Brake System Testing

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

Brakes should be tested on a dry, clean, reasonably smooth and level roadway. A true test of brake performance cannot be made if the roadway is wet, greasy, or covered with loose dirt whereby all tires do not grip the road equally. Testing will also be adversely affected if the roadway is crowned so as to throw the weight so roughly that the wheels tend to bounce. Test the brakes at different vehicle speeds with both light and heavy pedal pressure; however, avoid locking the brakes and sliding the tires. Locked brakes and sliding tires do not indicate brake efficiency since heavily braked, but turning, wheels will stop the vehicle in less distance than locked brakes. More tire-to-road friction is present with a heavily-braked, turning tire than with a sliding tire.

Because of the high deceleration capability, a firmer pedal may be felt at higher deceleration levels. There are three major external conditions that affect brake performance:

Tires having unequal contact and grip of the road will cause unequal braking. Tires must be equally inflated, and the tread pattern of the right and the left tires must be approximately equal.
Unequal loading of the vehicle can affect the brake performance since the most heavily loaded wheels require more braking power, and thus more braking effort, than the others.
Misalignment of the wheels, particularly conditions of excessive camber and caster, will cause the brakes to pull to one side.

To check for brake fluid leaks, hold constant foot pressure on the pedal with the engine running at idle and the shift lever in NEUTRAL. If the pedal gradually falls away with the constant pressure, the hydraulic system may be leaking. Perform a visual check to confirm any suspected leaks.

Check the master cylinder fluid level. While a slight drop in the reservoir level results from normal lining wear, an abnormally low level indicates a leak in the system. The hydraulic system may be leaking either internally or externally. Refer to the procedure below to check the master cylinder. Also, the system may appear to pass this test while still having a slight leak. If the fluid level is normal, check the vacuum booster pushrod length. If an incorrect pushrod length is found, adjust or replace the rod.

Check the master cylinder using the following procedure:

Check for a cracked master cylinder casting or brake fluid leaking around the master cylinder. Leaks are indicated only if there is at least one drop of fluid. A damp condition is not abnormal.
Check for a binding pedal linkage and for an incorrect pushrod length. If both of these parts are in satisfactory condition, disassemble the master cylinder and check for an elongated or swollen primary cylinder or piston seals. If swollen seals are found, substandard or contaminated brake fluid should be suspected. If contaminated brake fluid is found, all the components should be disassembled and cleaned, and all the rubber components should be replaced. All of the pipes must also be flushed.

Improper brake fluid, or mineral oil or water in the fluid, may cause the brake fluid to boil or cause deterioration of the rubber components. If the primary piston cups in the master cylinder are swollen, then the rubber parts have deteriorated. This deterioration may also be evidenced by swollen wheel cylinder piston seals on the drum brake wheels.

If deterioration of rubber is evident, disassemble all the hydraulic parts and wash the parts with alcohol. Dry these parts with compressed air before reassembly to keep alcohol out of the system. Replace all the rubber parts in the system, including the hoses. Also, when working on the brake mechanisms, check for fluid on the linings. If excessive fluid is found, replace the linings. If the master cylinder piston seals are in satisfactory condition, check for leaks or excessive heat conditions. If these conditions are not found, drain the fluid, flush the master cylinder with brake fluid, refill the master cylinder, and bleed the system. Refer to "MANUAL BLEEDING THE BRAKES :" or "PRESSURE BLEEDING THE BRAKES :".