wheel SUZUKI SWIFT 2004 2.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine 3A-6 Drive Shaft / Axle:
Front Drive Shaft Disassembly and ReassemblyS7RS0B3106004
Disassembly
Tripod joint
CAUTION!
• Disassembly of wheel side joint is not allowed. If any noise or damage exists in it,
replace it as assembly.
• Do not disassemble tripod joint spider. If any malcondition is found in it, replace it
as differential side joint assembly.

1) Remove differential side (or center shaft side) boot
big band (1) as follows.
• For boot big band without joint:Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint: Draw hooks of boot big band together and remove
band. 2) Wipe off grease from shaft and take off snap ring (1)
using snap ring pliers (2).
3) Remove tripod joint spid er (1) using 3 arms puller
(2).
CAUTION!
To prevent any problem caused by washing
solution, do not wash tripod joint except its
housing. Degreasing of tr ipod joint with cloth
is allowed.

4) Remove boot band as follows.
a) Remove differential side (or center shaft side) boot small band, and then pull out differential
side (or center shaft side) boot from shaft.
b) Remove damper band, and then pull out damper through shaft, if equipped.
c) Undo caulking (5) of wheel side boot big band (1) and small band (3) using flat end rod (2) or the
like, then pull out wheel side boot (4) from shaft.
[A]: For boot big band without joint
[B]: For boot big band with joint
I4RH0A310004-01
I5JB0A311008-01
I3RH0A311004-01
I4RS0A310006-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-7
DOJ
CAUTION!
Disassembly of wheel side joint is not
allowed. If any noise or damage exists in it,
replace it as assembly.

1) Remove differential side (or center shaft side) boot big band (1) as follows.
• For boot big band without joint:Remove boot big band by tapping boot and band
with plastic hammer. If it is hard to remove boot
big band, cut it using a nipper or an iron saw with
care not to damage joint housing.
• For boot big band with joint: Draw hooks of boot big band together and remove
band.
2) Remove differential side (or center shaft side) boot small band (1) using flat end rod (2) or the like.
3) Side boot (1) toward the center of shaft and remove snap ring (2) from outer race, and then take shaft out
of outer race (3). 4) Wipe off grease and remove circlip (1) used to fix
cage (2) by using snap ring pliers (3).
5) Draw away cage (1) by using bearing puller (2), and remove boot (3) from shaft.
6) Pull out differential side (or center shaft side) boot from shaft.
7) Undo caulking (5) of wheel side boot big band (1) and small band (3) using flat end rod (2) or the like,
then pull out wheel side boot (4) from shaft.
[A]: For boot big band without joint
[B]: For boot big band with joint
I4RH0A310004-01
2
1
I5RS0B310005-01
I2RH01310012-01
I5RS0B310006-01
I2RH01310014-01
I4RS0A310006-01

Downloaded from www.Manualslib.com manuals search engine 3A-8 Drive Shaft / Axle:
Reassembly
Tripod joint
Judging from abnormality noted before disassembly and
what is found through visual check of component parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly (1) and tripod
joint housing (2) are washed thoroughly and air dried.
Replace boot(s) (3) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• 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
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After washing, dry parts comp letely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside with specified grease.
6) Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure.
[A]: Wheel side
[B]: Differential side (or center shaft side)
I4RS0A310007-01
I4RS0A310009-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-9
7) Fasten boot bands (1) securely using special tool as
shown in figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 55 in.)
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Special tool
(A): 09943–57010 8) Set new differential side (or center shaft side) small
band and new differential side (or center shaft side)
boot (1) on shaft temporarily, and then apply grease
to tripod joint (2). Use specified grease in tube
included in spare parts.
9) Install tripod joint spider (3) on shaft using special
tool with hammer, directing its chamfered spline
toward wheel side, and then fasten it with new snap
ring (4) using snap ring pliers (5).
Special tool
(A): 09925–98221
10) Apply grease (including in spare parts) to inside of tripod joint housing (1), jo int it with tripod joint.
Grease color
“A”: Dark gray
Amount
“A”: 70 – 90 g (2.5 – 3.2 oz)
(A)
1
(A)
1
“a”
1
I5RS0B310008-01
I5JB0A311009-01
I4RS0B310003-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-11
DOJ
Judging from abnormality noted before disassembly and
what is found through visual check of components parts
after disassembly, prepare replacing parts and proceed
to reassembly.
Make sure that wheel side joint assembly and DOJ
housing are washed thoroughly and air dried.
Replace boot(s) with new one(s).
CAUTION!
• Do not wash boots in degreaser such as gasoline or kerosene. etc. Washing in
degreaser causes deterioration of boot.
• 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
referring to the followings for identification
of the grease.

1) Wash disassembled parts (except boots). After washing, dry parts completely by blowing air.
2) Clean boots with cloth.
3) Apply grease to wheel side joint. Use specified
grease in tube in wheel side boot set as a spare
parts.
Grease color
: Black
Amount
: 55 – 75 g (1.9 – 2.6 oz)
4) Install wheel side boot on shaft.
5) Fill up boot inside wi th specified grease.
6) Fit boot (1) to grooves of shaft and housing (2).
7) Insert screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same
as atmospheric pressure.
8) Place new wheel side boot big band (3) and small band (4) onto boot putting band outer end (1) against
forward rotation (2) as shown in figure. 9) Fasten boot bands (1) using special tool as shown in
figure.
Distance “a”
: 2.6 ± 1.4 mm (0.102 ± 0.055 in.)
CAUTION!
Do not squeeze or distort boot when
fastening it with bands.
Distorted boot caused by squeezing air may
reduce its durability.

Special tool
(A): 09943–57010
21I5RS0B310007-01
I4RS0A310009-01
(A)
1
(A)
1
“a”
1
I5RS0B310008-01

Downloaded from www.Manualslib.com manuals search engine 4-ii Table of Contents
Repair Instructions ..............................................4D-2Parking Brake Inspection and Adjustment ..........4D-2
Parking Brake Cable Removal and Installation ......................................................... 4D-3
Parking Brake Lever Removal and Installation ....4D-3
Specifications .... ...................................................4D-4
Tightening Torque Specifications ........................4D-4
ABS ........................................... .................4E-1
Precautions........................................................... 4E-1
Precautions in Diagnosing Troubles ................... 4E-1
Precautions in On-Vehicle Service...................... 4E-1
Precautions in Hydraulic Unit Operation Check ................................................................ 4E-1
General Description ............................................. 4E-2 ABS Description .................................................. 4E-2
ABS Hydraulic Unit / Control Module Assembly Description ....................................... 4E-2
CAN Communication System Description........... 4E-3
Schematic and Routing Diagram ........................ 4E-4 ABS Schematic ................................................... 4E-4
ABS Wiring Circuit Diagram ................................ 4E-5
Component Location ........... ................................ 4E-7
ABS Components Location ................................. 4E-7
Front Wheel Speed Sensor Components Location ............................................................ 4E-7
Rear Wheel Speed Sensor Components Location ............................................................ 4E-8
Diagnostic Information and Procedures ............ 4E-8 ABS Check .......................................................... 4E-8
ABS Warning Light Check................................. 4E-10
EBD Warning Light (Brake Warning Light) Check .............................................................. 4E-10
DTC Check........................................................ 4E-11
DTC Table ......................................................... 4E-11
DTC Clearance ................................................. 4E-12
Scan Tool Data ................................................. 4E-12
ABS Warning Light Does Not Come ON at Ignition Switch ON .......................................... 4E-13
ABS Warning Light Comes ON Steady ............. 4E-14
EBD Warning Light (Brake Warning Light) Comes ON Steady .......................................... 4E-15
Serial Data Link Circuit Check .......................... 4E-16
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-
Front / Right-Rear / Left-Rear Wheel Speed
Sensor Circuit or Sensor Ring ........................ 4E-18
DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front
/ Left-Front / Right-Rear / Left-Rear Inlet
Solenoid Circuit, Right-Front / Left-Front /
Right-Rear / Left-Rear Outlet Solenoid
Circuit .............................................................. 4E-20
DTC C1057: Power Source Circuit ................... 4E-21
DTC C1061: ABS Pump Motor and/or Motor Driver Circuit ................................................... 4E-22
DTC C1063: Solenoid Valve Power Supply Driver Circuit ................................................... 4E-23
DTC C1071: ABS Control Module..................... 4E-24 DTC U1073: Control Module Communication
Bus Off ............................................................ 4E-25
DTC U1100: Lost Communication with ECM (Reception Error)............................................. 4E-27
Repair Instructions ............ ................................ 4E-28
ABS Hydraulic Unit Operati on Check................ 4E-28
ABS Hydraulic Unit / Control Module
Assembly Components ...... ............................. 4E-29
ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4E-29
ABS Hydraulic Unit / Control Module
Assembly Removal and Inst allation ................ 4E-29
Front / Rear Wheel Speed Sensor On-Vehicle Inspection ........................................................ 4E-31
Front Wheel Speed Sensor Removal and Installation ....................................................... 4E-32
Front Wheel Speed Sensor Inspection ............. 4E-32
Rear Wheel Speed Sensor Removal and Installation ....................................................... 4E-33
Rear Wheel Speed Sensor Inspection .............. 4E-34
Front Wheel Encoder On-Veh icle Inspection .... 4E-34
Front wheel Enco der Removal and
Installation ....................................................... 4E-34
Rear Wheel Encoder On-Veh icle Inspection..... 4E-34
Rear Wheel Encoder Removal and Installation ....................................................... 4E-34
Specifications ..................... ................................ 4E-35
Tightening Torque Specifications ...................... 4E-35
Special Tools and Equipmen t ........................... 4E-35
Special Tool ...................................................... 4E-35
Electronic Stability Prog ram ...................4F-1
Precautions ........................................................... 4F-1
Precautions in Diagnosing Troubles ................... 4F-1
Precautions in On-Vehicle Service...................... 4F-1
Precautions in Hydraulic Unit Operation Check ................................................................ 4F-1
Precautions in Sensor Calibration ....................... 4F-1
Precautions in Speedometer Test or Other Tests ................................................................. 4F-2
General Description ............................................. 4F-2 Electronic Stability Program Description ............. 4F-2
Electronic Stability Program Construction ........... 4F-3
ESP® Hydraulic Unit / Control Module
Assembly Description........................................ 4F-5
Warning Lamp, Indicator Lamp Description ........ 4F-6
CAN Communication System Description........... 4F-6
CAN Communication System For Electronic Stability Program Description ............................ 4F-7
Schematic and Routing Diagram ........................ 4F-8 Electronic Stability Program Schematic .............. 4F-8
Electronic Stability Program Wiring Circuit Diagram............................................................. 4F-9
Component Location ............ ............................. 4F-11
Electronic Stability Program Component
Location........................................................... 4F-11
Diagnostic Information and Procedures .......... 4F-12 Electronic Stability Program System Check ...... 4F-12
ESP® Warning lamp Check .............................. 4F-14

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4-iii
ABS Warning Lamp Check ............................... 4F-14
EBD Warning Lamp (Brake Warning Lamp) Check .............................................................. 4F-15
DTC Check ....................................................... 4F-15
DTC Table ......................................................... 4F-15
DTC Clearance ................................................. 4F-18
Fail-Safe Table ................ .................................. 4F-19
Scan Tool Data ................................................. 4F-20
Visual Inspection ............................................... 4F-21
ESP ® Warning Lamp Does Not Come ON at
Ignition Switch ON .......................................... 4F-21
ESP ® Warning Lamp Comes ON Steady......... 4F-22
ABS Warning Lamp Does Not Come ON at Ignition Switch ON .......................................... 4F-23
ABS Warning Lamp Comes ON Steady............ 4F-24
EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady .......................................... 4F-24
Serial Data Link Circuit Check .......................... 4F-26
DTC C1016: Stop Lamp Swit ch Circuit Failure .. 4F-28
DTC C1017 / C1023: Yaw Rate / G Sensor Assembly Failure ............................................ 4F-29
DTC C1018: Brake Fluid Le vel Switch Failure .. 4F-30
DTC 1020: Master Cylinder Pressure Sensor Power Supply Failure ...................................... 4F-31
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Wheel Speed
Sensor Circuit or Encode r Failure ................... 4F-32
DTC C1024: Steering Angle Sensor Circuit
Failure ............................................................. 4F-34
DTC C1027: ESP ® OFF Switch Circuit
Failure ............................................................. 4F-34
DTC C1028: Master Cylinder Pressure Sensor Circuit Failure ....... .............................. 4F-35
DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure ...................................... 4F-36
DTC C1037: Steering Angle Sensor Power Supply Failure ................................................. 4F-37
DTC C1038: Steering Angle Sensor Detect Rolling Counter Fa ilure from ESP® Control
Module ............................................................ 4F-38
DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure .............. .................................. 4F-39
DTC C1040: Stability Control System Function Failure .............................................. 4F-39
DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 /
C1055 / C1056: Solenoid Circuit Failure ......... 4F-40
DTC C1057: ESP ® Control Module Power
Supply Circuit Failure .... .................................. 4F-41
DTC C1061: Pump Motor and/or Motor Driver Circuit Failure .................................................. 4F-42
DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure ....................................... 4F-43
DTC 1071: ESP ® Control Module Internal
Defect.............................................................. 4F-44 DTC C1073: Lost Communication With Yaw
Rate / G Sensor Assembly .............................. 4F-45
DTC C1075 / 1076 / 1078: Sensor Calibration Incomplete.......................... ............................. 4F-46
DTC C1090: Invalid Communication with
ECM ................................................................ 4F-47
DTC C1091 / C1094: ECM Data in CAN Line Failure / Invalid Torque Control
Communication with ECM .. ............................. 4F-48
DTC U1073: Control Module Communication Bus Off ............................................................ 4F-49
DTC U1100: Lost Communication with ECM (Reception Error)............................................. 4F-50
DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error)........ 4F-51
DTC U1140: Lost Communication with BCM (Reception Error)............................................. 4F-52
Repair Instructions ........... ................................. 4F-54
ESP® Hydraulic Unit Operation Check ............. 4F-54
Sensor Calibration............................................. 4F-54
ESP® Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4F-55
ESP ® Hydraulic
Unit / Control Module
Assembly Removal and Inst allation ................ 4F-56
Front / Rear Wheel Speed Sensor On-Vehicle Inspection ........................................................ 4F-57
Front Wheel Speed Sensor Removal and Installation ....................................................... 4F-58
Front Wheel Speed Sensor Inspection ............. 4F-59
Rear Wheel Speed Sensor Removal and Installation ....................................................... 4F-59
Rear Wheel Speed Sensor Inspection .............. 4F-60
Front Wheel Encode r On-Vehicle Inspection .... 4F-61
Front Wheel Encoder Removal and Installation ....................................................... 4F-61
Rear Wheel Encoder On-Veh icle Inspection..... 4F-61
Rear Wheel Encoder Removal and Installation ....................................................... 4F-61
Master Cylinder Pressure Sensor On-Vehicle
Inspection ........................................................ 4F-61
Yaw Rate / G Sensor Assembly On-Vehicle Inspection ........................................................ 4F-62
Yaw Rate / G Sensor Assembly Removal and Installation ....................................................... 4F-63
Yaw Rate / G Sensor Inspection ....................... 4F-64
Steering Angle Sensor On-Vehicle Inspection .. 4F-64
Steering Angle Sensor Removal and Installation ....................................................... 4F-65
Steering Angle Sensor Inspection ..................... 4F-65
ESP® OFF Switch Removal an d Installation .... 4F-65
ESP® OFF Switch Inspection ........................... 4F-65
Specifications .................... ................................. 4F-66
Tightening Torque Specifications ...................... 4F-66
Special Tools and Equipmen t ........................... 4F-66
Special Tool ...................................................... 4F-66

Downloaded from www.Manualslib.com manuals search engine 4-1 Precautions:
Brakes
Precautions
Precautions
Precautions for BrakesS7RS0B4000001
Suspension Caution
Refer to “Suspension Caution in Section 00”.
Wheels and Tires Caution
Refer to “Wheels and Tires Caution in Section 00”.
Brake Caution
Refer to “Brake Caution in Section 00”.
ESP® System Precautions
Refer to “Precaution for Vehicle Equipped with ESP ® System in Section 00”.
General Precautions
Refer to “General Precautions in Section 00”.
Vehicle Lifting Points
Refer to “Vehicle Liftin g Points in Section 0A”.
Fastener Caution
Refer to “Fastener Caution in Section 00”.
Fastener Information
Refer to “Fasteners Information in Section 0A”.

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-1
Brakes
Brake Control System and Diagnosis
Precautions
Precautions on BrakeS7RS0B4100001
Air Bag Warning
Refer to “Air Bag System Service Warning in Section 00”.
Brakes Diagnosis Note
Refer to “Brakes Diagnosis Note”.
General Description
Brakes ConstructionS7RS0B4101001
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (two
in front and two 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.
In this brake system, the disc brake type is used for the front wheel brake and the rear wheel 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 or pads are used for both parking and foot brakes.
A
5
3
2
1
4
8
8
6
7
I6RS0C410001-01
1. Brake booster 4. Primary side 7. Parking brake lever
2. Master cylinder 5. 4 way joint 8. Parking brake cable
3. Secondary side 6. ABS or ESP® hydraulic unit / control module assembly A: Forward

Downloaded from www.Manualslib.com manuals search engine 4A-4 Brake Control System and Diagnosis:
Rear Brake Hose / Pipe ConstructionS7RS0B4101003
Diagnostic Information and Procedures
Brakes Diagnosis NoteS7RS0B4104001
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 vari ous 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
wheel alignment and front suspension attachments for
looseness. See diagnosis table for other causes. Brake Fluid Leaks
Check the master cylinder fl
uid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low leve l indicates a leak in the
system. In such a case, chec k the entire brake system
for leakage. If even a slight ev idence 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.
[A]: ABS model 6. Master cylinder13. ESP® hydraulic unit
[B]: ESP ® model 7. From hydraulic unit to 4-way joint right : 11 N⋅m (11.0 kgf-m, 8.0 lb-ft)
1. From master cylinder primary to hydraulic unit 8. From hydraulic unit to 4-way joint left: 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
2. From master cylinder secondary to hydraulic unit 9. 4-way joint: 16 N⋅m (1.6 kgf-m, 11.5 lb-ft)
3. From hydraulic unit to right front brake 10.4-way joint to left rear brake hose : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft)
4. From hydraulic unit to left front brake 11. 4-way joint to right rear brake hose
5. ABS hydraulic unit 12. Master cylinder fixing nut
I6RS0C410003-01
A: View A4. Right rear brake hose8. Flexible hose joint bolt
1. To left rear brake hose 5. Left rear brake hose to left brake9. Caliper
2. To right rear brake hose 6. Right rear brake hose to right brake: 16 N⋅m (1.6 kgf-m, 12.0 lb-ft)
3. Left rear brake hose 7. Brake flexible hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)