Air SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

FRONT DRIVE SHAFT 4A-9
5) Fill up boot inside with specified grease and then fasten boot
with bands (1).
6) Install dynamic damper (1) on drive shaft according to
dimension specified below.
Drive shaft dynamic damper installing position
“a” : 347 - 353 mm (13.7 - 13.9 in.)
7) Set new differential side small band and differential side boot
(1) on shaft temporarily.
Apply grease to tripod joint (2). Use specified grease in tube
included in spare parts.
8) Install tripod joint spider (3) on shaft, facing its chamfered
spline inward (wheel side), then fasten it with snap ring (4).
Special tool
(A) : 09900-06107
9) Apply grease to inside of outer race (1), then install housing,
joint it with boot and fit boot to outer race.
After fitting boot, insert screwdriver into boot on outer race
side and allow air to enter boot so that air pressure in boot
becomes the same as atmospheric pressure. CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.

4A-10 FRONT DRIVE SHAFT
10) When fixing boot (1) to outer race (2) with differential side big
band (3), adjust so that measured dimensions become as
indicated below.
Drive shaft boot fixing position
“a” : 155.5 mm (6.12 in.) for M/T vehicle
“b” : 189.3 mm (7.45 in.) for A/T vehicle
CAUTION:
To prevent any problem caused by washing solution, do
not wash joint boots and tripod joint except its housing.
Degreasing of those parts with cloth is allowed.
[A] : Wheel side
[B] : Differential side
CAUTION:
Bend 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.

FRONT DRIVE SHAFT 4A-11
For DOJ Type Drive Shaft
Judging from abnormality noted before disassembly and what is
found though visual check of component parts after disassembly,
prepare replacing parts and proceed to reassembly.
Make sure that wheel side joint assembly (1) and DOJ housing
(2) are washed thoroughly and air dried, and boots (3) are
cleaned with cloth if they are to be reused.
“A” : Black grease (about 60 - 80 g/2.1 - 2.8 oz)
“B” : Black grease (rather light than “A”)
(about 70 - 90 g/2.5 - 3.2 oz)
1) Wash disassembled parts (except boots). After washing. dry
parts completely by blowing air.
2) Clean boots with cloth. Do not wash boots in degreaser,
such as gasoline or kerosene, etc.
Washing in degreaser causes deterioration of boot.
3) Apply grease to wheel side joint. Use specified grease in
tube included in wheel side boot set.
4) Install wheel side boot on shaft, fill up boot inside with
grease and then fasten boot with bands (1).
5) Install dynamic damper (1) on left side drive shaft according
to dimension specified below. (For A/T model of 2WD vehi-
cle)
Dynamic damper installing position
“a” : 151 - 157 mm (5.9 - 6.2 in.)
6) Set new differential side small bend and differential side boot
on shaft temporarily. CAUTION:
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.
[A] : Wheel side
[B] : Differential side
CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.

4A-12 FRONT DRIVE SHAFT
7) Driver in the cage (1) by using a pipe (2).
Drive shaft joint cage installing pipe diameter
“a” : 22.5 mm (0.886 in.) or more
“b” : 30.0 mm (1.181 in.) or less
8) Install circlip (1) by using special tool (A).
Special tool
(A) : 09900-06107
9) Apply grease to entire surface of cage.
Use specified grease in tube included in spare parts.
10) Insert cage into outer race and fit snap ring (1) into groove of
outer race (2).
11) Apply grease to inside of outer race, and fit boot to outer
race. After fitting boot, insert screwdriver into boot on outer
race side and allow air to enter boot so that air pressure in
boot becomes the same as atmospheric pressure. CAUTION:
Install cage directing smaller outside diameter side to
wheel side.
CAUTION:
Position opening of snap ring “c” so that it will not be
lined up with a ball.

FRONT DRIVE SHAFT 4A-13
12) When fixing boot (1) to outer race (2) with differential side big
band (3), adjust so that measurements become as indicated
below.
Drive shaft boot fixing position
“d” : 157.8 mm (6.21 in.) for left side
“e” : 192.9 mm (7.59 in.) foe right side
For Center Shaft and Center Bearing Support
Install center shaft by reversing removal procedure and noting fol-
lowing points
When installing bearing support circlip (1), make sure that if
fits in circlip groove in center bearing support (2) securely as
shown.
When installing left oil seal (1), use care so that oil seal in
proper direction as shown figure.
Be sure to apply grease to oil seal lip and bearing side space
indicated in figure.
“A” : Grease 99000-25010
After press-fit center shaft (2) from left oil seal side, install
circlip to groove of center shaft securely. CAUTION:
To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with
cloth is allowed.
CAUTION:
Bend each boot band against forward rotation (A).
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its
durability.
[A] : Differential side

BRAKES 5-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
5
9
10
10A
10B
SECTION 5
BRAKES
CONTENTS
GENERAL DESCRIPTION ................................ 5-2
DIAGNOSIS ....................................................... 5-4
ROAD TESTING BRAKES ............................. 5-4
BRAKE FLUID LEAKS ................................... 5-4
SUBSTANDARD OR CONTAMINATED
BRAKE FLUID ................................................ 5-4
DIAGNOSIS TABLE ....................................... 5-5
BRAKE PEDAL FREE HEIGHT
ADJUSTMENT ............................................... 5-8
BRAKE PEDAL PLAY INSPECTION ............. 5-8
STOP LIGHT SWITCH ADJUSTMENT.......... 5-8
EXCESSIVE PEDAL TRAVEL
INSPECTION ................................................. 5-9
FRONT BRAKE PAD INSPECTION .............. 5-9
BRAKE DISC INSPECTION........................... 5-9
PARKING BRAKE INSPECTION AND
ADJUSTMENT ............................................. 5-10
BOOSTER OPERATION INSPECTION....... 5-11
FLUID PRESSURE TEST (IF EQUIPPED
WITH LSPV) ................................................ 5-12
MASTER CYLINDER AND BRAKE FLUID
LEVEL INSPECTION ................................... 5-14
BRAKE HOSE AND PIPE INSPECTION ..... 5-15
HOSE ....................................................... 5-15
PIPE ......................................................... 5-15
ON-VEHICLE SERVICE .................................. 5-15AIR BLEEDING OF BRAKE SYSTEM ......... 5-15
FRONT BRAKE ........................................... 5-17
BRAKE PAD............................................. 5-17
CALIPER ASSEMBLY ............................. 5-19
BRAKE DISC ........................................... 5-23
REAR BRAKE .............................................. 5-25
BRAKE DRUM ......................................... 5-26
BRAKE SHOE .......................................... 5-29
WHEEL CYLINDER ................................. 5-30
BRAKE BACK PLATE (FOR 2WD
VEHICLE)................................................. 5-31
BRAKE BACK PLATE (FOR 4WD
VEHICLE)................................................. 5-33
MASTER CYLINDER ................................... 5-33
MASTER CYLINDER RESERVOIR ......... 5-33
MASTER CYLINDER ASSEMBLY........... 5-34
BRAKE BOOSTER ...................................... 5-38
BRAKE HOSE/PIPE .................................... 5-41
FRONT BRAKE HOSE/PIPE ................... 5-41
REAR BRAKE HOSE/PIPE...................... 5-44
PARKING BRAKE CABLE ........................... 5-46
LSPV (LOAD SENSING PROPORTIONING
VALVE) ASSEMBLY (IF EQUIPPED).......... 5-48
REQUIRED SERVICE MATERIAL.................. 5-50
SPECIAL TOOL .............................................. 5-50

NOTE:
All front fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of same
part number or with an equivalent part if replacement becomes necessary. Do not use a replacement
part of lesser quality or substitute design. Torque values must be used as specified during reassem-
bly to assure proper retention of all parts. There is to be no welding as it may result in extensive dam-
age and weakening of the metal.

5-4 BRAKES
DIAGNOSIS
ROAD TESTING BRAKES
Brakes should be tested on dry, clean, smooth and reasonably 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 the
vehicle stops evenly and effectively. Also drive vehicle to see if it leads to one side or the other without brake
application. If it does, check the tire pressure, front end alignment and front suspension attachments for loose-
ness. See diagnosis table for other causes.
BRAKE FLUID LEAKS
Check the master cylinder fluid levels. While a slight drop in reservoir level does result from normal lining wear,
an abnormally low level indicates a leak in the system. In such a case, check the entire brake system for leak-
age. If even a slight evidence of leakage is noted, the cause should be corrected or defective parts should be
replaced.
SUBSTANDARD OR CONTAMINATED BRAKE FLUID
Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components
in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the drum brake wheels.
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 conditions. 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 5-5
DIAGNOSIS TABLE
Condition Possible Cause Correction
Not enough braking
forceBrake oil leakage from brake lines Locate leaking point and repair.
Brake disc or pads stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Poor contact of shoes on brake drum Repair for proper contact.
Brake shoes linings stained with oil or wet with
waterReplace.
Badly worn brake pad linings Replace.
Defective wheel cylinders Repair or replace.
Malfunctioning caliper assembly Repair or replace.
Air in system Bleed system.
Maladjusted sensor spring length of LSPV, if
equippedCheck or adjust.
Broken sensor spring of LSPV, if equipped Replace.
Defective LSPV, if equipped Replace.
Malfunctioning ABS (Antilock brake system), if
equippedCheck system and replace as nec-
essary.
Brake pull
(Brakes not working in
unison)Pad linings and/or shoe linings are wet with
water or stained with oil in some brakesReplace.
Drum-to-shoe clearance out of adjustment in
some brakes
(Malfunctioning auto adjusting mechanism)Check for inoperative auto adjust-
ing mechanism.
Disc and/or drum is out of round in some
brakesReplace.
Wheel tires are inflated unequally Inflate equally.
Malfunction in wheel cylinders Repair or replace.
Disturbed front end 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 tub-
ing.
Malfunctioning caliper assembly Check for stuck or sluggish pistons
and proper lubrication of caliper
slide bush.
Caliper should slide.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifica-
tions.
Noise (high pitched
squeak without brake
applied)Front lining worn out Replace linings.
Contact wear indicator to brake disc Replace pads.
Rear brake locked pre-
maturelyMaladjusted sensor spring length of LSPV, if
equippedCheck or adjust.
Malfunction LSPV assembly, if equipped Replace assembly.

5-6 BRAKES
Excessive pedal travel
(Pedal stroke too
large)Partial brake system failure Check brake systems and repair as
necessary.
Insufficient fluid in master cylinder reservoirs Fill reservoirs with approved brake
fluid.
Check for leaks and air in brake
system.
Check warning light. Bleed system
if required.
Air in system (soft/spongy pedal) Bleed system.
Rear brake system not adjusted
(malfunctioning auto adjusting mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoes Replace brake shoes.
Worn rear brake shoes Replace brake shoes.
Brake locked
(For vehicle equipped
with ABS)Malfunctioning ABS Check system referring to Section
5E1.
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 double-walled steel
brake piping.
Incorrect parking brake adjustment on rear
brakesCheck and adjust to correct specifi-
cations.
Weakened or broken return springs in the brake Replace.
Sluggish parking brake cables or linkage Repair or replace.
Wheel cylinder or caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Pedal pulsation
(Pedal pulsates when
depressed for brak-
ing)Damaged or loose wheel bearings Replace wheel bearings.
Distorted steering knuckle or rear wheel spindle Replace knuckle or rear wheel spin-
dle.
Excessive disc lateral runout Check per instructions. If not within
specifications, replace or machine
disc.
Parallelism between pad and disc not within
specificationsCheck per instructions. If not within
specifications, replace or machine
disc.
Rear drums out of round Check runout.
Repair or replace drum as neces-
sary.
Braking noise
Glazed shoe linings, or foreign matters stuck to
liningsRepair or replace shoe linings.
Worn or distorted shoe linings Replace shoe lining (or pad).
Loose front wheel bearings Replace wheel bearing.
Distorted backing plates or loose mounting
boltsReplace or retighten securing bolts.
Contact wear indicator to brake disc Replace pads. Condition Possible Cause Correction

BRAKES 5-7
Brake warning lamp
lights after engine
startParking brake applied Release parking brake and check
that brake warning lamp turns off.
Insufficient amount of brake fluid Add brake fluid.
Brake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Brake warning lamp circuit faulty Repair circuit.
Malfunctioning EBD system, if equipped with
ABS.Check system referring to Table-E
of Section 5E1.
Brake warning lamp
turns on when brake
is appliedBrake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Insufficient amount of brake fluid Add brake fluid.
Brake warning lamp
fails to turn on even
when parking brake is
appliedBrake warning lamp circuit faulty Replace bulb or repair circuit.
ABS warning lamp
turns on after engine
start (If equipped)Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
turns on when brake
is applied (If
equipped)Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
does not turn on for 2
sec. after ignition
switch has turned ONBulb burnt out Replace bulb.
Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
flashesNew ABS hydraulic unit/control module assem-
bly installed.Perform “ABS Hydraulic Unit Oper-
ation Check”. Condition Possible Cause Correction