air bleed SUZUKI SWIFT 2006 2.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 4A-14 Brake Control System and Diagnosis:
6) Fill reservoir with specified fluid.
7) After completing the work, bleed air from brake and clutch system referring to “Air Bleeding of Brake
System” and “Air Bleeding of Clutch System in
Section 5C” (M/T model).
8) Install cowl top panel referring to “Cowl Top Components in Section 9K”.
9) Install windshield wiper referring to “Windshield
Wiper Removal and Insta llation in Section 9D”.
10) Perform brake test and check each installed part for fluid leakage.
Master Cylinder Assembly Disassembly and
Assembly
S7RS0B4106013
Disassembly
1) Push in primary piston (1) to remove secondary
piston stopper pin (2) from master cylinder as
shown.
2) Remove circlip (1).
3) Remove piston guide and primary piston. Then remove secondary piston by blowing compressed air
(2) into hole. Be cautions during removal as
secondary piston jumps out.
WARNING!
Do not apply too highly compressed air
which will cause piston to jump out of
cylinder. Place a cloth to prevent piston from
damage. It should be taken out gradually with
moderately compressed air. Do not place
your fingers in front of piston when using
compressed air.

Assembly
CAUTION!
• Never use any mineral oil such as kerosene oil and gasoline when washing
and assembling parts.
• Check inside of cylinder wall, pistons and cup seals are free from any foreign objects
such as dust and dirt and use case not to
cause any damage with a tool during
assembly.
• Do not drop parts. Do not use any part which has been dropped.

1) Apply brake fluid to inside of cylinder and contact surface of piston assembly (new piston cups, new O-
ring and piston guide).
2) Install secondary return spring and secondary piston (1) into cylinder body (4).
NOTE
Align oblong hole in secondary piston (2)
with stopper pin hole (3) in master cylinder
body (4) when installing it.

3) Install primary piston assembly into cylinder body.
4) Install piston stopper pin (2) with pistons pushed in all the way and install it.
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Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-17
2) Hold brake pedal depressed for 30 seconds. If pedal height does not change, condition is good. But it isn’t
if pedal rises.
Brake Booster Removal and InstallationS7RS0B4106017
Removal
1) Recover refrigerant from A/C system by using recovery and recycling equipment referring to
“Operation Procedure for Refrigerant Charge in
Section 7B” or “Operation Procedure for Refrigerant
Charge in Section 7B”.
2) Remove master cylinder assembly from booster referring to “Master Cylin der Assembly Removal and
Installation”.
3) Remove cowl top cover and cowl top panel referring to “Cowl Top Components in Section 9K”.
4) Remove suction hose referring to “Major Components of A/C System in Section 7B” or “Major
Components of A/C System in Section 7B”.
5) Disconnect vacuum hose from booster referring to “Brake Booster Components”.
6) Remove push rod clevis pin and booster mounting nuts and then remove booster. Installation
1) Loosen brake pedal bracket mounting bolt.
2) Install booster (2) to dash panel. Then connect push rod clevis (3) to pedal arm with clevis pin (1) and clip
(4).
3) Tighten booster mounting nuts (a) to specified torque.
Tightening torque
Booster mounting nut (a): 13 N·m (1.3 kgf-m, 9.5
lb-ft)
4) Tighten brake pedal bracket mounting bolt to specified torque.
Tightening torque
Brake pedal bracket mounting bolt (b): 13 N·m (
1.3 kgf-m, 9.5 lb-ft)
5) Install suction hose referring to “Major Components of A/C System in Section 7B” or “Major Components
of A/C System in Section 7B”.
6) Install cowl top panel and cowl top cover referring to
“Cowl Top Components in Section 9K”.
7) Install master cylinder assembly to booster referring to “Master Cylinder Assembly Removal and
Installation”.
8) Fill reservoir with specified fluid.
9) Bleed air from brake system.
H: Hold
T: 30 seconds
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1
2 4
3
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(b)
(a)
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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-4 Front Brakes:
Installation1) Torque caliper pin bolts (a) to specification.
NOTE
• Make sure that boots are fit into groove securely.
• If brake pads are replaced, use new caliper pin bolts included in repair kit. (if included)

Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
2) Connect caliper to flexible hose.
3) Torque flexible hose jo int bolt to specification.
Tightening torque
Flexible hose joint bolt (b): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
WARNING!
Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.

4) Tighten bleeder plug to specified torque. Tightening torque
Bleeder plug (c): 8.0 N·m (0.8 kgf-m, 6.0 lb-ft)
5) Lower hoist and torque wheel nuts to specifications. Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
6) After completing installation, fill reservoir with brake
fluid and bleed air from brake system referring to “Air
Bleeding of Brake System in Section 4A”.
7) Check each installed part for fluid leakage.
8) Perform brake test and check fluid leakage.
Front Disc Brake Caliper Disassembly and
Assembly
S7RS0B4206006
Disassembly
CAUTION!
• Clean around caliper with brake fluid before disassembly.
• Be careful not to damage inside (bore side) of cylinder.

1) Remove piston with air blown into flexible hose bolt installation hole.
WARNING!
Do not apply too highly compressed air
which will cause piston to jump out of
cylinder. Place a cloth (1) to prevent piston
from damage. It should be taken out
gradually with moderately compressed air.
Do not place your fingers in front of piston
when using compressed air.

2) Remove cylinder boot.
3) Remove piston seal using a thin blade like a thickness gauge, etc.
4) Remove bleeder plug and cap from caliper.
(a)
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Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-5
Assembly
Assemble parts in reverse order of disassembly,
observing the following instructions.
CAUTION!
• Wash each part cleanly before installation in the same fluid as the one used in master
cylinder reservoir.
• Never use other fluid or thinner.
• Before installing piston seal or cylinder boot to cylinder, apply brake fluid to them.
• Install a new piston seal into groove in cylinder securely making sure that it is not
twisted.
• Before installing caliper to carrier, check for slid pin smooth movement in thrust
direction.
• After reassembling brake lines, bleed air from them.

• Install piston seal, boot and piston to caliper referring to the following instructions.
1) Replace with a new piston seal (1) at every overhaul. After applying rubber grease (included in repair kit)
or brake fluid, fit piston seal (1) into groove in
cylinder taking care not to twist it. 2) Before inserting piston (1) into cylinder, apply rubber
grease (included in repair kit) or brake fluid to new
boot “a” and install it onto piston as shown.
3) Fit boot as it is in figure into boot groove in cylinder with fingers.
4) Insert piston into cylinder by hand and fit boot in boot groove in piston.
NOTE
Check that boot is fitted in boot groove
securely all around piston and cylinder.

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1
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“A”: 1 grooved side directed cylinder side
“B”: 2 grooved side directed pad side
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Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-1
Brakes
Rear Brakes
Repair Instructions
Rear Disc Brake ComponentsS7RS0B4306001
(d)
(c)
(a)
(a)
(a)16171413
2
1
15 2 19
12
117
7
3
7
4
20 20
5
10
9
8
(b)
18
6
24
23
22
21
I7RS0B430001-01
1. Caliper
11. Brake caliper carrier21. Shaft cover
: Apply rubber grease.
2. Caliper pin bolt 12. Caliper carrier bolt22. Lever
3. Boot 13. Rear caliper bleeder plug23. Washer
4. No.1 slide pin : Apply rubber grease. 14. Bleeder plug cap
24. Parking nut
5. Brake pad 15. Brake flexible hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
6. Return spring 16. Flexible hose joint bolt: 27 N⋅m (2.7 kgf-m, 19.5 lb-ft)
7. Pad spring 17. Hose washer: 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
8. Disk brake piston : Apply brake fluid to contact surface of cylinder. 18. Brake disc
: 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
9. Piston seal : Apply small amount of brake fluid to all around part of piston seal. 19. No.2 slide pin
: Apply rubber grease. : Do not reuse.
10. Cylinder boot : Apply small amount of brake fluid. 20. Pad shim

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-5
4) Pass parking brake cable (1) through bracket (3) of caliper.
5) Hang parking brake cable on lever (2) as follows.
NOTE
Make sure that lever (4) contacts pin (5).

6) Install brake pads and caliper referring to “Rear Disc Brake Pad Removal and Installation”.
7) Connect flexible hose (1) with new washers to caliper (2).
WARNING!
Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.

Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft) 8) Install brake cable clip (1) securely to bracket (2).
9) After reassembling brake lines, bleed air from them
referring to “Air Bleeding of Brake System in Section
4A”.
10) Check to make sure that system is free from fluid
leakage.
11) Start engine and then depress brake pedal with about 300 N (30 kg, 66 lbs) load 3 times or more so
as to obtain proper disc to pad clearance.
12) Check to make sure that parking brake lever stroke is as specified. Refer to “Parking Brake Inspection
and Adjustment in Section 4D”.
13) Tighten wheel nuts to specified torque.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Remove vehicle from hoist and perform brake test (foot brake and parking brake).
1
23
45
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2
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Downloaded from www.Manualslib.com manuals search engine 4E-31 ABS:
2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage and perform “ABS Hydraulic Un it Operation Check”.
NOTE
For new ABS hydraulic unit / control module
assembly, if “ABS Hydraulic Unit Operation
Check” has not been performed, ABS
warning light may flash when ignition switch
is turned ON position.
Accordingly preform “ABS Hydraulic Unit
Operation Check” to stop flashing of ABS
warning light.

Front / Rear Wheel Speed Sensor On-Vehicle
Inspection
S7RS0B4506005
Output Voltage Inspection
1) Disconnect negative cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Disconnect wheel speed grommet from vehicle body.
5) Set up measuring devices as shown in figure, the resistance to 115 Ω and the power supply voltage to
12 V.
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

6) Measure voltage at resistance without wheel rotation.
If voltage is out of specification, check sensor,
mating encoder and their installation conditions.
Voltage at the resistance (115
Ω) without wheel
rotation
680 to 960 mV
7) Measure voltage at resistance with wheel rotation and confirm voltage alternately changes between
high and low voltages.
If voltage does not change with wheel rotation, check
sensor, mating encoder and their installation
conditions.
Voltage at the resistance (115
Ω) with wheel
rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
Reference
When using oscilloscope for this check, check if peak-to-
peak voltage and waveform meet specification.
Peak-to-peak Voltage at the resistance (115
Ω) with
wheel rotation
High voltage “a”: 1360 to 1930 mV
Low voltage “b”: 680 to 960 mV
[A]: Front wheel speed sensor 3. “WHT” wire terminal
[B]: Rear wheel speed sensor 4. “BLK” wire terminal
1. Wheel speed sensor connector 5. Power supply (12 V)
2. Resistance (115 Ω )
V
2
5
41
3
43
1
[A]
[B]
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[A]: Voltage [B]: Time
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Downloaded from www.Manualslib.com manuals search engine Electronic Stability Program: 4F-57
3) Remove front brake pipe referring to “Front Brake Hose / Pipe Removal and In stallation in Section 4A”.
4) Remove ESP ® hydraulic unit / control module with
bracket from vehicle by removing bracket bolts.
5) Remove bolt (4) and pull out ESP ® hydraulic unit /
control module assembly (1) from bracket (3) using
flat end rod or the like (2).
Installation 1) Install hydraulic unit / co ntrol module assembly and
by reversing removal procedure.
Tightening torque
Brake pipe flare nut: 16 N·m (1.6 kgf-m, 11.5 lb-
ft)
ESP ® hydraulic unit / control module assembly
bolt: 9 N·m (0.9 kgf-m, 6.5 lb-ft)
ESP ® hydraulic unit / control module assembly
bracket bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2) Bleed air from brake system referring to “Air Bleeding of Brake System in Section 4A”.
3) Check each installed part for fluid leakage.
4) Connect SUZUKI Scan Tool.
5) Turn ignition switch to ON position. And SLIP indicator lamp flush. (Other than replace with new
one) If other than SLIP indicator lamp light, check
DTC and repair it.
6) Turn ignition switch to ON position. And ESP®
warning lamp, SLIP indicator lamp, ESP ® OFF
lamp, Brake warning lamp lights and ABS warning
lamp flush. (Replace new one)
7) Check DTC.
NOTE
If any DTC(s) other than C1075, C1076 or
C1078 are detected, sensor calibration can
not be completed. Repair the detected it(s)
first.

8) Perform “Sensor Calibration”.
9) Perform “ESP ® Hydraulic Unit Operation Check”.
10) Turn ignition switch to OFF position once and then
ON position. In this state, make sure that indicator
light and warning light turns off.
11) Check DTC(s) are not stored in hydraulic unit / control module.
Front / Rear Wheel Speed Sensor On-Vehicle
Inspection
S7RS0B4606028
CAUTION!
Incorrect voltage and/or wrong connection
cause damage to wheel speed sensor.

Output Voltage Inspection
1) Disconnect negative (–) cable from battery.
2) Hoist vehicle a little.
3) Disconnect wheel speed sensor connector.
4) Disconnect wheel speed grommet from vehicle body.
5) Set up measuring devices as shown in figure, the resistance to 115 Ω and the power supply voltage
to12 V.
4
1
2 3
I6RS0B460030-02
[A]: Front wheel speed sensor 3. “WHT” wire terminal
[B]: Rear wheel speed sensor 4. “BLK” wire terminal
1. Wheel speed sensor connector 5. Power supply (12 V)
2. Resistance (115 Ω)
V
2
5
4 1
3
43
1
[A]
[B]
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Downloaded from www.Manualslib.com manuals search engine 4F-62 Electronic Stability Program:
4) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
5) When brake pedal is released, check “Master Cyl Press” under “DATA LIST” of SUZUKI scan tool.
If pressure is out of specification, replace ESP ®
hydraulic unit / cont rol module assembly.
Master cylinder pressure specification
Brake pedal released: 0 ± 0.8 MPa (0 ± 8 kg/cm2, 0
± 113 psi)
6) Hoist vehicle and remove right-side front wheel.
7) Connect special tool with rubber hose (1) to Front brake caliper bleeder plug (2).
Special tool
(A): 09956–02311
8) When bleeder plug loosen and depress brake pedal to make special tool gauge reading 10 MPa (100 kg/
cm
2, 1422 psi), check “Master Cyl Press” under
“DATA LIST” of SUZUKI scan tool.
If pressure displayed on SUZUKI scan tool is out of
specification, replace ESP ® hydraulic unit / control
module assembly.
Master cylinder pressure specification
Brake pedal depressed 10 MPa (100 kg/cm2, 1422
psi): 10 ± 1.2 MPa (100 ± 12 kg/cm2, 1422 ± 170
psi)
9) After completing the check, turn ignition switch to
OFF position and disconnect SUZUKI scan tool from
DLC.
10) Tighten bleeder plug and bleed air from brake system, referring to “Air Bleeding of Brake System in
Section 4A”.
Yaw Rate / G Sensor Assembly On-Vehicle
Inspection
S7RS0B4606017
Lateral G Inspection
1) Calibrate yaw rate / G sens or assembly referring to
“Sensor Calibration”.
2) Park and level the vehicle with parking brake and fix wheels with chokes.
3) Check yaw rate / G sensor assembly installation
condition. 4) Connect SUZUKI scan tool to data link connector
(DLC) (1) with ignition switch OFF.
Special tool
(A): SUZUKI scan tool
5) Turn ignition switch to ON position and select menu “DATA LIST” mode of SUZUKI scan tool. Refer to
scan tool operator's manual for further derails.
6) Check “G Sensor (lateral)” under “DATA LIST” of SUZUKI scan tool in the following vehicle conditions.
• Level condition
• Right-up condition
• Left-up condition
If Lateral G condition is ou t of specification, replace
yaw rate / G sensor assembly.
Lateral G sp ecification
2
(A)
1
I6JB01460025-01
Vehicle condition G Sensor (lateral)
Level condition 0 ± 0.1 G
Right-up condition 0.1 ± 0.1 G
Left-up condition –0.1 ± 0.1 G
[A]: Right-up condition “a”: Approx 350 mm (13.78 in.)
[B]: Left-up condition 1. Safety stand
(A)
1
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[A]
[B]“a”
1
“a”1
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