Brake Booster Removal And Installation; Brake Booster Inspection; Booster Push Clevis Rod Adjustment - Suzuki SX4 Service Manual

4A-16 Brake Control System and Diagnosis:

Brake Booster Removal and Installation

Removal
1) Remove master cylinder assembly from booster
referring to "Master Cylinder Removal and
Installation".
2) Disconnect vacuum hose from booster referring to
"Master Cylinder and Brake Booster Components".
3) Remove front brake pipe (from master cylinder
primary and secondary to ABS hydraulic unit pipe)
referring to "Front Brake Hose and Pipe Removal
and Installation".
4) Remove clip (1) and then remove push rod clevis pin
(2).
5) Loosen booster mounting nuts (3) and then remove
booster.
3
Installation
1) Install booster to dash panel. Then connect push rod
clevis pin (2) and clip (1).
2) Tighten booster mounting nuts (3) to specified
torque.
Tightening torque
Booster mounting nut (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
3,(a)
S7RW0A4106016
2
1
3
I5RW0A410019-02
2
1
3,(a)
I5RW0A410021-02
3) Connect vacuum hose to booster referring to
"Master Cylinder and Brake Booster Components".
4) Install front brake pipe (from master cylinder primary
and secondary to ABS hydraulic unit pipe) referring
to "Front Brake Hose and Pipe Removal and
Installation".
5) Install master cylinder assembly to booster referring
to "Master Cylinder Removal and Installation".
6) Fill reservoir with specified fluid.
7) Bleed air from brake system referring to "Air
Bleeding of Brake System" and at the same time
bleed air from clutch system referring to "Air
Bleeding of Clutch System in Section 5C" (M/T
model).
8) Check pedal height and play referring to "Brake
Pedal Free Height Inspection" and "Brake Pedal
Play Inspection".
9) Check each installed part for fluid leakage and
perform brake test.

Brake Booster Inspection

• Check brake booster for damage and operation.
• Check boot for damage and deterioration.
• Check for push clevis rod distance.
If any malfunction is found, replace brake booster.

Booster Push Clevis Rod Adjustment

Install push clevis rod (1) so that measurement "a" is
obtained and torque nut (2) to specification.
Tightening torque
Clevis pin lock nut (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
Clevis installing position (length "a")
"a": 129.5 - 130.5 mm (5.10 - 5.13 in.)
S7RW0A4106017
S7RW0A4106018
IYSQ01410050-01