MOUNT SUZUKI SWIFT 2008 2.G Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine 2D-7 Wheels and Tires:
Wheel Removal and InstallationS7RS0B2406003
Removal
WARNING!
Do not removal all of the wheel nuts at once,
because all the wheels of this vehicle are
mounted by the wheel nuts.
Leave a nut at least not to drop the wheel.
Support the wheel and/or tire and then
remove the nut(s) left with the wheel.

1) Loosen wheel nuts by approximately 180° (half a
rotation).
2) Hoist vehicle.
3) Make sure that the vehicle will not fall off by trying to
move vehicle body in both ways.
4) Remove wheel nut except one.
5) Support the wheel and/or tire not to drop the wheel and then remove the nut left with the wheel.
CAUTION!
Never use heat to loosen tight wheel because
the application of heat to wheel causes the
wheel life shorter and the wheel bearing
damage.

Installation
CAUTION!
When installing wheel (with tire) which has
arrow (1) indicating tire rotation direction on
its side, make sure that arrow direction is
same as actual tire ro tation direction when
vehicle is moving forw ard (2). Otherwise,
water drainage performance and straight line
vehicle stability will be affected.

For installation, reverse removal procedure, noting the
following.
• Wheel nuts must be tightened in sequence and to specified torque to avoid bending wheel or brake disc.
NOTE
Before installing wheels, remove any build-
up of corrosion on wheel mounting surface
and brake disc mounting surface by scraping
and wire brushing. Installing wheels without
good metal-to-metal contact at mounting
surfaces can cause wheel nuts to loosen,
which can later allow a wheel to come off
while vehicle is moving.

Tightening order
“A” – “B” – “C” – “D” – “E”
Tightening torque
Wheel nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
I6RS0B240005-01
I6RS0C240001-01

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 3A-4 Drive Shaft / Axle:
Front Drive Shaft Assembly On-Vehicle
Inspection
S7RS0B3106002
• Check boots for breakage or deterioration.
• Check wheel side joint for rattle or smooth rotation.
• Check differential side (or center shaft side) joint for smooth rotation.
If any abnormality is found, replace.
Front Drive Shaft Assembly Removal and
Installation
S7RS0B3106003
Removal
1) Hoist vehicle and remove wheel.
2) Undo caulking (1) and remove drive shaft nut (2). 3) Drain transaxle oil.
4) Disconnect tie-rod end (1) from steering knuckle (2)
using puller (3).
5) Remove stabilizer join t referring to “Front
Suspension Frame, Stabiliz er Bar and/or Bushings
Removal and Installati on in Section 2B”.
6) Remove brake hose mounting bolt (1) and break hose (2) from bracket and then detach wheel speed
sensor harness (3) from strut bracket.
7) Remove suspension contro l arm ball joint bolt (4).
[A]: Right side drive shaft assembly (M/T model) 8. Wheel side joint (Constant velocity ball joint)
: Apply black grease included in spare part to joint.
[B]: Left side drive shaft assembly (M/T model) 9. Center shaft side joint (Constant velocity tripod joint)
: Apply dark gray grease included in spare part to joint.
[C]: Right side drive shaft assembly (A/T model) 10. Oil seal
: Apply grease 99000-25011 to oil seal lip.
[D]: Left side drive shaft assembly (A/T model) 11. Center bearing support circlip
[E]: Center shaft assembly (A/T model) 12. Center bearing support
[F]: Center shaft assembly (M/T model) 13. Center bearing
1. Circlip 14. Center shaft
2. Differential side joint (Constant velocity tripod joint) : Apply dark gray grease included in spare part to joint. 15. Cage
3. Snap ring 16. Tripod joint spider
: Never disassemble.
4. Boot band (Large) 17. O-ring
: Apply grease 99000-25011 to all round of O-ring.
5. Boot (Differential or center shaft side) 18. Differential side joint (Constant velocity tripod joint)
: Apply dark gray grease included in spare part to joint.
6. Boot band (Small) 19. Center shaft side joint (Constant velocity tripod joint)
: Apply dark gray grease included is spare part to joint.
7. Boot (Wheel side) : Do not reuse.
I6RS0C310004-01
F: Vehicle front
I3RM0A310003-01
I6RS0C310005-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-5
8) Disconnect front suspension control arm ball joint
stud from steering knuckle.
9) Pull out drive shaft joint as follows. • For differential sideUsing tire lever (1), pull out drive shaft joint (2) so
as to release snap ring fitting of joint spline at
differential side.
• For center shaft side Using plastic hammer (3), drive out drive shaft
joint (2) so as to release snap ring fitting of joint
spline at center shaft.
10) Remove drive shaft assembly. 11) Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from
differential side gear. Installation
CAUTION!
• Be careful not to damage oil seals and
boots when installing drive shaft.
• Do not hit joint boot with hammer. Inserting joint only by hands is allowed.
• Make sure that differential side joint is inserted fully and its snap ring is seated as
it was.

Install drive shaft assemb ly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as sp ecified referring to “A/T
Fluid Change in Section 5A” or “Manual Transaxle Oil
Change in Section 5B”.
• Check toe setting referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B” and adjust
as required.
[A]: Differential side
[B]: Center shaft side
I6RS0C310006-01
3
2
1I2RH01310007-01

Downloaded from www.Manualslib.com manuals search engine 3A-8 Drive Shaft / Axle:
Reassembly
Tripod joint
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly (1) and tripod
joint housing (2) are washed thoroughly and air dried.
Replace boot(s) (3) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• To ensure full performance of joint as designed, be sure to distinguish between
two types of grease in repair set and apply
specified volume to respective joint
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After washing, dry parts comp letely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside with specified grease.
6) Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure.
[A]: Wheel side
[B]: Differential side (or center shaft side)
I4RS0A310007-01
I4RS0A310009-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-9
7) Fasten boot bands (1) securely using special tool as
shown in figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 55 in.)
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Special tool
(A): 09943–57010 8) Set new differential side (or center shaft side) small
band and new differential side (or center shaft side)
boot (1) on shaft temporarily, and then apply grease
to tripod joint (2). Use specified grease in tube
included in spare parts.
9) Install tripod joint spider (3) on shaft using special
tool with hammer, directing its chamfered spline
toward wheel side, and then fasten it with new snap
ring (4) using snap ring pliers (5).
Special tool
(A): 09925–98221
10) Apply grease (including in spare parts) to inside of tripod joint housing (1), jo int it with tripod joint.
Grease color
“A”: Dark gray
Amount
“A”: 70 – 90 g (2.5 – 3.2 oz)
(A)
1
(A)
1
“a”
1
I5RS0B310008-01
I5JB0A311009-01
I4RS0B310003-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-11
DOJ
Judging from abnormality noted before disassembly and
what is found through visual check of components parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly and DOJ
housing are washed thoroughly and air dried.
Replace boot(s) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• To ensure full performance of joint as designed, be sure to distinguish between
two types of grease in repair set and apply
specified volume to respective joint
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified
grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside wi th specified grease.
6) Fit boot (1) to grooves of shaft and housing (2).
7) Insert screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same
as atmospheric pressure.
8) Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure. 9) Fasten boot bands (1) using special tool as shown in
figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Special tool
(A): 09943–57010
21I5RS0B310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

Downloaded from www.Manualslib.com manuals search engine 3A-12 Drive Shaft / Axle:
10) Set new differential side (or center shaft side) small band and new differential side (or center shaft side)
boot on shaft temporarily.
11) Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
12) Install circlip (1) by using snap ring pliers (2).
13) Apply grease to entire su rface of cage. Use specified
grease in tube included in spare parts.
14) Insert cage into joint housing (2) and fit snap ring (1) into groove of joint housing (2).
CAUTION!
Position opening of snap ring “c” so that it
will not be lined up with a ball.

15) Apply grease (including in spare parts) to inside of joint housing (1).
Grease color
“A”: Dark gray
Amount
“A”: 70 – 90 g (2.5 – 3.2 oz) 16) Fit boot (1) to grooves of shaft and housing (2) adjust
length to specification below.
17) Inset screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between boot end (housing side) and small boot
band center)
Left side and right side drive shafts “a”: 89.5 mm
(3.52 in.)
CAUTION!
• Band each boot band against forward rotation.
• Do not squeeze or distort boot when fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

(A)
1
I5RS0B310009-01
I5RS0B310010-01
I2RH01310036-01
[A]: Drive shaft inserted into differential side
[B]: Drive shaft inserted into center shaft side
I5RS0B310011-02
I5RS0B310012-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-15
Specifications
Tightening Torque SpecificationsS7RS0B3107001
NOTE
The specified tightening torque is also described in the following.
“Front Drive Shaft Assembly Components Location”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B3108001
NOTE
Required service material is also described in the following.
“Front Drive Shaft Components”

Special ToolS7RS0B3108002
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake hose mounting bolt 25 2.5 18.0 )
MaterialSUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011)
09913–84510 09925–15410
Bearing installer Oil seal installer
))
09925–98221 09943–57010
Bearing installer Band compressor
)) / ) / )
09943–57021
Pliers, Low-Profile Clamp
) / )

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-5
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol out
of the system. Replace all rubber parts in the system,
including hoses. Also, when working on the brake
mechanisms, check for fluid on the linings.
If excessive fluid is found, replace the pads. If master cylinder piston seals
are satisfactory, check for
leakage or excessive heat co nditions. If leakage is not
found, drain fluid, flush with brake fluid, refill and bleed
system.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to
contaminated fluid.
Brakes Symptom DiagnosisS7RS0B4104002
Condition Possible cause Correction / Reference Item
Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair.
Brake disc or brake pad stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Badly worn brake pad Replace.
Malfunctioning caliper assembly Repair or replace.
Malfunctioning brake booster Check system and replace assembly.
Malfunctioning brake master cylinder Check system and replace as necessary.
Air in system Bleed system.
Malfunctioning ABS (ESP ®). Check system and replace as necessary.
Brake pull (Brakes not
working in unison) Brake pad and disc are wet with water or
stained with oil in some brakes Clean or replace.
Disc is out of round in some brakes Replace.
Tires are inflated unequally Inflate equally.
Disturbed front wheel alignment Adjust as prescribed.
Unmatched tires on same axle Tires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hoses Check for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assembly Caliper should slide.
Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifications.
Noise (High pitched
squeak without brake
applied) Contact wear indicator to brake disc
Replace brake pads.
Worn brake pad Replace brake pads.
Excessive pedal travel
(Pedal stroke too large) Partial brake system failure
Check brake systems and repair as necessary.
Brake fluid leaking Repair the leaking point and bleed air.
Air in system (soft / spongy pedal) Bleed system.
Brake locked Malfunctioning ABS (ESP®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
Dragging brakes (A very
light drag is present in all
brakes immediately after
pedal is released.) Master cylinder pistons not returning
correctly
Replace master cylinder.
Restricted brake pipes or hoses Check for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakes Check and adjust to correct specifications.
Weakened or broken return springs in
rear brakes. Replace.
Sluggish parking brake cables or linkage Repair or replace.
Brake caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Improper brake pedal free height Check brake pedal free height.