disc SUZUKI SWIFT 2006 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Front Suspension: 2B-16
4) Hoist vehicle and remove both wheels referring to “Wheel Removal and Installation in Section 2D”.
5) Remove cotter pins and tie-rod end nuts, and then disconnect both tie-rod ends from steering knuckles
referring to “Tie-Rod End Re moval and Installation in
Section 6C”.
6) Disconnect couplers of torque sensor and P/S motor.
7) Remove suspension control arm referring to “Suspension Control Arm / Bushing Removal and
Installation”.
8) Remove stabilizer joints (1). When loosening joint nu t, hold stud with special
tools.
Special tool
(A): 09900–00411 socket
(B): 09900–00413 5 mm
9) Support engine assemble by using supporting device referring to “Engine Supporting Points in
Section 0A”.
10) Disconnect muffler No.1 mounting (1) from suspension frame (2). 11) Remove engine rear mounting bolts (1) from engine
rear mounting (2).
12) Support front suspension frame (2) by using mission jack (1).
13) Remove front suspension frame mounting bolts (1), and then lower mission jack and remove front
suspension frame (2) with st abilizer bar and steering
gear case.
14) Remove steering gear case mounting No.1 bolts (1) and No.2 bolts (2), then remove gear case (3) from
front suspensio n frame (4).
11
(A)
(A)
(B)
(B)
I4RS0A220038-01
1
2
I4RS0A220040-01
3. Suspension frame
2
3 1
I4RS0A220041-01
2
1
I4RS0A220042-01
1
2 1
I4RS0A220043-01
1
3
4 2
I4RS0B220010-02

Downloaded from www.Manualslib.com manuals search engine 2B-19 Front Suspension:
13) Install suspension control arm referring to
“Suspension Control Arm / Bushing Removal and
Installation”.
14) Connect couplers of torque sensor and P/S motor.
15) Connect tie-rod ends to knuckles (right & left) and then install cotter pins referring to “Tie-Rod End
Removal and Installa tion in Section 6C”.
16) Be sure that steering wheel and brake discs (right & left) are all straight-ahead position and then insert
steering lower shaft (5) into steering pinion shaft (3)
with matching marks (4).
17) Tighten steering shaft joint lower bolt (1) and upper bolt (2) to specified torque (Lower side first and then
upper side).
Tightening torque
Steering shaft joint bolt (a): 25 N·m (2.5 kgf-m,
18.5 lb-ft)
18) Install both wheels and tighten wheel bolts to specified torque.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
19) Lower hoist.
20) Check toe setting. Adjust as required refer to “Front Wheel Alignment Inspection and Adjustment”.
Front Suspension Frame CheckS7RS0B2206016
Inspect for cracks, deformation or damage.
If defective, replace.
Front Stabilizer Bar, Bushing and/or Joint
Check
S7RS0B2206017
Stabilizer Bar
Inspect for damage or deformation.
If defective, replace.
Stabilizer Bushing
Inspect for damage, wear or deterioration.
If defective, replace.
Stabilizer Joint
1) Check for smooth rotation.
2) Check damages of ball stud.
3) Check damages of dust cover.
NOTE
Stabilizer joint (1) cannot be disassembled.

If there is any damage to either parts, stabilizer joint
assembly must be replaced as a complete unit.
Front Suspension Fasteners CheckS7RS0B2206018
Check each bolt and nut fastening suspension parts for
tightness. Tighten loose one, if any, to specified torque,
referring to “Front Suspension Construction”.
5
4
1, (a)
3
2, (a)
1, (a)
5
I4RS0B630016-01
I4RS0A220054-01
I4RS0A220052-01
I4RS0A220056-01
1
I4RH01220007-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-1
Suspension
Rear Suspension
General Description
Rear Suspension ConstructionS7RS0B2301001
I6RS0C230001-03
A: View A7. Circlip 14. Spindle cap : 90 N⋅m (9.0 kgf-m, 65.0 lb-ft)
1. Rear coil spring 8. Rear trailing arm bolt 15. Wheel hub : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
2. Rear spring upper seat 9. Rear shock absorber upper
nut 16. Washer
: 175 N⋅m (17.5 kgf-m, 126.5 lb-ft)
3. Rear shock absorber 10. Rear shock absorber lower nut “F”: Vehicle front : 88 N⋅m (8.8 kgf-m, 64.0 lb-ft)
4. Rear axle 11. Rear spindle bolt “I”: Body inside : Do not reuse.
5. Wheel bearing : Seal side of bearing comes
brake back plate side. 12. Wheel nut
: 73 N⋅m (7.3 kgf-m, 53.0 lb-ft)
6. Brake disc 13. Rear spindle nut
: Caulk spindle nut as shown
“a”. :28 N
⋅m (2.8 kgf-m, 20.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 2C-6 Rear Suspension:
Spring Upper Seat and Lower Seat Removal and
Installation
S7RS0B2306007
Removal1) Remove coil spring referring to “Rear Coil Spring Removal and Installation”.
2) Remove spring upper seat (1) and lower seat (2).
Installation 1) Install spring upper seat (1) and lower seat (2).
NOTE
For proper installing direction of spring
upper seat (1) and lower seat (2), refer to the
figure.

2) Install coil spring referr ing to “Rear Coil Spring
Removal and Installation”.
Rear Axle Removal and InstallationS7RS0B2306008
Removal
1) Hoist vehicle and remove rear wheels (right & left).
2) Disconnect rear brake caliper flexible hoses (1) (right & left) from brake pipes (2) and put bleeder plug cap
(3) onto pipe (2) prevent fluid from spilling.
CAUTION!
Do not drop brake fluid onto painted surface.

1
2
I4RS0A230016-01
I3RM0A230021-01
A: Vehicle body side (Upper side)
F: Vehicle front3. Stepped part
I4RS0A230017-01
1
2
2 3
I6RS0B230002-01

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 Rear Suspension: 2C-11
Installation
Install wheel hub by reversing removal procedure noting
the following instructions.
• Insert new wheel stud bolt in wheel hub hole and rotate it slowly to assure serrations are aligned with
those made by replaced bolt.
• Never apply grease to encoder (1).
• Install new rear axle nut (1) and tighten to specified torque.
CAUTION!
Never reuse rear axle nut. Otherwise, nut may
loosen.

Tightening torque
Rear axle nut (a): 175 N·m (17.5 kgf-m, 126.5 lb-ft) • Caulk new rear axle nut (1) as shown.
CAUTION!
Take care while staking nut. If a split occurs
in staked area of nut,
replace it with new one.

Stake specification
“a”: 0.5 mm (0.02 in.) or more
• Install new spindle cap.
Rear Wheel Disc, bolt and Bearing InspectionS7RS0B2306013
• Check tightness of wheel nuts and, if necessary, retighten to specified torque.
• Check wheel disc deformation, damage, crack and etc.
Replace defective disc with new one.
• Check installation face insi de of wheel disc for rust.
As rust affects adversely, remove it thoroughly.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Check wear of wheel bearings. When measuring thrust play, apply a dial gauge to axle shaft center.
When the thrust play exce eds limit, replace bearing.
Rear wheel bearing thrust play
limit
“a”: 0.1 mm (0.004 in.)
I6RS0C230004-01
1
I6RS0B230012-01
1, (a)
I6RS0B230013-01
1
“a”
I6RS0B230014-01
I7RS0A230002-02

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 2D-1 Wheels and Tires:
Suspension
Wheels and Tires
Precautions
Precaution for Emergency Flat Tire Repair KitS7RS0B2400001
WARNING!
Flat tire repair sealant including in kit is
harmful. Be sure to observe the following.
Otherwise, your health may be ruined.
• If swallowed, get medical attention immediately.
• Keep out of reach of children.
• Select place where there is good ventilation for this work.
• If it enters eye or contacts skin, wash thoroughly with water. If anything
abnormal still rema ins, get medical
attention immediately.
• Do not discard tire containing sealant as it is. Make sure to remove sealant from tire,
referring to “Tire Repair for Emergency
Repaired-Tire with Sealant”.
• Dispose of sealant as waste oil.

CAUTION!
• When tire repaired with Emergency Flat Tire Repair Kit is brought in, remove flat
tire repair sealant from tire and repair flat
tire referring to “Tire Repair for Emergency
Repaired-Tire with Sealant”.
• Sealant expiration date is printed on bottle label. if it expires, sealant should be
replaced with a new one to ensure
emergency flat tire repair.

General Description
Tires DescriptionS7RS0B2401001
The tire is of tubeless type. The tire is designed to
operate satisfactorily with loads up to the full rated load
capacity when inflated to the recommended inflation
pressures.
Correct tire pressures and driving habits have an
important influence on tire life. Heavy cornering,
excessively rapid acceleration, and unnecessary sharp
braking increase tire wear.
Tire Placard
The “Tire Placard” is located on the left or right door lock
pillar and should be referred to tire information.
The placard lists the maximum load, tire size and cold
tire pressure where applicable.
NOTE
Whether rim size and/or maximum load are
listed or not depends on regulations of each
country.

Inflation of Tires
The pressure recommended for any model is carefully
calculated to give a satisfacto ry ride, stability, steering,
tread wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for 3
hours or more, or driven less than one mile) should be
checked monthly or before any extended trip. Set to the
specifications on the “Tire Placard” located on the left
door lock pillar.
It is normal for tire pressure to increase when the tires
become hot during driving.
Do not bleed or reduce tire pressure after driving.
Bleeding reduces the “Cold Inflation Pressure”.
Higher than recommended pressure can cause:
• Hard ride
• Tire bruising or carcass damage
• Rapid tread wear at center of tire
Unequal pressure on same axle can cause:
• Uneven braking
• Steering lead
• Reduced handling
• Swerve on acceleration