Engine removal SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-17
2) Hold brake pedal depressed for 30 seconds. If pedal height does not change, condition is good. But it isn’t
if pedal rises.
Brake Booster Removal and InstallationS7RS0B4106017
Removal
1) Recover refrigerant from A/C system by using recovery and recycling equipment referring to
“Operation Procedure for Refrigerant Charge in
Section 7B” or “Operation Procedure for Refrigerant
Charge in Section 7B”.
2) Remove master cylinder assembly from booster referring to “Master Cylin der Assembly Removal and
Installation”.
3) Remove cowl top cover and cowl top panel referring to “Cowl Top Components in Section 9K”.
4) Remove suction hose referring to “Major Components of A/C System in Section 7B” or “Major
Components of A/C System in Section 7B”.
5) Disconnect vacuum hose from booster referring to “Brake Booster Components”.
6) Remove push rod clevis pin and booster mounting nuts and then remove booster. Installation
1) Loosen brake pedal bracket mounting bolt.
2) Install booster (2) to dash panel. Then connect push rod clevis (3) to pedal arm with clevis pin (1) and clip
(4).
3) Tighten booster mounting nuts (a) to specified torque.
Tightening torque
Booster mounting nut (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
4) Tighten brake pedal bracket mounting bolt to specified torque.
Tightening torque
Brake pedal bracket mounting bolt (b): 13 N·m (
1.3 kgf-m, 9.5 lb-ft)
5) Install suction hose referring to “Major Components of A/C System in Section 7B” or “Major Components
of A/C System in Section 7B”.
6) Install cowl top panel and cowl top cover referring to
“Cowl Top Components in Section 9K”.
7) Install master cylinder assembly to booster referring to “Master Cylinder Assembly Removal and
Installation”.
8) Fill reservoir with specified fluid.
9) Bleed air from brake system.
H: Hold
T: 30 seconds
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1
2 4
3
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(b)
(a)
I4RS0B410021-02

Downloaded from www.Manualslib.com manuals search engine 4B-2 Front Brakes:
Front Disc Brake Pad On-Vehicle InspectionS7RS0B4206002
Inspect pad linings (1) periodically according to
maintenance schedule whenever wheels are removed
(for tire rotation or other reason). Take a look through
each end (or hole) of caliper and check lining thickness
of outside and inside pads.
If lining is worn and its thic kness (“a” in figure) is less
than limit, all pads must be replaced at the same time.
Front brake pad thickness “a” (lining thickness)
Standard: 10 mm (0.40 in.)
Limit: 2 mm (0.08 in.)
Front Disc Brake Pad Removal and InstallationS7RS0B4206003
NOTE
When replacing brake pad, replace it on the
right and left.

Removal
1) Loosen wheel nuts, lifted vehicle and remove wheels referring to “Wheel Remova l and Installation in
Section 2D”.
2) Remove caliper pin bolts (1). 3) Remove caliper (1) from caliper carrier (2).
NOTE
Hang removed caliper (1) with a wire hook (4)
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.

4) Remove brake pads (3).
5) Remove brake pad spring (1) as shown in figure.
Installation
WARNING!
Do not apply grease on pad lining surface.

1) Apply small amount of pad grease “a” (included in spare parts) to pad spring and set brake pad spring
as shown in figure.
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1
I2RH01420003-01
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1
I7RW01420014-01
"a"
I7RW01420011-01

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-3
2) Set brake pad springs (1), shim (2) and install brake pads (3).
NOTE
Install right side brake pad with wear
indicator (4) to vehicle center side.

3) Install caliper and tighten caliper pin bolts (a) to specified torque.
Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
4) Install wheel and lower lift.
5) Tighten wheel nuts to specified torque. Tightening torque
Wheel nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
6) After completion of installation, check for brake effectiveness.
Front Disc Brake Pad InspectionS7RS0B4206004
Check pad lining for wear. When wear exceeds limit,
replace with new one.
CAUTION!
Never polish pad lining with sandpaper. If
lining is polished with sandpaper, hard
particles of sandpaper will be deposited in
lining and may damage disc. When pad lining
requires correction, replace it with a new one.

Front brake pad thickness (lining thickness)
Standard: 10 mm (0.40 in.)
Limit: 2 mm (0.08 in.)
NOTE
When pads are removed, visually inspect
caliper for brake fluid leak. Correct leaky
point, if any.

Front Disc Brake Caliper Removal and
Installation
S7RS0B4206005
Removal
1) Hoist vehicle and remove wheel.
2) Loosen flexible hose joint bolt (1) a little at caliper.
CAUTION!
Be careful not to twist flexible hose while
loosening the bolt.

3) Remove caliper pin bolts (1).
4) Remove caliper fr om caliper carrier.
5) Disconnect flexible hose fr om caliper using care not
to twist it. As this will allow brake fluid to flow out of
flexible hose, have a container ready beforehand.
I6RS0C420002-01
(a)
I4RS0A420002-01
I2RH01420005-01
I6RS0C420003-01
1
I2RH01420010-01

Downloaded from www.Manualslib.com manuals search engine 4B-6 Front Brakes:
5) To confirm that boot is fitted in its groove in cylinder
properly, pull piston out of cylinder a little but do not
take it all out.
NOTE
Boot’s face (1) should be at the same level
from cylinder’s face (2) all around.

6) Insert piston into cylinder by hand.
Front Disc Brake Caliper InspectionS7RS0B4206007
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage.
If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate
unsmooth return of piston.
In such case, replace rubber seal.
Front Brake Disc Removal and InstallationS7RS0B4206008
CAUTION!
During removal, be care ful not to damage
brake flexible hose and not to depress brake
pedal.

Removal
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper carrier bolts (2 pcs).
NOTE
Hang removed caliper with a wire hook or the
like so as to prevent brake hose from
bending and twisting excessively or being
pulled.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
I4RS0A420004-01
I2RH01420014-01
I2RH01420015-01
I2RH01420024-01
I2RH01420025-01

Downloaded from www.Manualslib.com manuals search engine 4C-2 Rear Brakes:
Rear Disc Brake Pad Removal and InstallationS7RS0B4306002
NOTE
When replacing brake pad, replace it on the
right and left.

Removal1) Hoist vehicle and remove wheel.
2) Release parking brake lever.
3) Remove caliper pin bolts (1).
4) 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.

5) Remove brake pads (1) and pad springs. Installation
1) Turn brake caliper piston clockwise to obtain clearance between brake disc and pads.
Special tool
(A): 09945–16060
2) Clean (and degrease) pad spring installation face (3) of caliper carrier (1).
3) Attach pad springs (2) to caliper carrier (1).
4) Before installing brake p ad shims (1), apply small
amount of grease (included in spare parts) to mating
surfaces of brake pad and pad shim.
5) Set pad shims (1) to brake pads (2).
1 2
I6RS0C430002-01
1
I6RS0C430003-01
(A)
I6RS0B431004-01
113
2
I6RS0B431005-03
2
1
1 2
I6RS0C430004-01

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-3
6) With lug (1) of brake pad matched with dent (2) of brake piston, install caliper (3) to caliper carrier.
7) Tighten caliper pin bolts (4) to specified torque.
Tightening torque
Caliper pin bolt (a): 23 N·m (2.3 kgf-m, 17 lb-ft)
8) Tighten wheel bolts temporarily and lower lift.
9) Tighten wheel nuts to specified torque. Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
10) After completion of installation, check for brake effectiveness.Rear Disc Brake Caliper Removal and
Installation
S7RS0B4306003
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Hoist vehicle and remove rear wheel.
2) Release parking brake lever.
3) Remove clip (1).
4) Disconnect flexible hose (1) from caliper.
4, (a) 21
3
I6RS0C430005-01
1
I6RS0C430006-01
1
I6RS0C430007-01

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-5
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).

6) Install brake pads and caliper referring to “Rear Disc Brake Pad Removal and Installation”.
7) Connect flexible hose (1) with new washers to caliper (2).
WARNING!
Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.

Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft) 8) Install brake cable clip (1) securely to bracket (2).
9) After reassembling brake lines, bleed air from them
referring to “Air Bleeding of Brake System in Section
4A”.
10) Check to make sure that system is free from fluid
leakage.
11) Start engine and then depress brake pedal with about 300 N (30 kg, 66 lbs) load 3 times or more so
as to obtain proper disc to pad clearance.
12) Check to make sure that parking brake lever stroke is as specified. Refer to “Parking Brake Inspection
and Adjustment in Section 4D”.
13) Tighten wheel nuts to specified torque.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Remove vehicle from hoist and perform brake test (foot brake and parking brake).
1
23
45
I6RS0C430010-01
1 (a)2
I6RS0C430011-01
1
2
I6RS0C430012-01

Downloaded from www.Manualslib.com manuals search engine 4C-8 Rear Brakes:
Rear Disc Brake Caliper InspectionS7RS0B4306006
Pin Boot and Cylinder Boot
Check boots (1) for breakage, crack and damage.
If defective, replace.
Disc Brake Piston
Check all around piston for rust, corrosion and any other
damage.
If it is found faulty, replace.
Caliper
Push in adjusting bolt (1) by hand and move lever to
check that adjusting bolt (1) moves smoothly in the
arrow direction.
Also, check adjusting bolt (1) for any damage. If it is
found faulty, replace.
Slide Pin
Check guide pin for smooth movement.
If it is found faulty, correct or replace.
Apply rubber grease to guide pin outer surface. Rubber
grease should be the one whose viscosity is less
affected by such low temperature as –40 °C (–40 ° F).
Rear Flexible Hose Removal and InstallationS7RS0B4306007
Removal
1) Hoist vehicle and remove tire and wheel.
2) Remove caliper (4) assembly referring to “Rear Disc Brake Caliper Disassembly and Assembly”.
3) Loosen brake pipe flare nut (1) using by flare nut wrench.
4) Remove clip (2).
5) Remove brake flexible hose (3) from brake pipe.
Installation
Install reverse order of removal nothing the following.
• Tighten brake pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0 lb-ft)
1 1
1
I6RS0B431019-01
I6RS0B431020-01
1
I6RS0B431021-01
1
2
3
4
I6RS0C430013-01

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-9
Rear Brake Disc Removal and InstallationS7RS0B4306008
Removal1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper
carrier bolts (1) (2 pcs).
CAUTION!
During removal, be ca reful not to damage
brake flexible hose and not to depress brake
pedal.

NOTE
Hang removed caliper 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.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs). Installation
Install in reverse order of removal nothing the following.
• Tighten brake disc screws and caliper carrier bolts to
specified torque.
Tightening torque
Caliper carrier bolt (a): 60 N·m (6.0 kgf-m, 43.5 lb-
ft)
• Tighten wheel nuts to specified torque. Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Upon completion of installation, perform brake test.
Rear Brake Disc InspectionS7RS0B4306009
• Using magnetic stand and with dial gauge positioned at about 10 mm (0.39 in.) inward from periphery of
disc, measure deflection of disc.
If limit value is exceeded, replace correct or replace.
Rear brake disc deflection
Limit: 0.10 mm (0.004 in.) max.
Special tool
(A): 09900–20607
(B): 09900–20701
1
I6RS0C430014-01
1 1I6RS0C430017-01
(a)
I6RS0C430015-01
(B)
(A)
I6RS0B431031-01

Downloaded from www.Manualslib.com manuals search engine 4D-3 Parking Brake:
6) Release parking brake lever and then make sure that there is no drag in rear wheel.
If there is, repeats go to step 2).
7) Make sure that the number of notch is between 4 and 9 when operating parking brake lever.
8) If the number of notch is not between 4 and 9, replace parking brake cable and/or inspect rear
brake caliper.
Parking brake stroke
When lever is pulled up at 200 N (20kg, 44lbs) : 4
to 9 notches
Parking Brake Cable Removal and InstallationS7RS0B4406002
Removal
NOTE
When it is necessary to remove both right
and left parking brake cables, repeat below
steps 2) and 5) on right and left wheels.

1) Hoist vehicle.
2) Remove wheel.
3) Disconnect parking brake cable from equalizer (parking brake lever) and clamps.
4) Disconnect parking brake cable from lever referring to “Rear Disc Brake Caliper Removal and Installation
in Section 4C”.
5) Remove parking brake cable and parking cable bracket.
Installation
Install it by reversing removal procedure, noting the
following points.
• Install clamps properly referring to “Parking Brake Cable Construction”.
• Tighten bolts and nuts to specified torque referring to “Parking Brake Cable Construction”.
Tightening torque
Parking brake lever bolt: 25 N·m (2.5 kgf-m, 18.0
lb-ft)
Parking cable clamp bolt: 11 N·m (1.1 kgf-m, 8.0
lb-ft)
Parking cable bracket bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Adjust parking brake cable. Refer to “Parking Brake Inspection and Adjustment”.
• Check brake disc for dragging and brake system for proper performance. Brake test should be performed.
Parking Brake Lever Removal and InstallationS7RS0B4406003
Removal
1) Remove console box.
2) Block vehicle wheels and release parking brake lever.
3) Disconnect lead wire of parking brake switch at coupler.
4) Loosen parking brake cable adjusting nut (1).
5) Remove parking brake lever bolts (1) and then remove parking brake lever assembly (2) with
equalizer (3).
NOTE
Don’t disassemble parking brake lever
switch. It must be removed and installed as a
complete switch assembly.

I4RS0A440004-01
I4RS0A440005-01