Rear Disc Brake Caliper Removal and Installation: Installation

Reference:  REAR DISC BRAKE PAD INSPECTION  

Reference:  REAR DISC BRAKE CALIPER CHECK  

1. Install brake caliper carrier (1) to rear axle (2).

   Tightening torque 

   Caliper carrier bolt (a): 60 N.m (6.0 kg-m, 43.5 lbf-ft) 

   Fig 1: Installing Brake Caliper Carrier To Rear Axle

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2. Install new slide pin boots (1) to brake caliper carrier.
3. Apply rubber grease to slide pins, then install slide pin (2) to front side and slide pin (3) to rear side of brake caliper carrier.
   NOTE: Be sure not to install wrongly because the shape of slide pins are different as shown in figure below.
   Fig 2: Identifying Rear Side Of Brake Caliper Carrier Grease Application Areas

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4. Pass parking brake cable (1) through bracket (3) of caliper.
5. Hang parking brake cable on lever (2) as follows.
   NOTE: Make sure that lever (4) contacts pin (5).
   Fig 3: Identifying Lever And Contacts Pin

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6. Install brake pads and caliper referring to REAR DISC BRAKE PAD REMOVAL AND INSTALLATION  .
7. Connect flexible hose (4) with new washers (5) to caliper and brake pipe temporarily by hand. Then install clip (2).
8. Tighten flexible hose joint bolt (3) and brake pipe flare nut (1).

   Tightening torque 

   Flexible hose joint bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft) 

   Brake pipe flare nut (b): 16 N.m (1.6 kg-m, 12.0 lbf-ft) 

   Fig 4: Tightening Flexible Hose Joint Bolt And Brake Pipe Flare Nut

   Courtesy of SUZUKI OF AMERICA CORP.
9. Install brake cable clip (1) securely to bracket (2).
   Fig 5: Installing Brake Cable Clip

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10. After reassembling brake lines, bleed air from them referring to AIR BLEEDING OF BRAKE SYSTEM .
11. Check to make sure that system is free from fluid leakage.
12. Check to make sure that parking brake lever stroke is as specified. If not, adjust. Refer to PARKING BRAKE INSPECTION AND ADJUSTMENT .
13. Install rear wheel referring to WHEEL (WITH TIRE) REMOVAL AND INSTALLATION .
14. Remove vehicle from hoist and perform brake test (foot brake and parking brake).