Service Manual Update: Rear Disc Brake System (TS 03 09094)

Publication date: 2014-09-09
Reference number: TS 03 09094

SERVICE MANUAL UPDATE: REAR DISC BRAKE SYSTEM

TECHNICAL SERVICE BULLETIN

Reference Number(s): TS 03 09094, Date of Issue: September 9, 2014

SUZUKI:

2007 - 2013 SX4 (RW420)

CONDITION

This bulletin is being provided to inform you of service manual corrections for rear brake system service. Corrections apply to 2007 - 2013 SX4 (RW420) Service Manuals, Section 4C - Rear Brakes.

CORRECTION

Please refer to changes illustrated in the attached pages of this bulletin. The following table describes the corresponding section that has been amended. The Online Service Manual has been revised prior to the release of this bulletin.

AFFECTED SERVICE MANUALS

Manual Name	Manual Number	Corresponding Item
SX4 (RW420)	99500-80J20-01E	Section 4C: Rear Brakes (Disc Brake Model) Repair Instructions Rear Brake Components Rear Brake Pad Removal and Installation
SX4 (RW420)	99500-80J10-01E

Please refer to changes illustrated in the following pages.

4C REAR BRAKES DISC

Repair Instructions

Rear Disc Brake Components

Rear Disc Brake Pad Removal and Installation

Reference: "REAR DISC BRAKE COMPONENTS ": Disc

CAUTION:

During removal, be careful not to damage brake flexible hose and not to depress brake pedal.
Do not operate brake pedal with pads removed.

NOTE: When replacing brake pad, replace it both side caliper as the set.

Removal

Hoist vehicle and remove wheel.
Release parking brake lever.
Remove caliper pin bolts (1).
Remove caliper (2) from caliper carrier.
NOTE: Hang removed caliper (2) with a wire hook or the like so as to prevent brake hose from bending and twisting excessively or being pulled.
Don't operate brake pedal with brake pads removed.
Remove brake pads and pad springs.

Installation

Reference: "Rear Disc Brake Pad Inspection": Disc

Turn brake caliper piston clockwise to obtain clearance between brake disc and pads.
Special tool

(A): 09945-16060
When brake pad set is replaced with a new one, apply small amount of grease "a" (included in spare parts) to brake caliper carrier (1).
Attach pad springs (2) to caliper carrier (1).
Before installing brake pad shims (1), apply small amount of grease "b" (included in spare parts) to surfaces of brake pad in contact with pad shim (1) and pad springs when brake pad set is replaced with a new one.
Set pad shims (1) to brake pads (2).
With lug (1) of brake pad matched with dent (2) of brake piston, install caliper (3) to caliper carrier.
Tighten caliper pin bolts (4) to specified torque.
Tightening torque

Caliper pin bolt (a): 23 N.m (2.3 kgf-m, 17 lbf-ft)