Booster cylinder removal SUZUKI SWIFT 2007 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-14
Throttle Body CleaningS7RS0B1406008
Clean electric throttle body assembly referring to
“Throttle Valve Visual Check” under “Electric Throttle
Body Assembly On-Vehicle Inspection in Section 1C”.
Intake Manifold Removal and InstallationS7RS0B1406009
Removal1) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
2) Remove throttle body referring to “Electric Throttle Body Assembly Removal and Installation”.
3) Disconnect MAP sensor coupler (1).
4) Disconnect the following hoses: • Brake booster hose (2) from cylinder head cover
• Breather hose (3) from cylinder head cover
• PCV hose (4) from intake manifold
• EVAP canister purge valve hose (5) from intake manifold
5) Remove hose clamp (6) from intake manifold.
6) Remove EGR pipe bolt (7) from EGR valve. 7) Remove stiffener (1) and ground terminal (2) from
intake manifold.
8) Remove intake manifold (1) with EGR pipe (2) from
cylinder head, and then remove their gaskets (3).
9) Remove EGR pipe from intake manifold, if necessary.
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Downloaded from www.Manualslib.com manuals search engine 1D-17 Engine Mechanical:
Engine Assembly Removal and InstallationS7RS0B1406011
NOTE
After replacing electric throttle body
assembly, perform calibration of throttle
valve referring to “Electric Throttle Body
System Calibration in Section 1C”.

Removal1) Relieve fuel pressure according to “Fuel Pressure Relief Procedure in Section 1G”.
2) Disconnect negative and pos itive cable at battery.
3) Remove battery and tray.
4) Remove engine hood after disconnecting windshield washer hose.
5) Remove right and left side engine under covers.
6) Remove A/C compressor belt by referring to “Compressor Drive Belt Remo val and Installation in
Section 7B” or “Compressor Drive Belt Removal and
Installation in Section 7B”.
7) Drain engine oil, transaxle oil and coolant.
8) Remove cowl top plate referring to “Cowl Top Components in Section 9K”.
9) Remove air cleaner assembly referring to “Air Cleaner Components”.
10) With hose connected, detach A/C compressor from its bracket (A/C model) referring to “Compressor
Assembly Removal and Installation in Section 7B” or
“Compressor Assembly Removal and Installation in
Section 7B”.
CAUTION!
Suspend removed A/C compressor at a place
where no damage will be caused during
removal and installation of engine assembly.

11) Remove intake manifold rear stiffener (1) from intake manifold and cylinder block. 12) Disconnect the following electric wires:
• MAP sensor (1)
• ECT sensor (2)
•EGR valve (3)
• CMP sensor (4)
• Electric throttle body assembly (5)
• Ignition coil assembly (6)
• Injectors (7)
• Heated oxygen sensor No. 2 (8) and No. 1 (9)
• Oil control valve (10)
• Engine oil pressure switch (11)
• CKP sensor (12)
• Knock sensor (13)
• Back up light switch (14)
• Generator (15)
• Starting motor (16)
• Ground terminal (17) from intake manifold
• Battery ground terminal (18) from exhaust manifold
• Battery ground cable (19) from transaxle
• Magnet clutch switch of A/C compressor (A/C model)
• Each wire harness clamps
• Output shaft speed sensor (VSS) (34) (A/T model)
• Solenoid valve (33) (A/T model)
• Transmission range sensor (32) (A/T model)
• Input shaft speed sensor (31) (A/T model)
13) Remove fuse box from its bracket.
14) Disconnect the following cables: • Gear select control cable (23) (M/T model)
• Gear shift control cable (24) (M/T model)
• A/T select cable (A/T model)
15) Disconnect the following hoses: • Brake booster hose (26) from intake manifold
• Radiator inlet and outlet hoses (20) from each pipe
• Heater inlet and outlet hoses (21) from each pipe
• Fuel feed hoses (22) from fuel feed pipe
• EVAP canister purge valve hose (30) from purge pipe
• A/T fluid cooler hoses (A/T model)
16) With hose connected, detach clutch operating cylinder (25). (M/T model)
CAUTION!
Suspend removed clutch operating cylinder
at a place where no damage will be caused
during removal and installation of engine
assembly.

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Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1 Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System Construction ...................................................... 4A-2
Front Brake Hose / Pipe Co nstruction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4 Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7 Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-8
Brake Fluid Level Inspection ............................... 4A-8
Stop Light Switch Adjustment ............................. 4A-8
Air Bleeding of Brake System ............................. 4A-9
Front Brake Hose / Pipe Removal and Installation ....................................................... 4A-10
Rear Brake Hose / Pipe Removal and Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-11
Master Cylinder Components............................ 4A-11
Master Cylinder Assembly Removal and Installation ....................................................... 4A-12
Master Cylinder Rese rvoir Removal and
Installation ....................................................... 4A-13
Master Cylinder Assemb ly Disassembly and
Assembly ........................................................ 4A-14
Master Cylinder Assembly Inspection ............... 4A-15
Brake Booster Components .............................. 4A-15
Booster Operation Inspection ........................... 4A-16
Brake Booster Removal and Installation ........... 4A-17
Brake Booster Inspection and Adjustment ........ 4A-18
Specifications ..................................................... 4A-18
Tightening Torque Specifications ...................... 4A-18
Special Tools and Equipmen t ........................... 4A-18 Recommended Service Material ....................... 4A-18
Front Brakes .......
..................................... 4B-1
Repair Instructions ........... ...................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Ca liper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and Assembly........................................................... 4B-4
Front Disc Brake Caliper In spection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .................... ...................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipmen t .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes................... ........................... 4C-1
Repair Instructions ........... ...................................4C-1
Rear Disc Brake Components.............................4C-1
Rear Disc Brake Pad Removal and Installation .........................................................4C-2
Rear Disc Brake Caliper Removal and Installation .........................................................4C-3
Rear Disc Brake Pad Inspection .........................4C-6
Rear Disc Brake Caliper Disassembly and Assembly...........................................................4C-6
Rear Disc Brake Caliper Inspection ....................4C-8
Rear Flexible Hose Remova l and Installation .....4C-8
Rear Brake Disc Removal and Installation..........4C-9
Rear Brake Disc Inspection.................................4C-9
Specifications .................... .................................4C-10
Tightening Torque Specifications ......................4C-10
Special Tools and Equipmen t ...........................4C-11
Recommended Service Material .......................4C-11
Special Tool ......................................................4C-11
Parking Brake ................. ......................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1

Downloaded from www.Manualslib.com manuals search engine 4A-12 Brake Control System and Diagnosis:
Master Cylinder Assembly Removal and
Installation
S7RS0B4106011
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) Clean outside of master cylinder.
2) Drain brake fluid in reservoir.
3) Remove clutch reservoir hose clamp (1) and disconnect clutch reservoir hose (3) from reservoir
(2) (M/T model).
4) Disconnect fluid level switch coupler (1) on reservoir.
5) Disconnect brake pipes (2) connected to master cylinder.
6) Remove master cylinder fixing nuts (1). 7) Remove master cylinder and master cylinder seal.
Installation 1) Install new master cylinder seal.
2) Apply small amount of silic on grease (included in
spare parts) to piston rod.
3) Install master cylinder to booster and tighten master cylinder fixing nuts (a) to specified torque.
Tightening torque
Master cylinder fixing nut (a): 15 N·m (1.5 kgf-
m, 11.0 lb-ft)
4) Connect brake pipe to master cylinder and tighten flare nuts (a) to specified torque.
Tightening torque
Brake pipe flare nut for M10 (a): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)
Brake pipe flare nut for M12 (a): 19 N·m (1.9 kgf-
m, 14.0 lb-ft)
5) Connect fluid level switch connector (1) of reservoir.
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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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Downloaded from www.Manualslib.com manuals search engine 5C-6 Clutch:
Clutch Fluid Pipe Removal and InstallationS7RS0B5306007
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and push clamp (5) of clutch operating cylinder (4) and then
disconnect clutch fluid pipe (2).
Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted surface.
• Do not allow pipe to contact hard against vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and bleed air from system referring to “Clutch Pedal
Inspection” and “Air Blee ding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS7RS0B5306008
Check pipe (1) for dent, kink, crack, dirt and dust.
Replace if check result is not satisfactory.
Clutch Master Cylinder Removal and
Installation
S7RS0B5306009
Removal 1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe from clutch master cylinder (1) referring to “C lutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal.
5) Turn clutch master cylinder (1) clockwise as shown in figure, and then remove it.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
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