knuckle.
  12.  
  13. Remove the caliper.

    Click image to see an enlarged view

    Fig. Rear brake caliper removal

  14.  

To install:

  1. Install the caliper with the mounting bolts. Tighten the caliper mounting bolts to 33 ft. lbs. (45 Nm).
  2.  
  3. Connect the brake hose with the bolt and ring seals. Tighten the brake hose inlet bolt and ring seals to 24 ft. lbs. (32 Nm).
  4.  
  5. Install the rear wheels.
  6.  
  7. Lower the vehicle.
  8.  
  9. Fill the master cylinder to the proper level with clean brake fluid.
  10.  
  11. Bleed the caliper.
  12.  

 
label.common.footer.alt.autozoneLogo