rear brake SUZUKI SWIFT 2000 1.G RG413 Service Owner's Guide

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 5-9
EXCESSIVE PEDAL TRAVEL INSPECTION
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 30 kg (66
lbs) load, measure brake pedal to wall (dash panel silencer)
clearance “a”.
If clearance “a” is less than specification, the most possible
cause is either rear brake shoes are worn out beyond limit or
air is in lines.
Should clearance “a” remain less than specification even
after replacement of brake shoes and bleeding of system,
other possible but infrequent cause is malfunction of rear
brake shoe adjusters or booster push rod length out of
adjustment.
–Bleed brake system. Refer to “AIR BLEEDING OF BRAKE
SYSTEM”.
–Remove brake drums for adjuster inspection. (Refer to
“REAR BRAKE”.) If defective, correct or replace.
Clearance “a” between brake pedal and dash panel
silencer
LH steering vehicle : over 135 mm (5.32 in.)
RH steering vehicle : over 140 mm (5.52 in.)
FRONT BRAKE PAD INSPECTION
Inspect pad linings (1) periodically according to maintenance
schedule whenever wheels are removed (for tire rotation or other
reason). Take a look through each end (or hole) of caliper and
check lining thickness of outside and inside pads.
If lining is worn and its thickness (“a” in figure) is less than limit, all
pads must be replaced at the same time.
Front brake pad thickness “a” (lining thickness)
Standard : 10 mm (0.40 in.)
Limit : 2 mm (0.08 in.)
BRAKE DISC INSPECTION
Refer to “BRAKE DISC” for inspection point and procedure.
“a”

5-10 BRAKES
PARKING BRAKE INSPECTION AND
ADJUSTMENT
INSPECTION
Hold center of parking brake lever grip and pull it up with 200 N
(20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count ratchet
notches. There should be 4 to 9 notches.
Also, check if both right and left rear wheels are locked firmly.
To count number of notches easily, listen to click sounds that
ratchet makes while pulling parking brake lever without pressing
its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable referring
to adjustment procedure so as to obtain specified parking brake
store.
ADJUSTMENT
After confirming that above conditions are all satisfied, adjust
parking brake lever stoke by loosening or tightening adjust nut
(1).NOTE:
Check tooth tip of each notch for damage or wear.
If any damage or wear is found, replace parking brake
lever.
NOTE:
Make sure for the following conditions before cable
adjustment.
No air is trapped in brake system.
Brake pedal travel is proper.
Brake pedal has been depressed a few times with
about 100 N (10 kg, 22 lbs) load.
Parking brake lever is pulled up a few times with about
500 N (50 kg, 110 lbs) load.
Rear brake shoes are not worn beyond limit, and self
adjusting mechanism operates properly.
If parking brake lever stroke is less than specification,
loosen adjusting nut (1) as far as end of bolt. Then
depress brake pedal repeatedly with about 300 N (30
kg, 66 lbs) load until adjuster actuator clicking sound
can not be heard from drum brake.
NOTE:
Check brake drum for dragging after adjustment.

BRAKES 5-13
1) Stop vehicle on level floor and place approximately about
1,000 N (100 kg, 220 lbs) weight (1) on rear housing so that
rear axle weighs 4,500 N (450 kg, 992 lbs).
Rear axle weight
“L” : 4,500 N (450 kg, 992 lbs)
2) Install special tool to front and rear brake.
For front wheel
Special tool
(A) : 09956-02310
(C) : 55473-82030 (Air bleeder plug as a spare part)
For rear wheel
Special tool
(A) : 09956-02310
(C) : 55473-82030 (Air bleeder plug as a spare part)
(D) : 09952-48320
3) Depress brake pedal gradually till fluid pressure of front
brake becomes as specified below and check corresponding
pressure of rear brake then. It should be within specification
given below.
LSPV specification
4) As done above, apply 100 kg/cm
2 pressure to front brake
and check that rear brake pressure then is within specifica-
tion as given below.
LSPV specification (apply 100 kg/cm
2 pressure to front
brake) NOTE:
Pressure gauge should be connected to bleeder plug
hole of front (left side brake) and rear (right side brake).
After testing front left side and rear right side, test front
right side and rear left side in the same way.
Front brake Rear brake
7,500 kPa
75 kg/cm
2
1,067 psi4,700 – 6,900 kPa
47 – 69 kg/cm
2
669 – 981 psi
Front brake Rear brake
10,000 kPa
100 kg/cm
2
1,422 psi5,400 – 7,700 kPa
54 – 77 kg/cm
2
768 – 1,094 psi

5-14 BRAKES
5) If rear brake pressure is not within specification, adjust it by
changing bolt (2) position as follows.
If rear brake pressure is higher than specification, move bolt
(2) center side and if it is lower, out side.
Repeat steps 3) and 4) until rear brake pressure is within
specification.
After adjustment, be sure to torque nut (1) to specification.
Tightening torque
LSPV nut (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
6) Upon completion of fluid pressure test, bleed brake system
and perform brake test.
MASTER CYLINDER AND BRAKE FLUID
LEVEL INSPECTION
1) Check master cylinder and reservoir tank for crack, damage
and brake fluid leakage. If any faulty condition exists, correct
or replace.
2) Check that brake fluid level is between MAX and MIN marks
on reservoir tank.
2
1, (a)
NOTE:
Be sure to use particular brake fluid either as indicated
on reservoir cap of that vehicle or recommended in
owner’s manual which comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked
on reservoir.
When brake warning lamp lights sometimes during driv-
ing, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake system for
leakage. Correct leaky points and then refill to specified
level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has
been used for mineral oil or a container which is wet from
water. Mineral oil will cause swelling and distortion of
rubber parts in hydraulic brake system and water mixed
into brake fluid will lower fluid boiling point. Keep all fluid
containers capped to prevent contamination.
MAX
MIN

BRAKES 5-15
BRAKE HOSE AND PIPE INSPECTION
HOSE
The brake hose assembly should be checked for road hazard
damage, for cracks and chafing of outer cover, for leaks and blis-
ters. A light and mirror may be needed for an adequate inspec-
tion. If any of above conditions are observed on brake hose, it is
necessary to replace it.
PIPE
Inspect the pipe for damage, cracks, dents and corrosion. If any
defect is found, replace it.
ON-VEHICLE SERVICE
AIR BLEEDING OF BRAKE SYSTEM
Bleeding operation is necessary to remove air whenever it
entered hydraulic brake system.
Hydraulic lines of brake system are based on the diagonal split
system. When a brake pipe or hose was disconnected at the
wheel, bleeding operation must be performed at both ends of the
line of the removed pipe or hose. When any joint part of the mas-
ter cylinder of other joint part between the master cylinder and
each brake (wheel) was removed, the hydraulic brake system
must be bled at all 4 wheel brakes.
CAUTION:
Brake fluid is extremely damaging to paint. If fluid should
accidentally touch painted surface, immediately wipe
fluid from paint and clean painted surface.
NOTE:
Perform bleeding operation starting with wheel cylinder
farthest from master cylinder and then at front caliper of
the same brake line. Do the same on the other brake line.
1. Right brake caliper 4. Left wheel cylinder
2. Left brake caliper A : FRONT
3. Right wheel cylinder B : REAR

5-16 BRAKES
1) Fill master cylinder reservoir with brake fluid and keep at
least one-half full of fluid during bleeding operation.
2) Remove bleeder plug cap.
Attach a vinyl tube (1) to bleeder plug, and insert the other
end into container (2).
3) Depress brake pedal several times, and then while holding it
depressed, loosen bleeder plug about one-third to one-half
turn.
4) When fluid pressure in cylinder is almost depleted, retighten
bleeder plug.
5) Repeat this operation until there are no more air bubbles in
hydraulic line.
6) When bubbles stop, depress and hold brake pedal and
tighten bleeder plug.
Tightening torque
Front bleeder plug : 11.0 N·m (1.1 kg-m, 8.0 lb-ft)
Rear bleeder plug : 8.0 N·m (0.8 kg-m, 6.0 lb-ft)
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid pressure to
pipe line and check for leakage.
9) Replenish fluid into reservoir up to specified level.
10) Check brake pedal for sponginess. If found spongy, repeat
entire procedure of bleeding.
MAX
MIN
MAX
MIN

BRAKES 5-25
REAR BRAKE
1. Brake back plate
: Apply water tight sealant (99000-31090) to joint seam of brake back plate and rear axle 9. Bleeder plug
2. Brake shoe10. Bleeder plug cap
3. Push nut 11. Parking lever spring
4. Shoe hold down spring12. Parking brake shoe lever
5. Shoe return upper spring 13. Brake Drum
6. Shoe hold down pin 14. Spindle nut (For 2WD vehicle only)
: Calk spindle nut after tightening
7. Brake strutTightening torque
8. Wheel cylinder
: Apply brake fluid to piston cup Do not reuse.

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).