SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

5-28 BRAKES
INSTALLATION
1) Put flat end rod or the like between rod (1) and ratchet (2)
and pull ratchet as shown to maximize clearance between
shoe and drum.
2) Install brake drum (1) after making sure that inside of brake
drum and brake shoes are free from dirt and oil.
3) Install new spindle nut (2). (For 2WD vehicle only)
4) Tighten spindle nut (2) to specified torque. (For 2WD vehicle
only)
Tightening torque
Spindle nut (a) : 175 N·m (17.5 kg-m, 127.0 lb-ft)
5) Calk spindle nut (1) as shown in figure. (For 2WD vehicle
only)
6) Install spindle cap. (For 2WD vehicle only)
7) Tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts (a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
8) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load 3 to 5 times so as to obtain proper drum-
to-shoe clearance.
9) Adjust parking brake cable. Refer to “PARKING BRAKE
INSPECTION AND ADJUSTMENT”.
10) Check to make sure that brake drum is free of dragging and
brake works properly. Then remove vehicle from lift and per-
form brake test.
NOTE:
Removed spindle nut should be replaced with new one.
NOTE:
When installing spindle cap, hammer lightly several
locations on the collar of cap until collar comes closely
into contact with brake drum.
If fitting part of cap is deformed or damaged or if it is
fitted loosely, replace with new one.

BRAKES 5-29
BRAKE SHOE
REMOVAL
1) Remove brake drum referring to “BRAKE DRUM”.
2) Remove shoe hold down springs (1) by turning shoe hold
down pins (2).
3) Remove return springs, brake shoes and strut.
4) Disconnect parking brake shoe lever (1) from parking brake
cable (2).
5) Remove push nut (1).
6) Remove parking brake shoe lever (2) from shoe rim (3).
INSPECTION
Check ratchet of brake strut (1) assembly for wear or dam-
age.
Check shoe return spring, strut shoe return spring and shoe
hold down spring for damage, corrosion and weakening.
Check for smooth movement of brake shoe lever (2) along
shoe rim.
CAUTION:
Use a new push nut.

5-30 BRAKES
INSTALLATION
Install parts in reverse order of removal, noting the followings.
Install shoe hold down springs (2) by pushing them down in
place and turning hold down pins (1).
For procedure hereafter referring to “BRAKE DRUM”.
WHEEL CYLINDER
REMOVAL
1) Remove brake drum referring to “BRAKE DRUM”.
2) Remove break shoe referring to “BRAKE SHOE”.
3) Loosen brake pipe flare nut (1) but only within the extent that
fluid does not leak.
4) Remove wheel cylinder mounting bolts. Disconnect brake
pipe from wheel cylinder and put bleeder plug cap (1) onto
pipe to prevent fluid from spilling.
INSPECTION
Inspect wheel cylinder disassembled parts for wear, cracks, cor-
rosion or damage.
NOTE:
Clean wheel cylinder components with brake fluid.

BRAKES 5-31
INSTALLATION
1) Take off bleeder plug cap from brake pipe and connect pipe
to wheel cylinder (1) just enough to prevent fluid from leak-
ing.
2) Install wheel cylinder (1) to brake back plate (2) to specified
torque.
Tightening torque
Cylinder mounting bolts (a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
3) Tighten flare nut (3) of brake pipe to specified torque.
Tightening torque
Rear brake pipe flare nut (b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
4) Install bleeder plug cap.
5) Install brake shoes. (Refer to “BRAKE SHOE”.)
6) Install brake drum. (Refer to “BRAKE DRUM”.)
7) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation referring to “AIR BLEEDING OF BRAKE
SYSTEM”.)
8) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load 3 to 5 times so as to obtain proper drum-
to-shoe clearance.
Adjust parking brake cable.
9) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts : 85 N·m (8.5 kg-m, 61.5 lb-ft)
10) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
11) Check each installed part for oil leakage.
BRAKE BACK PLATE (FOR 2WD VEHICLE)
REMOVAL
1) Remove brake drum referring to “BRAKE DRUM”.
2) Remove brake shoe referring to “BRAKE SHOE”.
3) Remove wheel cylinder referring to “WHEEL CYLINDER”.
4) Remove parking brake cable securing clip (1) and discon-
nect brake cable (2) from brake back plate (3).

5-32 BRAKES
5) Remove brake back plate (1) by removing bolts (2).
INSTALLATION
1) Apply water tight sealant to mating surfaces of brake back
plate and rear axle.
“A” : Sealant 99000-31090
2) Install brake back plate and tighten back plate bolts to speci-
fied torque.
Tightening torque
Brake back plate bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
3) Apply water tight sealant where plate and cable contact, and
run parking brake cable (1) through brake back plate (2) and
secure it with clip (3).
“A” : Sealant 99000-31090
4) Install wheel cylinder, and tighten wheel cylinder bolts and
brake pipe flare nut to specified torque. (Refer to “WHEEL
CYLINDER”.)
5) For procedure hereafter referring to “WHEEL CYLINDER”.
A: Forward

BRAKES 5-33
BRAKE BACK PLATE (FOR 4WD VEHICLE)
REMOVAL AND INSTALLATION
Refer to “REAR AXLE SHAFT AND WHEEL BEARING (4WD VEHICLE)” in Section 3E.
MASTER CYLINDER
MASTER CYLINDER RESERVOIR
REMOVAL
1) Remove master cylinder.
2) Pull out retainer (1) and remove reservoir (2).
1. Reservoir tank 9. Sleeve Tightening torque
2. Retainer 10. Primary piston
: Apply brake fluid to contact surface of cup.Do not reuse.
3. Grommet
: Apply brake fluid.11. Primary cup
: Confirm installing direction.
4. Master cylinder body 12. Washer
5. Secondary return spring 13. Cap
6. Secondary cup
: Confirm installing direction Size of cup : 6=11>14>8 .14. Cap cup
: Confirm installing direction.
7. Secondary piston
: Apply brake fluid to contact surface of cup.15. Master cylinder gasket
8. Sleeve cup
: Confirm installing direction.
2
1

5-34 BRAKES
INSTALLATION
1) Apply brake fluid to new grommets and attach grommets (2)
to master cylinder (1).
2) Install reservoir (2) to master cylinder and insert retainer (1).
3) Install master cylinder.
4) Fill reservoir with specified brake fluid up to MAX mark on it.
5) After installation, purge air and check for brake fluid leakage.
MASTER CYLINDER ASSEMBLY
REMOVAL
1) Clean outside of master cylinder.
2) Drain brake fluid in reservoir.
3) Disconnect fluid level switch coupler (1) on reservoir.
4) Disconnect brake pipes (2) connected to master cylinder.
5) Remove master cylinder fixing nuts (3).
6) Remove master cylinder and master cylinder gasket.NOTE:
Be sure to use new grommets.
1 2
2
1
CAUTION:
Do not allow brake fluid to get on painted surface.
Painted surface will be damaged by brake fluid, flush it
with water immediately if any fluid is spilled.
13
MAX
MIN
2
3

BRAKES 5-35
INSPECTION
1) Check all disassembled parts for wear and damage.
If anything faulty is found, replace.
2) Check screw hole in master cylinder for gall or corrosion.
If anything faulty is found, replace.
DISASSEMBLY
1) Loosen cap and remove it.
2) Remove component parts from master cylinder body.
ASSEMBLY
1) Apply brake fluid to inside of cylinder and contact surface of
piston assembly.
Install secondary return spring (2) to cylinder body (1) with
noting spring direction. CAUTION:
Wash disassembled parts with brake fluid.
Do not reuse piston cups.
CAUTION:
Wash master cylinder with new brake fluid. Do not use
cloth to dry cylinder so as to avoid fibers being attached
to internal surface of cylinder.
NOTE:
For this work, apply a cloth to outlet port at the tip end (1)
of master cylinder body and secure cylinder using soft
jawed vise.
CAUTION:
Never use any mineral oil such as kerosene oil and
gasoline when washing and assembling parts.
Check inside of cylinder wall, pistons and cup seals
are free from any foreign objects such as dust and dirt
and use case not to cause any damage with a tool dur-
ing assembly.
Do not drop parts. Do not use any part which has been
dropped.

5-36 BRAKES
2) Attach secondary cup (1) to secondary piston (2), they install
it to cylinder body such a direction as shown.
3) Push secondary cup to the bottom by using special tool.
Special tool
(A) : 09951-18220
4) Remove O-ring (1) from sleeve (2).
Special tool
(A) : 09900-06106
5) Install sleeve cup (3) and O-ring (2) to sleeve (1) such a
direction as shown.
6) Install sleeve assembly with aligning protrusion (1) of sleeve
and dent (2) of cylinder body. NOTE:
Secondary cup is the same as primary cup.
Diameter of secondary cup is the largest compared
with sleeve cup and cap cup.
(A)
CAUTION:
Do not cause any damage to inside of sleeve.
If caused, replace primary piston assembly.
NOTE:
Diameter of sleeve cup and O-ring are smaller than
those of cap.
O-ring is the same as that of smaller one of cap O-ring.

BRAKES 5-37
7) Install cup (1) and washer (2) such a direction as shown.
8) Remove cap cup (1) from cap with caring not to cause any
damage to inside of cap (2).
9) Install cap cup and O-rings (3) to cap such a direction as
shown.
10) Install cap and tighten it to specified torque, then confirm the
length “A”.
Tightening torque
Cap (a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
Cap installation position
“A” : Less than 26 mm (1.02 in.)
INSPECTION AFTER ASSEMBLY
1) Install radiator cap test with special tool to master cylinder
port (1).
Special tool
(A) : 09952-46010
(B) : 09952-26020
2) Apply air and confirm that pressure is not applied.NOTE:
Primary cup is the same as secondary cup.
Primary cup is the largest compared with that of cap
and sleeve.
NOTE:
For without ABS vehicle, install special tool (B) to oppo-
site side port (2).
1(B)
2 (A)