Front Disc Brake Caliper Disassembly and Assembly - Suzuki Jimny Workshop Manual
4B
Front Disc Brake Caliper Disassembly and Assembly
Disassembly
1)
Before disassembly, clean all around caliper with brake fluid.
2)
Remove piston set ring (1) and boot from caliper, pry off with a flat-bladed tool. Be careful not to damage boot. (M13 engine model)
3)
Blow compressed air into cylinder through bolt hole where flexible hose was fitted.
With this air pressure, piston can be pushed out of cylinder.
With this air pressure, piston can be pushed out of cylinder.
WARNING:
Do not apply too much highly compressed air which will cause piston to jump out of cylinder. Place a cloth (1) to prevent piston from damage. It should be taken out gradually with moderately compressed air. Do not place your fingers in front of piston when using compressed air.
4)
Remove piston boot (1) prying it with a metal tool (2) (no sharp edge). (K9K engine model)
CAUTION:
Be careful not to damage inside (bore side) of cylinder.
5)
Remove piston seal using a thin blade like a thickness gauge, etc.
CAUTION:
Be careful not to damage inside (bore side) of cylinder.
6)
Remove bleeder plug and cap from caliper.
Assembly
Reassemble front brake in reverse order of disassembly, noting the following points.
M13 Engine Model
CAUTION:
•
Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir.
• Never use other fluid or thinner.
• Before installing piston and piston seal to cylinder, apply fluid to them.
• After reassembling brake lines, bleed air from them.
• Never use other fluid or thinner.
• Before installing piston and piston seal to cylinder, apply fluid to them.
• After reassembling brake lines, bleed air from them.
1)
Check that slide bushes and boots for wear, corrosion, damage, movement or deterioration. If it is found faulty, correct or replace.
Apply rubber grease to bush outer surface. And then make sure that each bush slides easily through each caliper bolt hole.
Apply rubber grease to bush outer surface. And then make sure that each bush slides easily through each caliper bolt hole.
NOTE:
Where temperature gets as low as –30 °C (–22 °F) in cold weather, use rubber grease whose viscosity varies very little even at –40 °C (–40 °F).
2)
Tighten bleeder plug to specified torque and install cap.
| 1. | Apply rubber grease. |
3)
Piston seal is used to seal piston and cylinder and to adjust clearance between pad and disc. Replace with a new one at every overhaul. Fit piston seal into groove in cylinder taking care not to twist it.
4)
Before inserting piston (2) into cylinder, install new boot (1) onto piston (2) as shown.
Boot direction
“A”: 2-grooved side directed inside
“B”: 3-grooved side directed outside
5)
Fit boot as it is in the figure into boot groove in cylinder with fingers.
6)
Insert piston into cylinder by hand and fit boot in boot groove in piston.
7)
To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out.
NOTE:
Boot’s face “B” should be at the same level from cylinder’s face “A” all around.
8)
Insert piston into cylinder by hand.
9)
Install piston set ring.
K9K Engine Model
CAUTION:
•
Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir.
• Never use other fluid or thinner.
• Before installing piston and piston seal to cylinder, apply fluid to them.
• After reassembling brake lines, bleed air from them.
• Install a new piston seal into groove in cylinder securely making sure that it is not twisted.
• Before installing caliper to carrier, install slide pin with grease applied into caliper carrier hole and check for its smooth movement in thrust direction.
• Never use other fluid or thinner.
• Before installing piston and piston seal to cylinder, apply fluid to them.
• After reassembling brake lines, bleed air from them.
• Install a new piston seal into groove in cylinder securely making sure that it is not twisted.
• Before installing caliper to carrier, install slide pin with grease applied into caliper carrier hole and check for its smooth movement in thrust direction.
1)
Install piston seal to caliper referring to the following instructions.
•
Piston seal is used to seal piston and cylinder and to adjust clearance between pad and disc.
• Replace with a new one at every overhaul.
• Fit piston seal into groove in cylinder taking care not to twist it.
• Replace with a new one at every overhaul.
• Fit piston seal into groove in cylinder taking care not to twist it.
2)
Before inserting piston (2) into cylinder, install new boot (1) onto piston (2) as shown.
Boot direction
“A”: 1-grooved side directed inside (cylinder side)
“B”: 2-grooved side directed pad side
| 3. | Cylinder | 4. | Piston seal |
3)
Fit boot as it is in the figure into boot groove in cylinder with fingers.
4)
Insert piston into cylinder by hand and fit boot in boot groove in piston.
5)
To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out.
NOTE:
Boot’s face “B” should be at the same level from cylinder’s face “A” all around.
6)
Insert piston into cylinder by hand.