1990 Suzuki Sidekick Brake Service (ONLINE REPAIR MANUALS)

• Clean any dirt from around reservoir cap. Remove cap, then brake fluid.
• Remove reservoir connector screw, Fig., then reservoir.
• Disconnect brake lines from master cylinder. Do not allow brake fluid to get on painted surfaces.
• Remove master cylinder attaching bolts, then master cylinder.
• Adjust clearance of booster piston rod to master cylinder piston as follows:
• Push piston rod several times to ensure reaction disc is in place.
• Measure with gasket in place on master cylinder and booster at atmospheric pressure.
• Set measuring tool No. 09950-98210 or equivalent, on master cyl...

RWAL ECM

• Disconnect battery ground cable, then remove left side radio speaker from instrument panel.
• Remove engine ECM with cover, bracket and fuse box from steering column holder.
• Disconnect coupler from RWAL ECM, then remove RWAL ECM from dash panel.
• Reverse procedure to install.

WHEEL SPEED SENSOR

• Turn ignition switch Off, then remove sensor cover.
• Disconnect coupler from sensor, then remove sensor from differential carrier.
• Rev...

Refer to Figs through when performing this procedure.

• Remove piston rod from booster, then push rod clevis and nut.
• Set booster in booster overhaul set No. 09950-88210, Fig.
• Tighten tool bolt clockwise until No. 1 body projecting part and No.2 body depressed part fit each other, Fig. Mark both body parts.
• Remove booster from tool, then separate No. 1 and No. 2 bodies. Hold both bodies carefully to prevent either body from jumping off by spring force.
• Remove piston return spring.
• From No. 2 body, remove boot, air cleaner elements and air cleaner separator.
• On Sidekick models, ...

ROAD TEST

Brakes should be tested on dry, clean, smooth and reasonable level roadway which is not crowned. Road test brakes by making brake applications with both light and heavy pedal forces at various speeds to determine if car stops evenly and effectively.

Also drive car to see if it leads to one side without brake application. If it does, check tire pressure, front end alignment and front suspension attachments for looseness.

CHECKING FOR BRAKE FLUID LEAKAGE

Check master cylinder fluid levels. While a slight drop in reservoir level does result from normal lining wear, an abnormally lo...

SAMURAI

Pads, Replace

• Raise and support vehicle, then remove wheel assembly.
• Remove caliper antirattle clip, Fig. .
• Remove caliper guide pin caps.
• Using a 6mm Allen wrench, remove caliper guide pins.
• Remove pad protectors, then caliper cylinder.
• Remove pads.
• Reverse procedure to install noting the following:
• Torque caliper bolts to specifications.
• Install wheel assemblies.
• Lower vehicle and perform brake test.

Caliper Service

• Raise and support vehicle.
• Disconnect brake hose from caliper.
• Remove caliper guide pin caps.
• Using a 6mm Allen wrench, remove caliper guide pins, then caliper.
• Cl...

The Rear Wheel Anti-Lock (RWAL) system operation is controlled by the rear hydraulic brake line pressure which is regulated by a pressure limit valve. The pressure limit valve is located under the master cylinder and consists of two valves. One is a dump valve which releases pressure into an accumulator and the other valve is an isolation valve which holds rear brake pressure. The valve is controlled by a microcomputer which is a part of the Electronic Control Module (ECM). The ECM is installed near the fuse box located un...