height SUZUKI SWIFT 2000 1.G RG413 Service Workshop Manual

MAINTENANCE AND LUBRICATION 0B-3
IntervalKm (x 1,000) 153045607590
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
BRAKE
Brake discs and pads (thickness, wear, damage) I I I I I I
Brake drums and shoes (wear, damage)–I–I–I
Brake hoses and pipes (leakage, damage, clamp)–I–I–I
Brake fluid–R–R–R
Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles only)
CHASSIS AND BODY
Clutch (pedal height and travel)–I–I–I
Tires (wear, damage, rotation) /wheels (damage) I I I I I I
Suspension system (tightness, damage, rattle, breakage)–I–I–I
Steering system (tightness, damage, breakage, rattle)–I–I–I
Drive shaft (axle) boots/Propeller shafts (4WD)––I––I
Manual transmission oil (leakage, level) (I : 1st 15,000 km only) I–R––R
Automatic transmission
fluidFluid level–I–I–I
Fluid change Replace every 165,000 km (99,000 miles)
Transfer oil (4WD) (leakage, level) I–I–I–
Rear differential oil (4WD) (leakage, level) (R : 1st 15,000 km
only)R or I–I–I–
All latches, hinges and locks–I–I–I
NOTE:
 “R” : Replace or change
 “I” : Inspect and correct or replace if necessary

0B-14 MAINTENANCE AND LUBRICATION
2) Check tooth tip of each notch for damage or wear. If any
damage or wear is found, replace parking lever.
3) Check parking brake lever for proper operation and stroke,
and adjust it if necessary.
For checking and adjusting procedures, refer to “PARKING
BRAKE INSPECTION AND ADJUSTMENT” in Section 5.
Parking brake lever stroke
“a” :4 - 9 notches (with 20 kg (44 lbs) of pull pressure)
CHASSIS AND BODY
CLUTCH
INSPECTION
Check clutch pedal for height and free travel (1) referring to
“CLUTCH PEDAL HEIGHT CHECK” and “CLUTCH PEDAL
FREE TRAVEL CHECK” in Section 7C. Adjust or correct if neces-
sary.
TIRES / WHEELS
TIRES INSPECTION
1) Check tires for uneven or excessive wear, or damage.
If defective, replace.
Refer to “TIRE DIAGNOSIS” in Section 3 for details.
2) Check inflating pressure of each tire and adjust pressure to
specification as necessary.
3) Rotate tires.
For details, refer to “TIRE ROTATION” in Section 3F.
1. Wear indicator
NOTE:
 Tire inflation pressure should be checked when tires
are cool.
 Specified tire inflation pressure should be found on
tire placard or in owner’s manual which came with the
vehicle.

3-4 STEERING, SUSPENSION, WHEELS AND TIRES
Wander or Poor
Steering StabilityMismatched or uneven tires Replace or inflate tires to proper
pressure.
Loosen ball joints and tie rod ends Replace suspension arm or tie rod
end.
Faulty struts or mountings Replace strut or repair mounting.
Loose stabilizer bar Tighten or replace stabilizer bar or
bush.
Broken or sagging springs Replace spring.
Rack and pinion adjustment Check and adjust rack and pinion
torque.
Disturbed front end alignment Check and adjust front end align-
ment.
Erratic Steering When
BrakingWorn wheel bearings Replace.
Broken or sagging springs Replace coil spring.
Wheel tires are inflated unequally Inflate tires to proper pressure.
Disturbed front end alignment Check and adjust front end align-
ment.
Brakes not working in unison Check and adjustment brake sys-
tem.
Leaking wheel cylinder or caliper Repair or replace wheel cylinder or
caliper.
Warped discs Replace brake disc.
Badly worn brake linings Replace brake shoe lining.
Drum is out of round in some brakes Replace brake drum.
Defective wheel cylinders Replace or repair wheel cylinder.
Low or Uneven Trim
Height
NOTE:
See NOTE *1.Broken or sagging springs Replace.
Over loaded Check loading.
Incorrect springs Replace.
Ride Too Soft
Faulty struts (shock absorber) Replace strut.
Suspension Bottoms
Overloaded Check loading.
Faulty struts (shock absorber) Replace strut.
Incorrect, broken or sagging springs Replace.
Body Leans or Sways
in CornersLoose stabilizer bar Tighten stabilizer bar bolts or nuts,
or replace bushes.
Faulty struts (shock absorbers) or mountings Replace strut or tighten mounting.
Broken or sagging springs Replace.
Overloaded Check loading.
Cupped Tires
Front struts defective Replace.
Worn wheel bearings Replace.
Excessive tire or wheel run-out Replace tire or wheel disc.
Worn ball joints Replace front suspension arm.
Tire out of balance Adjust tire balance. Condition Possible Cause Correction

STEERING, SUSPENSION, WHEELS AND TIRES 3-5
TIRE DIAGNOSIS
IRREGULAR AND/OR PREMATURE WEAR
Irregular and premature wear has many causes. Some of them
are: incorrect inflation pressures, lack of tire rotation, driving hab-
its, improper alignment.
If the following conditions are noted, rotation is necessary:
Front tire wear is different from rear.
Uneven wear exists across the tread of any tire.
Front tire wear is unequal between the right and left.
Rear tire wear is unequal between the right and left.
There is cupping, flat spotting, etc.
A wheel alignment check is necessary if following conditions are
noted:
Front tire wear is unequal between the right and left.
Wear is uneven across the tread of any front tire.
Front tire treads have scuffed appearance with “feather”
edges on one side of tread ribs or blocks.
WEAR INDICATORS
Original equipment tires have built-in tread wear indicators (1) to
show when they need replacement.
These indicators (1) will appear as 12 mm (0.47 in) wide bands
when the tire tread depth becomes 1.6 mm (0.063 in).
When the indicators (1) appear in 3 or more grooves at 6 loca-
tions, tire replacement is recommended.NOTE:
*1: Right-to-left trim height (“H”) difference should be
within 15 mm (0.6 in.) with curb weight. (same with rear
side.)
“H”
[A] : Hard Cornering, under inflation or lack of tire rotation
[B] : Incorrect wheel alignment, tire construction not uniform or wheel heavy acceleration

FRONT END ALIGNMENT 3A-3
DIAGNOSIS
DIAGNOSIS TABLE
For the details, refer to Section 3.
PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT
Steering and vibration complaints are not always the result of improper alignment. An additional item to be
checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the
vehicle from a straight path on a level road without hand pressure on the steering wheel. Procedure for deter-
mining the presence of a tire lead problem contains in SECTION 3. Before making any adjustment affecting toe
setting, the following checks and inspections should be made to ensure correctness of alignment readings and
alignment adjustments:
1) Check all tires for proper inflation pressures and approximately the same tread wear.
2) Check for loose of ball joints. Check tie rod ends; if excessive looseness is noted, it must be corrected
before adjusting.
3) Check for run-out of wheels and tires.
4) Check vehicle trim heights; if out of limits and a correction is to be made, it must be made before adjusting
toe.
5) Check for loose of suspension arms.
6) Check for loose or missing stabilizer bar attachments.
7) Consideration must be given to excess loads, such as tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment checks.
8) Consider condition of equipment being used to check alignment and follow manufacturer's instructions.
9) Regardless of equipment used to check alignment, vehicle must be on a level surface both fore and aft and
transversely.
TOE ADJUSTMENT
1) Loosen right and left tie rod end lock nuts (1) first.
2) Rotate right and left tie rods (2) by the same amount to align
toe-in to specification. In this adjustment, right and left tie
rods (2) should become equal in length “A”.
3) After adjustment, tighten lock nuts (1) to specified torque.
Tightening torque
Tie rod end lock nuts (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft) NOTE:
Before rotating tie rods (2), apply grease between tie
rods and rack boots so that boots won't be twisted.
NOTE:
Make sure that rack boots are not twisted.

STEERING WHEEL AND COLUMN 3C-5
INSPECTION
Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.
Air bag being deployed
Trim cover (pad surface) (1) being cracked
Wire harness or connector (2) being damaged
Air bag (inflator) module being damaged or having been
exposed to strong impact (dropped)
INSTALLATION
1) Check that horn wire is connected to horn connector (2)
securely.
2) Connect yellow connector (1) of driver air bag (inflator) mod-
ule (3) and horn connector in order a) – d) shown in figure
securely.
3) Install driver air bag (inflator) module to steering wheel, tak-
ing care so that no part of wire harness is caught between
them.
4) Make sure that clearance between module and steering
wheel is uniform all the way.
5) Tighten driver air bag (inflator) module mounting bolts (1) to
specified torque.
Tightening torque
Driver air bag (inflator) module mounting bolt
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
6) Connect negative cable at battery.
7) Enable air bag system. Refer to “ENABLING AIR BAG SYS-
TEM” under “SERVICE PRECAUTIONS” in Section 10B. WARNING:
Never disassemble driver air bag (inflator) module or
measure its resistance. Otherwise, personal injury may
result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.

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.

5-8 BRAKES
BRAKE PEDAL FREE HEIGHT ADJUSTMENT
1) Check brake pedal free height.
If it is not within specification, check and adjust following
item 1) and 2).
Brake pedal free height “a” from dash silencer
LH steering vehicle : 205 – 225 mm (8.08 – 8.85 in.)
RH steering vehicle : 217 – 237 mm (8.55 – 9.33 in.)
2) Check measurement between booster mounting surface and
center of clevis pin hole. When booster push rod clevis has
been reinstalled, it is important that the measurement is
adjusted (refer to BRAKE BOOSTER INSPECTION AND
ADJUSTMENT).
3) Check stop light switch position. Adjust it if it is out of specifi-
cation.
BRAKE PEDAL PLAY INSPECTION
Pedal play should be within specification below. If out of specifi-
cation, check stop light switch for proper installation position and
adjust if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Brake pedal play
“a” : 1 - 8 mm (0.04 - 0.31 in.)
STOP LIGHT SWITCH ADJUSTMENT
Adjustment should be made as follows when installing switch.
Pull up brake pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread and
brake pedal is as specified. Then adjust stop light switch assem-
bly position and lock it by turning clockwise.
Clearance between brake pedal and stop light switch
“a” : 0.5 - 1.5 mm (0.02 -0.06 in.)
“a”
“a”

5-12 BRAKES
2) Start engine while depressing brake pedal. If pedal travel
increases a little, operation is satisfactory. But no change in
pedal travel indicates malfunction.
CHECK AIR TIGHTNESS UNDER LOAD
1) With engine running, depress brake pedal. Then stop engine
while holding brake pedal depressed.
2) Hold brake pedal depressed for 30 seconds. If pedal height
does not change, condition is good. But it isn’t if pedal rises.
FLUID PRESSURE TEST (IF EQUIPPED WITH
LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
H: Hold
H: Hold
T: 30 seconds

ENGINE MECHANICAL (M13 ENGINE) 6A1-23
Clean sealing surface on oil pan and cylinder block.
Remove oil, old sealant and dust from sealing surface.
INSTALLATION
1) Apply sealant continuously to oil pan mating surface as
shown in figure.
“A” : sealant 99000-31150
Sealant amount for oil pan
Width “a” : 3 mm (0.12 in.)
Height “b” : 2 mm (0.08 in.)
2) Install new O-rings (2) in the position as shown in figure and
install oil pump strainer (1).
Tighten strainer bolt (3) first and then bracket bolt (4) to
specified torque.
Tightening torque
Oil pump strainer bolt (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Oil pump strainer bracket bolt
(b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
3) After fitting oil pan to cylinder block, run in securing bolts and
start tightening at the center :
move wrench outward, tightening one bolt at a time. Tighten
bolts and nuts to specified torque.
Tightening torque
Oil pan bolts and nuts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
4) Install new gasket and drain plug to oil pan.
Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug bolt (b) : 50 N·m 5.0 kg-m, 36.5 lb-ft)