KAMPANJE AZG : Skifte bakre bremsecalipere

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Viggo Berger
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1 KAMPANJE AZG : Skifte bakre bremsecalipere Berørte modeller: Swift AZG produsert i Ungarn fra til..05. Totalt 656 biler Eierne kontaktes pr. brev fra Teknisk avdeling. NB! Ikke alle bilene har eiere, sjekk derfor alltid om bilen er omfattet av kampanjen vha. "Kampanjesøk" på Forhandlerweb. Ved tvil tar dere kontakt med teknisk avdeling. Problem/symptomer: Mulig bremsevæskelekkasje fra bakre bremsecalipere. Tiltak: Skifte bakre bremsecalipere. Les nøye gjennom arbeidsbeskrivelsen før jobben gjøres. Delebehov: Sett med begge bremsecalipere: RX Tilleggsinformasjon: Velg "Kampanjesøk" på "Dashbord" (den siden du kommer til ved innlogging) og legg inn registreringsnummer eller VIN. Om bilen er omfattet av kampanjen vises dette på skjermen. Kampanjesøk kan også gjøres før innlogging på Forhandlerweb. Liste med chassisnummer over berørte biler legges IKKE ved dette skriv. Bruk Forhandlerweb! Ved reklamasjon: Legg inn chassisnummer/registreringsnummer under "Teknisk" / "Opprett Reklamasjon" på Forhandlerweb og trykk på "Søk". Trykk på "Velg" når bil kommer opp under "Søkeresultat" Du får nå valget mellom å opprette en blank reklamasjon eller en forhåndssøknad eller en kampanje. Merk av for kampanje AZG-5 "Skifte bakre bremsecalipere", fyll ut datoer, arbeidsordrenummer og kilometerstand og lagre. Rapporten fylles automatisk ut med arbeid og deler. Legg inn beskrivelser. IKKE endre andre felt!! Trykk så på "Send reklamasjon" nederst på siden. Rapport ferdig. Se også eget skriv angående kampanjesøk og innlegging av kampanjer som finnes på samme sted som dette skriv på RSA Ekstranett. Kampanje AZG Dato: Revisjon A

2 ANNEX Replacement Procedure for AZG SWIFT Rear Brake Caliper

3 Workflow. Confirmation of Affected Vehicle Page. Replacement procedure for Rear Brake Caliper Page 3 -. Necessary Tools Page 3 -. Replacement Part Page 4-3. Replacement Procedures Page 5

4 . Confirmation of Affected Vehicle Check Vehicle Identification Number to see if the vehicle is affected or not. Vehicle Identification Number (VIN) Location... On the cowl top panel in the engine room. Affected Vehicle: According to ANNEX HUVU VIN list

. Replacement procedure for Rear Brake Caliper -. Necessary Tools 3 4 5 6 7 8 9 0 NO.

5 . Replacement procedure for Rear Brake Caliper -. Necessary Tools NO. Tool Name Phillips screwdriver ( Medium ) Flat-bladed screwdriver 3 Ring wrench ( 0 mm ) 4 Socket wrench ( 9.5sq, 0 mm ) 5 Socket wrench ( 9.5sq, 4 mm ) 6 Socket wrench (.7sq, 9 mm ) 7 Ratchet handle ( 9.5sq ) 8 Torque wrench ( 9.5sq, 0-40 N m ) 9 Torque wrench (.7sq, N m ) 0 Hammer 3

-. Replacement Part Replacement Parts Part Name Part Number Qty.

Cylinder Set 55860-6880-RX0 Flexible hose gasket ( pcs ) Grease ( pcs

is trace that tightened bolt in attachment surface of rear brake

This is contact trace at the time of inspection facility at parts

Necessary material Be sure to use brake fluid indicated on brake

6 -. Replacement Part Replacement Parts Part Name Part Number Qty. Remarks Rear brake caliper cylinder ( Right and Left ) Blue paint mark Cylinder Set RX0 Flexible hose gasket ( pcs ) Grease ( pcs ) NOTE : In rear brake caliper cylinder for replacement parts, there is trace that tightened bolt in attachment surface of rear brake caliper pin bolt. This is contact trace at the time of inspection facility at parts manufacturing and it does not influence installation. Necessary material Be sure to use brake fluid indicated on brake master cylinder reservoir cap of the vehicle. Part Name Part Number Qty. Comment Brake Fluid SUZUKI Brake Fluid DOT3 0.5L SUZUKI Brake Fluid DOT4 4

7 -3. Replacement Procedures Rear Brake Caliper Components Rear brake caliper cylinder 9. Parking brake cable clamp bolt. Rear brake caliper carrier 0. Rear brake pad 3. Rear brake caliper pin bolt. Pad spring 4. Rear brake flexible hose : 6 N m 5. Flexible hose joint bolt : 3 N m 6. Flexible hose gasket : N m 7. Parking brake cable : Apply grease 8. E-ring : Do not reuse 5

NOTICE : Brake fluid is extremely damaging to painted surfaces. If brake fluid contacts painted surfaces, immediately wipe it off and flush the surfaces with water thoroughly.

Using shock absorber fluid or any other fluid that contains mineral oil for the brake fluid will cause the rubber parts in the brake hydraulic system to swell or distort.

8 NOTICE : Brake fluid is extremely damaging to painted surfaces. If brake fluid contacts painted surfaces, immediately wipe it off and flush the surfaces with water thoroughly. Using improper or contaminated brake fluid can cause brake system failure. Using shock absorber fluid or any other fluid that contains mineral oil for the brake fluid will cause the rubber parts in the brake hydraulic system to swell or distort. If water is mixed in the brake fluid, the boiling point will be lowered. - Use only the specified brake fluid from a sealed container. - Do not use a container that has been used for a mineral oil or is wet with water for refilling the brake system. - Keep all fluid containers capped to prevent contamination and entry of moisture. Removal NOTE : Prepare container to catch brake fluid when rear brake flexible hose is removed from rear brake caliper cylinder. ) Hoist vehicle and remove rear wheel. ) Remove floor console rear box. 3) Release parking brake. 4) Loosen parking brake adjusting nut (). 5) Remove E-ring () and parking brake cable clamp bolt (). 6) Turn lever () in arrow direction and remove parking brake cable () from lever and bracket (3). 3 6

0) Remove rear brake caliper cylinder () from rear brake caliper carrier (3). 3 ) Remove contralateral rear brake caliper cylinder by the same Step from 5) to 0).

9 7) Place a container to catch brake fluid from disconnected rear brake flexible hose () below rear brake caliper cylinder (). 8) Remove flexible hose joint bolt (3), flexible hose () and flexible hose gasket from rear brake caliper cylinder (). 3 9) Remove rear brake caliper pin bolts (). 0) Remove rear brake caliper cylinder () from rear brake caliper carrier (3). 3 ) Remove contralateral rear brake caliper cylinder by the same Step from 5) to 0). Installation NOTICE: If the rear brake flexible hose is twisted, the hose will be damaged. If the rear brake flexible hose is twisted, reinstall rear brake caliper being careful not to let rear brake flexible hose get twisted. ) Remove rear brake pad, then apply grease included in replacement parts to hatched areas A of pad springs, and install rear brake pad. A A 7

) Install rear brake caliper while aligning slot of brake piston () with protrusion on the back of rear brake pad ().

torque. Tightening torque Rear brake caliper pin bolt (a) : 6 N m (.7 kgf-m, 9.

joint bolt (3) to specified torque. Tightening torque Flexible hose joint bolt (a) : 3 N m (.3 kgf-m, 7.

10 ) Install rear brake caliper while aligning slot of brake piston () with protrusion on the back of rear brake pad (). 3) Install rear brake caliper cylinder () to rear brake caliper carrier () and tighten rear brake caliper pin bolt (3) to specified torque. Tightening torque Rear brake caliper pin bolt (a) : 6 N m (.7 kgf-m, 9.5 lbf-ft ) 3, (a) 4) Install rear brake flexible hose () to rear brake caliper cylinder with new gasket () and tighten flexible hose joint bolt (3) to specified torque. Tightening torque Flexible hose joint bolt (a) : 3 N m (.3 kgf-m, 7.0 lbf-ft ) 3, (a) 5) Pass parking brake cable () through bracket(3). 6) Align positions of parking brake cable () and bracket (3). Turn lever () in arrow direction and install cable () to lever (). 3 [A] [A] : Positioning part 8

7) Install E-ring () to hold parking brake cable () and then tighten parking brake cable clamp bolt (3) to specified torque. 3, (a) Tightening torque Parking brake cable clamp bolt (a) : N m (.

[A] [A] : Wheel side 8) Install contralateral rear brake caliper cylinder by the same step from ) to 7). 9) Fill reservoir with brake fluid and bleed air out of brake system.

11 7) Install E-ring () to hold parking brake cable () and then tighten parking brake cable clamp bolt (3) to specified torque. 3, (a) Tightening torque Parking brake cable clamp bolt (a) : N m (. kgf-m, 8.5 lbf-ft ) NOTE : Install E-ring toward wheel side from vehicle inside, and not to protrude from edge of bracket. [A] [A] : Wheel side 8) Install contralateral rear brake caliper cylinder by the same step from ) to 7). 9) Fill reservoir with brake fluid and bleed air out of brake system. Brake fluid specification : Refer to reservoir cap 0) Check that there is no leakage of brake fluid. ) Depress brake pedal three or more times with engine running so that rear brake pad clearance adjustment mechanism operates and clearance between rear brake disc and brake pads will become appropriate. ) Stop engine and check that lever of caliper () contacts the pin (). If the caliper does not contact the pin, repeat loosening parking brake adjusting nut until parking brake cable becomes free of tension and Step ) again. 9

12 3) Tighten parking brake adjusting nut () so that parking brake drags when parking brake is pulled by one notch. 4) Check that parking brake lever stroke is between 4 and 9 notches when the parking brake lever is pulled with 00 N (0.4 kgf, 45.0 lbf). 5) Check equalizer () inclination angle. If angle is not as specified, check parking brake cable, rear brake caliper and rear brake pads. Equalizer inclination angle a : Within 5 degrees a 6) After completion of adjustment, release parking brake and check that parking brake does not drag. 7) Install rear wheel and check that parking brake produces proper braking force. 8) Check that brakes do not drag and that appropriate braking force can be obtained. 9) Install floor console rear box. 0

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