Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Brake System Bleeding

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MODELS WITHOUT ABS



See Figures 1, 2 and 3


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.



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Fig. Fig. 1: On Samurai models, bleed the hydraulic brake system at the four points shown, starting at the furthest point and working your way closer to the master cylinder


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 1 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

Bleed the brake system in the following order only: left rear wheel cylinder, proportioning and bypass valve (Samurai models only), right front wheel caliper, left front wheel caliper.

  1. Fill the master cylinder reservoir to the MAX line with brake fluid and keep it at least half full throughout the bleeding procedure.
  2.  



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Fig. Fig. 2: Attaching a clear plastic hose to the bleeder valve helps avoid messy brake fluid spills-rear wheel cylinder shown



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Fig. Fig. 3: A clear hose (arrow) also allows you to view the emitted brake fluid and check for air bubbles-front caliper shown

  1. Remove the bleeder plug cap, then attach a clear vinyl tube to the wheel cylinder bleeder plug. Insert the open end of the hose into a container.
  2.  
  3. Have an assistant depress the brake pedal several times. While your helper holds the pedal in the depressed position, loosen the bleeder plug one-third to one-half of a turn (or until brake fluid starts to exit the bleeder valve).
  4.  
  5. When the fluid pressure is almost gone, retighten the bleeder plug, THEN have your assistant release the brake pedal. It is very important that the brake pedal stay depressed while the bleeder valve is open, because air will be sucked into the brake system if the pedal is released while the valve is still open.
  6.  
  7. If the fluid is level is low, fill the brake master cylinder fluid reservoir with clean DOT 3 fluid.
  8.  



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Fig. Fig. 4: Have an assistant depress the brake pedal repeatedly then hold the pedal depressed. Loosen the bleeder valve until brake fluid exits



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Fig. Fig. 5: Only once you tighten the bleeder valve can your assistant release the brake pedal

  1. Repeat Steps 3 through 5 until all air bubbles are gone from the hydraulic fluid.
  2.  
  3. If equipped, install the bleeder plug cap.
  4.  
  5. Proceed to the next item to bleed; remember to bleed the vehicle in the proper order. For Samurai models, start with the left rear wheel cylinder, then the P+D valve, then right front caliper, and finally the left front caliper. For all other models, start with the left rear wheel cylinder, then right front caliper, and finally the left front caliper.
  6.  
  7. Doublecheck that all bleeder plugs are tightened to 22 inch lbs. (2.5 Nm) after completion.
  8.  
  9. After completing the bleeding procedure, apply fluid pressure to the pipe line while checking for leaks.
  10.  
  11. Fill the brake fluid reservoir to the specified full level.
  12.  
  13. Check brake pedal for a spongy feeling; if any evidence exists, repeat the entire procedure.
  14.  

MODELS WITH ABS



See Figure 4

1996-98 Sidekick, Tracker and X-90 models equipped with the Anti-Lock Brake System (ABS) require a scan tool to properly bleed the brake system. If you are servicing such a vehicle, please refer to the applicable ABS information located at the end of this information BEFORE you perform any brake procedures.

The ABS systems used on 1990-95 models and Sidekick Sport models should be bled exactly like the non-ABS systems; refer to the previous bleeding procedure.



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Fig. Fig. 6: The RWAL and Sidekick Sport ABS systems should be bled the same as models not equipped with ABS

The 1996-98 Sidekick, Tracker and X-90 models equipped with the ABS system are bled using a special method and tool, refer to the specific ABS information for this procedure.

 
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