brake system SUZUKI SWIFT 2000 1.G RG413 Service User Guide

3-2 STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS
GENERAL DIAGNOSIS
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be consid-
ered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first. Pro-
ceed with the following preliminary inspection and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged
parts.
3) Spin front wheels. Inspect for out-of-round tires, out-of-balance tires, bent rims, loosen and/or rough wheel
bearings.
DIAGNOSIS TABLE
Condition Possible Cause Correction
Vehicle Pulls (Leads)
Mismatched or uneven tires Replace tire.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging springs Replace spring.
Radial tire lateral force Replace tire.
Disturbed front end alignment Check and adjust front end align-
ment.
Brake dragging in one road wheel Repair brake.
Loose, bent or broken front or rear suspension
partsTighten or replace suspension
parts.
Abnormal or
Excessive Tire WearSagging or broken spring Replace spring.
Tire out of balance Adjust balance or replace tire.
Disturbed front end alignment Check and adjust front end align-
ment.
Faulty strut (shock absorber) Replace strut.
Hard driving Replace tire.
Overloaded vehicle Replace tire.
Not rotating tire Replace or rotate tire.
Worn or loose wheel bearing Replace wheel bearing.
Wobbly wheel or tire Replace wheel or tire.
Tires not adequately inflated Adjust tire pressure.
Wheel Tramp
Blister or bump on tire Replace tire.
Improper strut (shock absorber) action Replace strut.
Shimmy, Shake or
VibrationTire or wheel out of balance Balance wheels or replace tire and/
or wheel.
Loosen wheel bearings Replace wheel bearing.
Worn tie rod ends Replace tie rod end.
Worn lower ball joints Replace front suspension arm.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire/wheel
assemblyReplace tire or wheel.
Disturbed front end alignment Check and adjust front end align-
ment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear case bolts Tighten case bolts.

3B1-8 ELECTRICAL POWER STEERING (P/S) SYSTEM
DTC CHECK
USING SUZUKI SCAN TOOL
1) Turn ignition switch to OFF position.
2) After setting cartridge connect SUZUKI scan tool to data link
connector (DLC) (1) located on underside of instrument
panel at driver’s seat side.
Special tool
(A) : 09931-76011
(B) : Master storage cartridge
(C) : 09931-76030
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 referring to SUZUKI
SCAN TOOL OPERATOR’S MANUAL for further details.
5) After completing the check, turn ignition switch to OFF posi-
tion and disconnect SUZUKI scan tool from DLC.
NOT USING SUZUKI SCAN TOOL
1) Remove glove box.
2) Apply chocks to wheels, set shift lever to neutral position and
pull parking brake fully.
3) Start engine.
4) Using jumper wire (4), short diagnosis switch terminal (1) to
ground terminal (2) of monitor coupler (3).
5) Read flashing of “EPS” warning lamp which represents DTC
and write it down. When more than 2 DTCs are stored in
memory, each DTC is repeated 3 times starting with the
smallest DTC number in increasing order.
For details and example of DTC, refer to “DTC TABLE”.
6) After completing the check, turn ignition switch to OFF posi-
tion and disconnect jumper wire (4) from monitor coupler. NOTE:
If Suzuki scan tool cannot display DTC, perform “SERIAL
DATA LINK CIRCUIT CHECK” described in this section.
(B)(A) (C)1
NOTE:
DTC No.22 is indicated when ignition switch is ON and
engine is not running but if DTC No.12 is indicated when
engine is started, it means nothing abnormal.
3
21
3
4

3B1-14 ELECTRICAL POWER STEERING (P/S) SYSTEM
INSPECTION
Step Action Yes No
1 1) Set parking brake.
2) Note combination meter when ignition
switch is turned to ON position.
Does the “BRAKE” indicator (warning lamp)
come ON?Go to Step 2.“BLK/YEL”, “BLK/WHT”
wire circuit or “IG METER”
fuse open or short to
ground.
2 1) Ignition switch OFF.
2) Remove and inspect “P/S” fuse.
Is fuse in good condition?Go to Step 3. Check “BLK/RED” wire
circuit for short to ground.
If OK, replace “P/S” fuse.
3 1) With ignition switch OFF, reinstall fuse and
disconnect P/S control module connector
(“G24”).
2) Check proper connection to P/S control
module at “G24-1” terminal.
3) If OK, check voltage between “G24-1”
(“BLK/RED” wire) terminal and body ground
with ignition switch ON.
Is it 10 – 14 V?Go to Step 4.“BLK/RED” wire circuit
open or short to ground.
4 1) Check proper connection to P/S control
module at “G24-8” terminal.
2) If OK, check voltage between “G24-8”
(“BLK/WHT” wire) terminal and body ground
with ignition switch ON.
Is it 10 – 14 V?Go to Step 5.“BLK/WHT” wire circuit
open or short to ground.
5 1) Check proper connection to P/S control
module at “G24-5” terminal.
2) If OK, check voltage between “G24-5”
(“YEL” wire) terminal and body ground with
ignition switch ON.
Is it 10 – 14 V?Substitute a known-good
P/S control module and
recheck.Go to Step 6.
6 1) Remove combination meter. Refer to “COM-
BINATION METER” in Section 8.
2) Remove and inspect “EPS” light bulb.
Is bulb in good condition?“YEL”, “BLK/WHT” wire
circuit or inside of combi-
nation meter open or
short to other circuit.Check “YEL” wire circuit
for short to ground.
If OK, replace “EPS” light
bulb.

3E-18 REAR SUSPENSION
8) Install wheel speed sensor and clamp wire securely (right &
left) (if equipped with ABS).
9) Install LSPV spring (1) to rear axle (2).
Tighten nut (3) temporarily at this step (if equipped with
LSPV).
10) Connect brake pipes (1) (right & left) to wheel cylinders (2)
and tighten brake pipe flare nuts (3) to specified torque.
Tightening torque
Brake pipe flare nuts (a) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
11) Connect brake flexible hoses (1) to bracket on rear axle and
secure it with E-rings (2).
12) Install brake drums (right & left). Refer to “BRAKE DRUM” in
Section 5.
13) Fill reservoir with brake fluid and bleed brake system (For
bleeding operation, refer to Section 5.)
14) Install wheel and tighten wheel nuts (1) to specified torque.
Tightening torque
Wheel nuts (a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
231

REAR SUSPENSION 3E-25
8) Connect brake pipe to wheel cylinder and tighten brake pipe
flare nut to specified torque.
Tightening torque
Brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
9) Refill rear axle (differential) housing with new specified gear
oil. Refer to Section 7F for refill.
10) Install brake drum. For details, refer to “BRAKE DRUM” of
Section 5.
11) Connect parking brake cable (1) to parking brake shoe lever.
Secure parking brake cable to brake back plate with clip (2).
Install wheel speed sensor (if equipped with ABS).
12) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “BLEEDING BRAKES” in Sec-
tion 5.)
13) Install wheel and tighten wheel nuts to specified torque.
14) Upon completion of all jobs, pull parking brake lever with
about 20 kg, (44 lbs) load three to five times so as to obtain
proper drum-to-shoe clearance.
Adjust parking brake cable (for adjustment, refer to “PARK-
ING BRAKE INSPECTION AND ADJUSTMENT” in Section
5).
15) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
16) Perform brake test (foot brake and parking brake).
(For brake test, see Section 5.)
17) Check each installed part for oil leakage.
REAR AXLE SHAFT OIL SEAL (4WD VEHI-
CLE)
REMOVAL
1) Remove rear axle shaft. For details, refer to steps 1) to 8) of
“REAR AXLE SHAFT AND WHEEL BEARING” in this sec-
tion.
CAUTION:
Check to ensure that clip is in good condition before
installing it. If deformed or broken, replace.
1. Plug cap
2. Vinyl tube (See-through tube)
3. Container

3E-30 REAR SUSPENSION
13) Connect brake pipe to wheel cylinder (1) and tighten brake
pipe flare nut (2) to specified torque.
Tightening torque
Brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
14) Clean mating surface of axle housing (2) (right & left) with
brake back plate and apply sealant as shown.
“B” : Sealant 99000-31090
15) Apply grease to axle shaft oil seals (1) lip (right & left) as
shown.
“A” : Grease 99000-25010
16) Install rear axle shaft (right & left) to rear axle housing and
tighten brake back plate bolts to specified torque.
Tightening torque
Brake back plate bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
17) Connect brake pipes (3) to wheel cylinders (1) (right & left)
and tighten brake pipe flare nuts (2) to specified torque.
Tightening torque
Brake pipe flare nuts (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
18) Connect parking brake cable (2) to parking brake shoe lever
(right & left) and secure it with clip (3).
Apply water tight sealant where brake back plate (1) and
parking brake cable contact.
“A” : Sealant 99000-31090
19) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, see Section 5.)
20) Refill differential gear housing with new specified gear oil.
Refer to Section 7F.
NOTE:
Check to ensure that clip is in good condition before
installing it. If deformed or broken, replace.
A : Forward

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.

5-2 BRAKES
GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pis-
tons (two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they
make two independent circuits. One connects front right & rear left brakes and the other connects front left &
rear right brakes.
The load sensing proportioning valve (LSPV) or the proportioning valve (P valve) is included in these circuits
between the master cylinder and the rear brake for the vehicle without ABS.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading/trailing
shoes) for the rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes are used for both parking and foot brakes.

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.