tail SUZUKI SWIFT 2008 2.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-3
2) Remove floor jack (2) from rear axle.
3) Install rear wheels and tighten wheel nuts specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
4) Lower hoist and vehicle in unloaded condition, tighten shock absorber nuts to specified torque.
Tightening torque
Rear shock absorber upper nut (a): 28 N·m (2.8
kgf-m, 20.0 lb-ft)
Rear shock absorber lower nut (b): 90 N·m (9.0
kgf-m, 65.0 lb-ft)
5) Install tail end member trim and quarter inner trim.Rear Shock Absorber InspectionS7RS0B2306002
• Inspect for deformation or damage.
• Inspect bushings for wear or damage.
• Inspect for evidence of oil leakage.
Replace any defective parts.
WARNING!
When handling rear shock absorber (1) in
which high-pressure gas is sealed, make
sure to observe the following precautions.
• Don’t disassemble it.
• Don’t put it into the fire.
• Don’t store it where it gets hot.
• Before disposing it, be sure to drill a hole (approximately 3 mm (0.12 in.) diameter)
(2) in it where indicated by arrow in the
figure and let gas and oil out.
Be sure to wear eye shield since the gas
itself is harmless but the absorber drill
hole debris maybe blown out.

(a)
1
(b) 2
I4RS0B230003-01
I4RS0A230005-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-7
3) Remove rear brake caliper assemblies (right & left)
and brake discs (right & left ). For details, refer to
Step 2) to 3) of “Removal” under “Rear Brake Disc
Removal and Installa tion in Section 4C”.
4) Remove rear wheel hubs (r ight & left). For details,
refer to Step 3) to 5) of “Removal” under “Rear
Wheel Hub Removal and Installation”.
5) Disconnect brake pipes (1) from brake hoses (2) and remove E-rings (3).
CAUTION!
Do not drop brake fluid onto painted surface.

6) Disconnect wheel speed sensors (1) and lead wire clamps (right & left).
7) Remove brake disc dust cover (2) and spindles (3) (right & left) from rear axle.
8) Remove coil springs (1) (right & left) referring to “Rear Coil Spring Removal and Installation”. 9) Disconnect wheel speed sensor clamp and parking
brake cable clamp from rear axle.
10) While supporting rear axle (1) at both ends (right & left), remove rear trailing arm bolts and then remove
rear axle from chassis by lowering floor jack
gradually.
11) Remove brake pipes (2) from rear axle (1) if necessary.
Installation 1) Install brake pipes to rear axle.
2) Place rear axle on floor jacks. Then install trailing arm, washers and new trailing
arm bolts (1) (right & left) and tighten bolts
temporarily by hand.
1
1
2
2
3
3I4RS0A230018-01
1
2
3
I6RS0B230003-01
1
I4RS0A230020-01
1. Parking brake cable clamp bolt
1I4RS0A230021-01
2
1
I6RS0B230004-01
1
I4RS0A230023-01

Downloaded from www.Manualslib.com manuals search engine 2C-12 Rear Suspension:
• Check noise and smooth rotation of wheel by rotating wheel. If it is defect ive, replace bearing.
Spindle Removal and InstallationS7RS0B2306014
Removal
1) Remove rear brake caliper assembly and brake disc. For details, refer to Step 2) to 4) of “Removal” under
“Rear Brake Disc Removal and Installation in
Section 4C”.
2) Remove rear wheel hub. For details, refer to Step 3) to 5) of “Removal” under “Rear Wheel Hub Removal
and Installation”.
3) Disconnect wheel speed sensor (1).
4) Remove brake disc dust cover (2) and spindle (3) from rear axle. Installation
1) Install brake disc dust cover (1), spindle (2) and new spindle bolts (3) and then tighten spindle bolts to
specified torque.
CAUTION!
Never reuse the removed rear spindle bolts.
Bolts are pre-coated wi th friction stabilizer.
Be sure to replace pre-coated bolt with a new
one, or bolt may loosen.

Tightening torque
Rear spindle bolt (a): 88 N·m (8.8 kgf-m, 64.0 lb-
ft)
2) Connect wheel speed sensor (4) and tighten wheel speed sensor bolt to specified torque.
Tightening torque
Wheel speed sensor bolt (b): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
3) Install rear wheel hub re ferring to “Rear Wheel Hub
Removal and Installation”.
4) Install brake disc and rear brake caliper assembly referring to “Rear Brake Disc Removal and
Installation in Section 4C”.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
6) Adjust parking brake cable. For adjustment, see “Parking Brake Inspection and Adjustment in Section
4D”.
7) Perform brake test (foot brake and parking brake).
8) Check each installed part for fluid leakage.
I3RM0A230050-01
2
1 3
I6RS0B230015-01
1
(b)
4
2
3, (a)
I6RS0B230016-01

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-8
Tire Mounting and DismountingS7RS0B2406004
CAUTION!
When installing tire which has arrow
indicating tire rotation direction to wheel,
make sure that this tire rotation direction is
same as actual tire rotation direction when
vehicle is moving forward. Otherwise, it is
not possible to install wheel with tire to
vehicle in specified direction.

Use a tire changing machine to mount or dismount tires.
Follow equipment manufacturer’s instructions. Do not
use hand tools or tire irons al one to change tires as they
may damage tire beads or wheel rim.
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, old rubber and
light rust. Before mounting or dismounting a tire, bead
area should be well lubricated with approved tire
lubricant.
After mounting, inflate to specified pressure shown on
tire placard so that beads are completely seated.
WARNING!
Do not stand over tire when inflating. Bead
may break when bead snaps over rim’s safety
hump and cause serious personal injury.
Do not exceed 330 kpa (47.9 psi) pressure
when inflating. If 330 kpa (47.9 psi) pressure
will not seat beads, deflate, re-lubricate and
reinflate.
Over inflation may cause bead to break and
cause serious personal injury.

Install valve core and inflate to proper pressure.
Tire RepairS7RS0B2406005
There are many different materials and techniques on
the market to repair tires. As not all of these work on all
types of tires, tire manufacturers have published detailed
instructions on how and when to repair tires. These
instructions can be obtained from each tire
manufacturer.
Tire Repair for Emergency Repaired-Tire with
Sealant
S7RS0B2406006
WARNING!
Be sure to observe “Precaution for
Emergency Flat Tire Repair Kit”. Otherwise,
your health may be ruined.

1) Remove flat tire repair sealant from tire using plug (1), filler hose (2), sealant bottle (3) and extension
hose (4) in kit as follows.
a) Remove plug from fille r hose of sealant bottle.
Then connect ext ension hose to tip of filler hose.
b) Remove tire containing flat tire repair sealant from vehicle.
c) Loosen valve core carefully to release air.
WARNING!
Take care not to make sealant blast out from
valve. Otherwise, your health may be ruined.

d) Remove tire bead inside rim of wheel.
e) Make a clearance by inserting a tire lever (2) between tire bead and rim, and then insert hose
(1) thought clearance as shown in figure.
f) Press the bottle and suck out sealant (4), using bottle (3) as a pump.
NOTE
To make sealant easy to suck up from tire,
set bottle lower than sealant surface.

g) Change hose end position and repeat above step f) until sealant is not sucked out.
h) Put cap on bottle so that collected sealant does not leak.
4
1
2
3
I6RS0B240004-01
1 4
3 2
I6RS0C240003-01

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-8
Rear Wheel Speed Sensor Components LocationS7RS0B4503003
Diagnostic Information and Procedures
ABS CheckS7RS0B4504001
Refer to the following items for the details of each step.
12
3
4
[A]
[B]1
1
(a)
(a)
I6RS0C450006-01
[A]: OK
1. Rear wheel speed sensor 3. Connector: 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
[B]: NG 2. Sensor ring 4. Grommet
StepAction YesNo
1 ) Malfunction analysis
1) Perform “Customer complaint analysis: ”.
2) Perform “Problem symptom confirmation: ”.
3) Perform “DTC check, record and clearance: ” and recheck DTC.
Is there any malfunction DTC? Go to Step 4.
Go to Step 2.
2 ) Driving test
1) Perform “Step 2: Driving Test: ”.
Is trouble symptom identified? Go to Step 3.
Go to Step 6.
3 ) DTC check
1) Perform “DTC Check”.
Is it malfunction code? Go to Step 4.
Go to Step 5.
4 ) ABS check
1) Inspect and repair referring to applicable DTC flow.
Does trouble recur? Go to Step 5.
Go to Step 7.
5 ) Brakes diagnosis
1) Inspect and repair referring to “Brakes Symptom Diagnosis in Section 4A”.
Does trouble recur? Go to Step 3.
Go to Step 7.

Downloaded from www.Manualslib.com manuals search engine 4E-9 ABS:
Step 1: Malfunction Analysis
Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown in the following will facilitate collec ting information to the
point required for proper analysis and diagnosis. Customer questionnaire (Example)
6
) Check for intermittent problem
1) Check intermittent troubles referring to “Intermittent and
Poor Connection Inspection in Section 00” and related
circuit of trouble code recorded in Step 1.
Does trouble recur? Go to Step 4.
Go to Step 7.
7 ) Final confirmation test
1) Perform “Step 7: Final Confirmation Test: ”.
Does trouble recur? Go to Step 3.
End.
Step
Action YesNo
I2RH01450014-01

Downloaded from www.Manualslib.com manuals search engine 4E-11 ABS:
DTC CheckS7RS0B4504004
1) Turn ignition switch to OFF position.
2) Connect SUZUKI scan tool to data link connector (1).
Special tool
(A): SUZUKI scan tool
3) Turn ignition switch to ON position.
4) Read DTC according to instructions displayed on SUZUKI scan tool and print it or write it down. Refer
to SUZUKI scan tool operator’s manual for further
details.
NOTE
If SUZUKI scan tool can not communicate
ABS hydraulic unit / control module, perform
“Serial Data Link Circuit Check”.

5) After completing the check, turn ignition switch off and disconnect SUZUKI scan tool from DLC.
DTC TableS7RS0B4504005
CAUTION!
Be sure to perform “ABS Check” before
starting diagnosis.

1 (A)I4RS0A450009-01
DTC (displayed on
SUZUKI scan tool) Diagnostic Items
NO DTC Normal
) C1021 RF
Wheel speed sensor circuit
)
C1025 LF
) C1031 RR
) C1035 LR
) C1022 RF
Wheel speed sensor circuit
or sensor ring
)
C1026 LF
) C1032 RR
) C1036 LR
) C1041
RFInlet solenoid valve circuit
) C1042 Outlet solenoid valve circuit
) C1045
LFInlet solenoid valve circuit
) C1046 Outlet solenoid valve circuit
) C1051
RRInlet solenoid valve circuit
) C1052 Outlet solenoid valve circuit
) C1055
LRInlet solenoid valve circuit
) C1056 Outlet solenoid valve circuit
) C1057 Power source
) C1061 ABS pump motor and/or motor
driver circuit
) C1063 Solenoid valve power supply driver
circuit
) C1071 ABS control module
) U1073 Control Module
Communication
Bus Off
) U1100 Lost Communication with ECM
(Reception error)

Downloaded from www.Manualslib.com manuals search engine 4F-2 Electronic Stability Program:
Perform sensor calibration according to “Sensor Calibration”.
Precautions in Speedometer Test or Other TestsS7RS0B4600005
When performing speedometer or other tests using speedometer tester or chassis dynamometer, ESP® function must
be deactivated by ESP ® OFF switch or using SUZUKI scan to ol to complete the tests correctly.
When using SUZUKI scan tool, set to the “MISC. TEST” mode to stop the ESP ® function. Refer to SUZUKI scan tool
operator's manual for further details.
General Description
Electronic Stability Program DescriptionS7RS0B4601006
Electronic Stability Program (ESP ®) is an auxiliary function to enable the vehicle to av oid a danger safely while the
vehicle is running, stopping or turning.
Electronic Stability Program (ESP ®) consists of following functions.
ESP ® is a registered trademark of Daimler Chrysler AG.
Antilock Brake System (ABS)
This system prevents tire locking which may occur when br ake is applied suddenly or on slippery roads. With this
function, as the vehicle body is kept in the stable state an d tires unlocked, the driver can avoid any obstacle by turning
the steering wheel.
Electronic Brake force Distribution (EBD)
This function distributes braking force of front and rear wheels properly according to the vehicle load condition.
With this function, the braking force of the front and rear wheels is controlled for the optimum effect to secure the
maximum braking force regardless of the loadage.
Traction Control System (TCS)
This system controls the engine and brake to prevent the dr iving wheels from spinning at the time of starting and
accelerating. Particularly, this fu nction is helpful for safe driving on muddy or icy roads. When ESP ® control module
detects wheel spinning using information from the yaw rate sensor and wheel speed sensor, it lower the engine torque
by closing the electronic controlled thro ttle and controlling ignition. At the same time, brake is applied to the spinning
tire.
Stability Control
This function controls the vehicle body in the stable state by controlling the engine and braking so as to prevent the
vehicle from over-steering or under-steering while turning.
When under-steering occurs, this function lowers the engine torque and applies brake to the inner rear wheel in the
vehicle forward direction so as to pr event the vehicle from moving outward.
When over-steering occurs, this function applies brake to the outer front wheel in the vehicle forward direction so as to
prevent the vehicle from moving inward. Sensor Procedures required calibration
Steering angle sensor • Power is not su pplied to steering angle sensor. (battery, fuse and/or connector is
removed.)
• Steering angle sensor is replaced.
• Power is not supplied to ESP ® control module. (battery, fuse and/or connector is
removed.)
• ESP® hydraulic unit / control module assembly is replaced.
Master cylinder pressure sensor • ESP® hydraulic unit / control module assembly is removed or replaced.
Yaw rate / G sensor assembly • Yaw rate / G sensor assembly is removed or replaced.
• ESP® hydraulic unit / control module assembly is replaced.

Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-5
Yaw rate / G sensor
The yaw rate / G sensor consists of the yaw rate (angular velocity in the vehicle turning direction) sensor and right-left
G (acceleration in right-left direction) sensor and is mounted to the P/S controller B/K at the lower part of the center
console. It detects the angular velocity in the vehicle turn ing direction and movement in the right-left direction, and
then it sends that information to ESP ® control module.
Wheel speed sensor
The vehicle speed is detected by the hall IC type wheel speed sensor (1) and encoder (4). The wheel speed sensor is
fixed to the knuckle and includes a hall IC (3) having 2 hall elements (2).
The encoder consisting of a permanent ma gnet which has S/N electrodes turns inside of the wheel hub along with the
wheel. The wheel speed sensor outputs alternate current.
As the cycle of the alternate current is in proportion to the revolution speed of the encoder, this AC signal (5) is
converted into the voltage signal in the ESP ® control module (6) for detection of the wheel speed.
ESP ® Hydraulic Unit / Control Module
Assembly Description
S7RS0B4601002
ESP ® control module is a component of ESP ® hydraulic
unit / control module assembly and has the following
functions.
Self-Diagnosis Function
ESP ® control module monitors each input and output
signals. When ESP ® control module detects any
malfunction, some of ABS warning lamp (1), EBD
warning lamp (brake warning lamp) (2), ESP ® warning
lamp (3), SLIP indicator lamp (4), ESP ® OFF lamp (5)
are turned ON and indicate the abnormality to driver.
• When ignition switch is turned ON, ABS warning lamp, EBD warning lamp, ESP ® warning lamp, SLIP
indicator lamp and ESP ® OFF lamp light for 2
seconds to check its circuit.
• When no abnormality is detected (the system is in good condition), ABS warning lamp, EBD warning
lamp, ESP ® warning lamp, SLIP indicator lamp and
ESP ® OFF lamp turn OFF after 2 seconds.
• When an abnormality in the system is detected, some of ABS warning lamp, EBD warning lamp (brake
warning lamp), ESP ® warning lamp, SLIP indicator
lamp and/or ESP ® OFF lamp are turned ON and the
area where that abnormality lies is stored in the
memory in ESP ® control module. Fail-Safe Mode
When ESP
® control module detects abnormality, the
system goes into fail-safe mode. And some of functions
of ABS, TCS, stability control system are shut down. For
details of fail safe mode, re fer to “Fail-Safe Table”.
S
N
S
N
S
N
N
S
N
S
12V
2
3
1
5
4
6I7RS0B460003-01
3245
1
I6RS0B460001-01

Downloaded from www.Manualslib.com manuals search engine 4F-12 Electronic Stability Program:
Diagnostic Information and Procedures
Electronic Stability Program System CheckS7RS0B4604001
Refer to the following items for the details of each step.
Step 1: Malfunction Analysis
Customer complaint analysis
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a questionnaire form as shown in the following will facilitate collec ting information to the
point required for proper analysis and diagnosis. Step Action Yes No
1 ) Malfunction analysis
1) Perform “Customer complaint analysis: ”.
2) Perform “Problem symptom confirmation: ”.
3) Perform “DTC check, record and clearance: ” and recheck DTC.
Is there any malfunction DTC? Go to Step 4. Go to Step 2.
2 ) Driving test
1) Perform “Step 2: Driving Test: ”.
Is trouble symptom identified? Go to Step 3. Go to Step 6.
3 ) DTC check
1) Perform “DTC Check”.
Is it malfunction code? Go to Step 4. Go to Step 5.
4 ) ESP ® check
1) Inspect and repair referring to applicable DTC flow.
Does trouble recur? Go to Step 5. Go to Step 7.
5 ) Brakes diagnosis
1) Inspect and repair referring to “Brakes Symptom Diagnosis in Section 4A”.
Does trouble recur? Go to Step 3. Go to Step 7.
6 ) Intermittent problem check
1) Check intermittent troubles referring to “Intermittent and
Poor Connection Inspection in Section 00” and related
circuit of trouble code recorded in Step 1.
Does trouble recur? Go to Step 4. Go to Step 7.
7 ) Final confirmation test
1) Perform “Step 7: Final Confirmation Test: ”.
Does trouble recur? Go to Step 3. End.