Piston SUZUKI SWIFT 2006 2.G Service Owner's 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-15
5) Apply small amount of rubber grease (included in spare parts) to mating surface of “a” (piston cup (3)
and piston guide (1)) and “b” piston guide (1) and O-
ring (2)).
6) Apply small amount of s ilicon grease (included in
spare parts) to mating surfaces of “c” (rod seal (4)
and primary piston (5)).
7) Install piston guide (1) and circlip (6).Master Cylinder Assembly InspectionS7RS0B4106014
Inspect all disassembled parts for wear or damage, and
replace parts if necessary.
NOTE
• Wash disassembled parts with brake fluid.
• Do not reuse inner parts and rubber parts.

Inspect master cylinder bore for scoring or corrosion. It is
best to replace corroded cylinder. Corrosion can be
identified as pits or excessive roughness.
NOTE
Polishing bore of master cylinder with cast
aluminium body with anything abrasive is
prohibited, as damage to cylinder bore may
occur.

Rinse cylinder in clean brake fluid. Shake excess rinsing
fluid from cylinder. Do not use a cloth to dry cylinder, as
lint from cloth cannot be kept from cylinder bore
surfaces.
Brake Booster ComponentsS7RS0B4106015
CAUTION!
Never disassemble brake booster. Disassembly will spoi l its original function. If faulty condition is
found, replace it with new one.

I4RS0A410024-01
9
10 17
4
8
5
6
3
(b)
(a)
(b)
2
I6RS0C410010-01
1. Booster assembly 5. Clip 9. Brake master cylinder : Do not reuse.
2. Gasket 6. Booster nut 10. Master cylinder fixing nut
3. Brake vacuum hose 7. Clevis pin lock nut : Tighten 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
by the specified procedure.
4. Clevis pin 8. Push rod clevis : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)

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 4B-6 Front Brakes:
5) To confirm that boot is fitted in its groove in cylinder
properly, pull piston out of cylinder a little but do not
take it all out.
NOTE
Boot’s face (1) should be at the same level
from cylinder’s face (2) all around.

6) Insert piston into cylinder by hand.
Front Disc Brake Caliper InspectionS7RS0B4206007
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage.
If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate
unsmooth return of piston.
In such case, replace rubber seal.
Front Brake Disc Removal and InstallationS7RS0B4206008
CAUTION!
During removal, be care ful not to damage
brake flexible hose and not to depress brake
pedal.

Removal
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper carrier bolts (2 pcs).
NOTE
Hang removed caliper with a wire hook or the
like so as to prevent brake hose from
bending and twisting excessively or being
pulled.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
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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 4C-2 Rear Brakes:
Rear Disc Brake Pad Removal and InstallationS7RS0B4306002
NOTE
When replacing brake pad, replace it on the
right and left.

Removal1) Hoist vehicle and remove wheel.
2) Release parking brake lever.
3) Remove caliper pin bolts (1).
4) Remove caliper (2) from caliper carrier.
NOTE
Hang removed caliper (2) with a wire hook 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.

5) Remove brake pads (1) and pad springs. Installation
1) Turn brake caliper piston clockwise to obtain clearance between brake disc and pads.
Special tool
(A): 09945–16060
2) Clean (and degrease) pad spring installation face (3) of caliper carrier (1).
3) Attach pad springs (2) to caliper carrier (1).
4) Before installing brake p ad shims (1), apply small
amount of grease (included in spare parts) to mating
surfaces of brake pad and pad shim.
5) Set pad shims (1) to brake pads (2).
1 2
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1
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(A)
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113
2
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2
1
1 2
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Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-3
6) With lug (1) of brake pad matched with dent (2) of brake piston, install caliper (3) to caliper carrier.
7) Tighten caliper pin bolts (4) to specified torque.
Tightening torque
Caliper pin bolt (a): 23 N·m (2.3 kgf-m, 17 lb-ft)
8) Tighten wheel bolts temporarily and lower lift.
9) Tighten wheel nuts to specified torque. Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
10) After completion of installation, check for brake effectiveness.Rear Disc Brake Caliper Removal and
Installation
S7RS0B4306003
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Hoist vehicle and remove rear wheel.
2) Release parking brake lever.
3) Remove clip (1).
4) Disconnect flexible hose (1) from caliper.
4, (a) 21
3
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1
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1
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Downloaded from www.Manualslib.com manuals search engine 4C-6 Rear Brakes:
Rear Disc Brake Pad InspectionS7RS0B4306004
Check pad lining for wear. When wear exceeds limit,
replace with new one.
CAUTION!
Never polish pad lining with sandpaper. If
lining is polished with sandpaper, hard
particles of sandpaper will be deposited in
lining and may damage disc. When pad lining
requires correction, replace it with a new one.

Rear brake pad thickness (lining thickness)
Standard: 9.0 mm (0.354 in.)
Limit: 1.0 mm (0.039 in.)
NOTE
When pads are removed, visually inspect
caliper for brake fluid leak. Correct leaky
point, if any.

Rear Disc Brake Caliper Disassembly and
Assembly
S7RS0B4306005
Disassembly
CAUTION!
Clean around caliper with brake fluid before
disassembly.

1) Remove disc brake piston (1) by turning piston counterclockwise with special tool.
CAUTION!
Be careful not to damage inside (bore side) of
cylinder.

Special tool
(A): 09945–16060 2) Remove cylinder boot and piston seal (1).
CAUTION!
Be careful not to damage inside (bore side) of
cylinder.

3) Remove bleeder plug and cap from caliper.
4) Remove return spring (1), parking nut (2), washer
(3), lever (4) and shaft cover (5).
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(A)
1
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1
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1
2
3
4
5
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