caliper pin SUZUKI SWIFT 2005 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-7
Fuel Filter ReplacementS7RS0B0206011
Fuel filter is installed in fuel pump assembly in fuel tank.
Replace fuel filter or fuel pump assembly with new one,
referring to “Fuel Pump Assembly Removal and
Installation in Section 1G” for proper procedure.
Fuel Tank InspectionS7RS0B0206012
Check fuel tank damage, cracks, fuel leakage, corrosion
and tank bolts looseness.
If a problem is found, repair or replace.
PCV Valve InspectionS7RS0B0206013
Check crankcase ventilation hose and PCV hose for
leaks, cracks or clog, and PCV valve for stick or clog.
Refer to “PCV Valve Inspection in Section 1B” for PCV
valve checking procedure.
Fuel Evaporative Emission Control System
Inspection
S7RS0B0206014
1) Visually inspect hoses for cracks, damage, or excessive bends. Inspect a ll clamps for damage and
proper position.
2) Check EVAP canister for operation and clog, referring to “EVAP Canister Inspection in Section
1B”.
If a malfunction is found, repair or replace.
Brake Discs and Pads InspectionS7RS0B0206015
1) Remove wheel and caliper but don’t disconnect brake hose from caliper. 2) Check disc brake pads and discs for excessive wear,
damage and deflection. Replace parts as necessary.
For details, refer to “Front Disc Brake Pad Inspection
in Section 4B”, “Front Brake Disc Inspection in
Section 4B”, “Rear Disc Brake Pad Inspection in
Section 4C” and/or “Rear Brake Disc Inspection in
Section 4C”.
Be sure to torque caliper pin bolts to specification.
Brake Hoses and Pipes InspectionS7RS0B0206016
Perform this inspection where these is enough light and
use a mirror as necessary.
• Check brake hoses and pipes for proper hookup, leaks, cracks, chafing and other damage.
• Check that hoses and pipes are clear of sharp edges and moving parts.
Repair or replace any of these parts as necessary.
CAUTION!
After replacing any brake pipe or hose, be
sure to carry out air purge operation.

I4RS0B020002-02
I4RS0A020006-01
I3RM0A020006-01
I4RS0A020008-01

Downloaded from www.Manualslib.com manuals search engine 2B-11 Front Suspension:
7) Install ball joint bolt (1) and nut (2) from the direction
as shown in figure.
8) Tighten new suspension co ntrol arm ball joint nut (2)
to specified torque.
Tightening torque
Suspension control arm ball joint nut (a): 60
N·m (6.0 kgf-m, 43.5 lb-ft)
CAUTION!
Never reuse the removed suspension control
arm ball joint nut.

9) Tighten strut bracket new nuts (3) to specified torque.
Tightening torque
Strut bracket nut (b): 90 N·m (9.0 kgf-m, 65.5 lb-
ft)
CAUTION!
Never reuse strut bracket nuts.
Nuts are pre-coated with friction stabilizer.
Be use to replace pre-coated nut with a new
one, or may loosen.

10) Install wheel speed sensor (1).
Tightening torque
Wheel speed sensor mounting bolt (a): 11 N·m (
1.1 kgf-m, 8.0 lb-ft) 11) Connect tie-rod end to steering knuckle and then
install cotter pin referrin g to “Tie-Rod End Removal
and Installation in Section 6C”.
12) Install brake disc (2) and brake caliper (3).
13) Tighten caliper carrier bolt to specified torque.
Tightening torque
Caliper carrier bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Depress foot brake pedal and hold it there. Tighten new drive shaft nut (1) to specified torque.
Tightening torque
Drive shaft nut (b): 200 N·m (20.0 kgf-m, 145.0
lb-ft)
CAUTION!
Never reuse drive shaft nut (1).

15) Caulk drive shaft nut (1) as shown.
CAUTION!
Be careful not to damage the drive shaft nut
while caulking it. If it is damaged, replace it
with new one.

16) Tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
17) After installing, confirm front wheel alignment.F: Vehicle front
I4RS0B220015-01
1 (a)
I4RS0B220006-01
I6RS0C220005-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-7
3) Remove rear brake caliper assemblies (right & left)
and brake discs (right & left ). For details, refer to
Step 2) to 3) of “Removal” under “Rear Brake Disc
Removal and Installa tion in Section 4C”.
4) Remove rear wheel hubs (r ight & left). For details,
refer to Step 3) to 5) of “Removal” under “Rear
Wheel Hub Removal and Installation”.
5) Disconnect brake pipes (1) from brake hoses (2) and remove E-rings (3).
CAUTION!
Do not drop brake fluid onto painted surface.

6) Disconnect wheel speed sensors (1) and lead wire clamps (right & left).
7) Remove brake disc dust cover (2) and spindles (3) (right & left) from rear axle.
8) Remove coil springs (1) (right & left) referring to “Rear Coil Spring Removal and Installation”. 9) Disconnect wheel speed sensor clamp and parking
brake cable clamp from rear axle.
10) While supporting rear axle (1) at both ends (right & left), remove rear trailing arm bolts and then remove
rear axle from chassis by lowering floor jack
gradually.
11) Remove brake pipes (2) from rear axle (1) if necessary.
Installation 1) Install brake pipes to rear axle.
2) Place rear axle on floor jacks. Then install trailing arm, washers and new trailing
arm bolts (1) (right & left) and tighten bolts
temporarily by hand.
1
1
2
2
3
3I4RS0A230018-01
1
2
3
I6RS0B230003-01
1
I4RS0A230020-01
1. Parking brake cable clamp bolt
1I4RS0A230021-01
2
1
I6RS0B230004-01
1
I4RS0A230023-01

Downloaded from www.Manualslib.com manuals search engine 2C-8 Rear Suspension:
3) Install coil springs (right & left) on spring seats of rear
axle referring to “Spring Upper Seat and Lower Seat
Removal and Installation” and “Rear Coil Spring
Removal and Installation”.
4) Install shock absorbers lower side (right & left) and washers referring to “Rear Shock Absorber Removal
and Installation”.
5) Install brake dust covers, spindles and wheel speed sensors (right and left) referring to “Spindle Removal
and Installation”.
6) Connect wheel speed sensors (1) and lead wire clamps (2) (right & left).
Tightening torque
Wheel speed sensor bolt (a): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
7) Connect brake flexible hoses (1) to bracket on rear axle with E-rings (3) (right & left) and tighten brake
pipe flare nuts (a) to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft) 8) Install wheel speed sensor clamp and parking brake
clamp and tighten parking brake clamp bolts (1) to
specified torque.
Tightening torque
Parking brake cable clamp bolt (a): 11 N·m (1.1
kgf-m, 8.0 lb-ft)
9) Install rear wheel hubs (right & left) referring to “Rear Wheel Hub Removal and Installation”.
10) Install brake discs (right & left) and rear brake caliper assemblies (right & left) referring to “Rear Brake Disc
Removal and Installati on in Section 4C”.
11) Connect rear brake caliper flexible hoses (1) to brake pipes (2) with E-rings (3) (right & left).
Tighten brake pipe flare nuts to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 11.5
lb-ft)
1 2
(a)
3
I6RS0B230005-01
I4RS0A230028-01
1, (a)I6RS0B230006-01
3
2 1
(a)
I6RS0B230007-01

Downloaded from www.Manualslib.com manuals search engine 2C-10 Rear Suspension:
Rear Wheel Hub ComponentsS7RS0B2306011
Rear Wheel Hub Removal and InstallationS7RS0B2306012
Removal1) Hoist vehicle and remove wheel.
2) Remove rear brake caliper assembly and rear brake disc referring to “Rear Brake Disc Removal and
Installation in Section 4C”.
3) Remove spindle cap (1) by hammering lightly at 3 locations around it so as not to deform or cause
damage to seating part of cap.
4) Uncaulk and remove rear axle nut (2). 5) Using special tools, draw out wheel hub (1).
Special tool
(A): 09943–17912
(B): 09942–15511
6) Remove wheel stud bolt (1) from wheel hub (2) by using hydraulic press (3).
(b)5
4
3
(a)2
1
6
I6RS0C230002-03
1. Spindle cap 4. Spindle: 175 N⋅m (17.5 kgf-m, 126.5 lb-ft)
2. Rear axle nut :Calk, after Tightening 5. Disc dust cover
: 88 N⋅m (8.8 kgf-m, 64.0 lb-ft)
3. Rear wheel hub :Never disassemble wheel hub assembly 6. Hub bolt
: Do not reuse.
2
1
I6RS0B230010-01
1
(A) (B)
I6RS0B230011-01
1
3
2
I6RS0C230003-01

Downloaded from www.Manualslib.com manuals search engine 2C-12 Rear Suspension:
• Check noise and smooth rotation of wheel by rotating wheel. If it is defect ive, replace bearing.
Spindle Removal and InstallationS7RS0B2306014
Removal
1) Remove rear brake caliper assembly and brake disc. For details, refer to Step 2) to 4) of “Removal” under
“Rear Brake Disc Removal and Installation in
Section 4C”.
2) Remove rear wheel hub. For details, refer to Step 3) to 5) of “Removal” under “Rear Wheel Hub Removal
and Installation”.
3) Disconnect wheel speed sensor (1).
4) Remove brake disc dust cover (2) and spindle (3) from rear axle. Installation
1) Install brake disc dust cover (1), spindle (2) and new spindle bolts (3) and then tighten spindle bolts to
specified torque.
CAUTION!
Never reuse the removed rear spindle bolts.
Bolts are pre-coated wi th friction stabilizer.
Be sure to replace pre-coated bolt with a new
one, or bolt may loosen.

Tightening torque
Rear spindle bolt (a): 88 N·m (8.8 kgf-m, 64.0 lb-
ft)
2) Connect wheel speed sensor (4) and tighten wheel speed sensor bolt to specified torque.
Tightening torque
Wheel speed sensor bolt (b): 11 N·m (1.1 kgf-m,
8.0 lb-ft)
3) Install rear wheel hub re ferring to “Rear Wheel Hub
Removal and Installation”.
4) Install brake disc and rear brake caliper assembly referring to “Rear Brake Disc Removal and
Installation in Section 4C”.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
6) Adjust parking brake cable. For adjustment, see “Parking Brake Inspection and Adjustment in Section
4D”.
7) Perform brake test (foot brake and parking brake).
8) Check each installed part for fluid leakage.
I3RM0A230050-01
2
1 3
I6RS0B230015-01
1
(b)
4
2
3, (a)
I6RS0B230016-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-5
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 co nditions. 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 Symptom DiagnosisS7RS0B4104002
Condition Possible cause Correction / Reference Item
Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair.
Brake disc or brake pad stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Badly worn brake pad Replace.
Malfunctioning caliper assembly Repair or replace.
Malfunctioning brake booster Check system and replace assembly.
Malfunctioning brake master cylinder Check system and replace as necessary.
Air in system Bleed system.
Malfunctioning ABS (ESP ®). Check system and replace as necessary.
Brake pull (Brakes not
working in unison) Brake pad and disc are wet with water or
stained with oil in some brakes Clean or replace.
Disc is out of round in some brakes Replace.
Tires are inflated unequally Inflate equally.
Disturbed front wheel 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 tubing.
Malfunctioning caliper assembly Caliper should slide.
Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifications.
Noise (High pitched
squeak without brake
applied) Contact wear indicator to brake disc
Replace brake pads.
Worn brake pad Replace brake pads.
Excessive pedal travel
(Pedal stroke too large) Partial brake system failure
Check brake systems and repair as necessary.
Brake fluid leaking Repair the leaking point and bleed air.
Air in system (soft / spongy pedal) Bleed system.
Brake locked Malfunctioning ABS (ESP®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
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 brake
piping.
Incorrect parking brake adjustment on
rear brakes Check and adjust to correct specifications.
Weakened or broken return springs in
rear brakes. Replace.
Sluggish parking brake cables or linkage Repair or replace.
Brake caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Improper brake pedal free height Check brake pedal free height.

Downloaded from www.Manualslib.com manuals search engine 4A-6 Brake Control System and Diagnosis:
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged or loose wheel bearings
Replace wheel bearings.
Distorted steering knuckle or rear wheel
spindle Replace knuckle or rear wheel spindle.
Excessive disc lateral runout Check per instructions. If not within
specifications, replace or machine disc.
Parallelism between brake pad and disc
not within specifications Check per instructions. If not within
specifications, replace or machine disc.
Brake caliper piston sticking Repair as necessary.
Braking noise Worn or distorted brake pad Replace pads.
Loose front wheel bearings Replace wheel bearings.
Distorted backing plates or loose
mounting bolts Replace or retighten securing bolts.
Contact wear indicator to brake disc Replace brake pad.
Brake warning light lights
after engine start Parking brake applied
Release parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluid Investigate leaky point, correct it and add
brake fluid.
Brake fluid leaking Investigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faulty Repair circuit.
Malfunctioning EBD system Check system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is applied Brake fluid leaking
Investigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluid Investigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is applied Brake warning light circuit faulty
Replace bulb or repair circuit.
ABS warning light or
ESP
® warning light turns
on after engine start Malfunctioning ABS (ESP
®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
ABS warning light or
ESP
® warning light turns
on when brake is applied Malfunctioning ABS (ESP
®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
ABS warning light or
ESP
® warning light does
not turn on for 2 sec. after
ignition switch has turned
ON Bulb burnt out
Replace bulb.
Malfunctioning ABS (ESP ®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
ABS warning light flashes New ABS hydraulic unit / control module
assembly installed. Perform “ABS Hydraulic
Unit Operation Check
in Section 4E”.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-1
Brakes
Front Brakes
Repair Instructions
Front Disc Brake ComponentsS7RS0B4206001
11
5
6
10
4
1
16
17
12
8
7
3
2(a)
15
(b)
14(c)2(a)
13
(d)
9
FLD
I6RS0C420005-02
1. Caliper 9. Disk brake piston
: Apply brake fluid to contact surface of cylinder. 17. Brake flexible hose
2. Caliper pin bolt 10. Pad spring : 26 N⋅m (2.6 kgf-m, 19.0 lb-ft)
3. Boot 11. Brake disc: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Slide pin : Apply rubber grease (included in slide pin boot set). 12. Brake caliper carrier
: 8 N⋅m (0.8 kgf-m, 6.0 lb-ft)
5. Brake pad 13. Caliper carrier bolt : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
6. Shim : Apply small amount of pad grease (include in pad
repair kit). 14. Bleeder plug
: Do not reuse.
7. Cylinder boot : Apply small amount of rubber grease included in
piston seal set. 15. Flexible hose joint bolt
8. Piston seal : Apply small amount of rubber grease included in
piston seal set. 16. Hose washer

Downloaded from www.Manualslib.com manuals search engine 4B-2 Front Brakes:
Front Disc Brake Pad On-Vehicle InspectionS7RS0B4206002
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 thic kness (“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.)
Front Disc Brake Pad Removal and InstallationS7RS0B4206003
NOTE
When replacing brake pad, replace it on the
right and left.

Removal
1) Loosen wheel nuts, lifted vehicle and remove wheels referring to “Wheel Remova l and Installation in
Section 2D”.
2) Remove caliper pin bolts (1). 3) Remove caliper (1) from caliper carrier (2).
NOTE
Hang removed caliper (1) with a wire hook (4)
or the like so as to prevent brake hose from
bending and twisting excessively or being
pulled.
Don’t operate brake pedal with brake pads
removed.

4) Remove brake pads (3).
5) Remove brake pad spring (1) as shown in figure.
Installation
WARNING!
Do not apply grease on pad lining surface.

1) Apply small amount of pad grease “a” (included in spare parts) to pad spring and set brake pad spring
as shown in figure.
I2RH01420001-01
1
I2RH01420003-01
I2RH01420004-01
1
I7RW01420014-01
"a"
I7RW01420011-01