Brake SUZUKI SWIFT 2006 2.G Service Repair Manual

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 Rear Suspension: 2C-13
Spindle InspectionS7RS0B2306015
• Inspect for cracks, deformation or damage.Replace any defective part.
Rear Suspension Fasteners InspectionS7RS0B2306016
Check each bolt and nut fastening suspension parts for
tightness. Tighten loose one, if any, to specified torque
referring to the figure in “Rear Suspension Construction”.
Specifications
Tightening Torque SpecificationsS7RS0B2307001
NOTE
The specified tightening torque is also described in the following.
“Rear Suspension Construction”
“Rear Wheel Hub Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Special ToolS7RS0B2308001
I6RS0B230017-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Wheel nut 85 8.5 61.5 ) / ) / ) / ) / )
Rear shock absorber upper nut 28 2.8 20.0 )
Rear shock absorber lower nut 90 9.0 65.0 ) / ) / )
Wheel speed sensor bolt 11 1.1 8.0 ) / )
Brake pipe flare nut 16 1.6 11.5 ) / )
Parking brake cable clamp bolt 11 1.1 8.0 )
Trailing arm bolt 73 7.3 53.0 )
Rear axle nut 175 17.5 126.5 )
Rear spindle bolt 88 8.8 64.0 )
09942–1551109943–17912
Sliding hammer Wheel hub remover
))

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-2
Lower than recommended pressure can cause:
• Tire squeal on turns
• Hard Steering
• Rapid and uneven wear on the edges of the tread
• Tire rim bruises and rupture
• Tire cord breakage
• High tire temperature
• Reduced handling
• High fuel consumption
Replacement Tires
When replacement is necessary, the original equipment
type tire should be used. Refer to the Tire Placard.
Replacement tires should be of the same size, load
range and construction as those originally on the vehicle.
Use of any other size or type tire may affect ride,
handling, speedometer / odometer calibration, vehicle
ground clearance and tire or snow chain clearance to the
body and chassis.
It is recommended that new tires be installed in pairs on
the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to
equalize braking traction.
WARNING!
Do not mix different types of tires on the
same vehicle such as radial, bias and bias-
belted tires except in emergencies, because
handling may be seriously affected and may
result in loss of control.

The metric term for tire infl ation pressure is the kilo
pascal (kPa). Tire pressures is usually printed in both
kPa and kgf/cm
2 on the “Tire Placard”.
Metric tire gauges are available from tool suppliers.
The chart, shown the table, converts commonly used
inflation pressures from kPa to kgf/cm
2 and psi.
Wheels DescriptionS7RS0B2401002
Wheel Maintenance
Wheel repairs that use welding, heating, or peening are
not approved. All damaged wheels should be replaced.
Replacement Wheels
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, air leak through welds,
have elongated bolt holes, if lug wheel bolts won’t stay
tight, or if they are heavily rusted. Wheels with greater
runout than shown in the following may cause
objectional vibrations.
Replacement wheels must be equivalent to the original
equipment wheels in load capacity, diameter, rim with
offset and mounting configuration. A wheel of improper
size or type may affect wheel and bearing life, brake
cooling, speedometer / odometer calibration, vehicle
ground clearance and tire clearance to body and
chassis.
How to Measure Wheel Runout
To measure the wheel runout, it is necessary to use an
accurate dial indicator. The tire may be on or off the
wheel. The wheel should be installed to the wheel
balancer of the like for proper measurement.
Take measurements of both lateral runout “a” and radial
runout “b” at both inside an d outside of the rim flange.
With the dial indicator set in place securely, turn the
wheel one full revolution slowly and record every reading
of the indicator.
When the measured runout exceeds the specification
and correction by the balancer adjustment is impossible,
replace the wheel. If the reading is affected by welding,
paint or scratch, it should be ignored.
Lateral runout limit “a”
: 0.3 mm (0.012 in.)
Radial runout limit “b”
: 0.3 mm (0.012 in.)
kPa kgf/cm2psi
Conversion: 1 psi =
6.895 kPa 1 kgf/cm
2 =
98.066 kPa 160 1.6 23
180 1.8 26
200 2.0 29
220 2.2 32
240 2.4 35
260 2.6 38
280 2.8 41
300 3.0 44
I4RS0A240001-01

Downloaded from www.Manualslib.com manuals search engine 2D-5 Wheels and Tires:
Radial Tire Lead / Pull DescriptionS7RS0B2401006
“Lead / Pull” is the deviation of the vehicle from a straight
path on a level road even with no pressure on the
steering wheel.
Lead is usually caused by the following conditions.
• Improper tire and wheel alignment.
• Uneven brake assemblies.
• Tire construction.
The way in which a tire is built can produce lead in a
vehicle. An example of this is placement of the belt. Off
center belts on radial tires can cause the tire to develop
a side force while rolling straight down the road. If one
side of the tire has a little larger diameter than the other,
the tire will tend to roll to one side. This will develop a
side force which can produce vehicle lead.
The procedure in the figure (Lead Diagnosis) should be
used to make sure that wheel alignment is not mistaken
for tire lead.
• Part of the lead diagnosis procedure is different from the proper tire rotation pattern currently in the owner
and service manuals. If a medium to high mileage tire
is moved to the other side of the vehicle, be sure to
check that ride roughness has not developed.
• Rear tires will not cause lead.
Balancing Wheels DescriptionS7RS0B2401007
There are two types of wheel an d tire balance: static and
dynamic. Static balance, as shown in figure, is the equal
distribution of weight around the wheel. Wheels that are
statically unbalanced cause a bouncing action called
tramp. This condition will eventually cause uneven tire
wear.
Dynamic balance, as shown in figure, is the equal
distribution of weight on each side of the wheel
centerline so that when the tire spins there is no
tendency for the assembly to move from side to side.
Wheels that are dynamically unbalanced may cause
shimmy.
1. Heavy spot wheel tramp [A]: Before correction
2. Balance weights addition point [B]: Corrective weights
3. C/L of spindle
1. Heavy spot wheel shimmy [C]: Before correction
2. Balance weights addition point [D]: Corrective weights
3. C/L of spindle
I2RH01240008-01
I2RH01240009-01

Downloaded from www.Manualslib.com manuals search engine 2D-7 Wheels and Tires:
Wheel Removal and InstallationS7RS0B2406003
Removal
WARNING!
Do not removal all of the wheel nuts at once,
because all the wheels of this vehicle are
mounted by the wheel nuts.
Leave a nut at least not to drop the wheel.
Support the wheel and/or tire and then
remove the nut(s) left with the wheel.

1) Loosen wheel nuts by approximately 180° (half a
rotation).
2) Hoist vehicle.
3) Make sure that the vehicle will not fall off by trying to
move vehicle body in both ways.
4) Remove wheel nut except one.
5) Support the wheel and/or tire not to drop the wheel and then remove the nut left with the wheel.
CAUTION!
Never use heat to loosen tight wheel because
the application of heat to wheel causes the
wheel life shorter and the wheel bearing
damage.

Installation
CAUTION!
When installing wheel (with tire) which has
arrow (1) indicating tire rotation direction on
its side, make sure that arrow direction is
same as actual tire ro tation direction when
vehicle is moving forw ard (2). Otherwise,
water drainage performance and straight line
vehicle stability will be affected.

For installation, reverse removal procedure, noting the
following.
• Wheel nuts must be tightened in sequence and to specified torque to avoid bending wheel or brake disc.
NOTE
Before installing wheels, remove any build-
up of corrosion on wheel mounting surface
and brake disc mounting surface by scraping
and wire brushing. Installing wheels without
good metal-to-metal contact at mounting
surfaces can cause wheel nuts to loosen,
which can later allow a wheel to come off
while vehicle is moving.

Tightening order
“A” – “B” – “C” – “D” – “E”
Tightening torque
Wheel nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
I6RS0B240005-01
I6RS0C240001-01

Downloaded from www.Manualslib.com manuals search engine 3A-4 Drive Shaft / Axle:
Front Drive Shaft Assembly On-Vehicle
Inspection
S7RS0B3106002
• Check boots for breakage or deterioration.
• Check wheel side joint for rattle or smooth rotation.
• Check differential side (or center shaft side) joint for smooth rotation.
If any abnormality is found, replace.
Front Drive Shaft Assembly Removal and
Installation
S7RS0B3106003
Removal
1) Hoist vehicle and remove wheel.
2) Undo caulking (1) and remove drive shaft nut (2). 3) Drain transaxle oil.
4) Disconnect tie-rod end (1) from steering knuckle (2)
using puller (3).
5) Remove stabilizer join t referring to “Front
Suspension Frame, Stabiliz er Bar and/or Bushings
Removal and Installati on in Section 2B”.
6) Remove brake hose mounting bolt (1) and break hose (2) from bracket and then detach wheel speed
sensor harness (3) from strut bracket.
7) Remove suspension contro l arm ball joint bolt (4).
[A]: Right side drive shaft assembly (M/T model) 8. Wheel side joint (Constant velocity ball joint)
: Apply black grease included in spare part to joint.
[B]: Left side drive shaft assembly (M/T model) 9. Center shaft side joint (Constant velocity tripod joint)
: Apply dark gray grease included in spare part to joint.
[C]: Right side drive shaft assembly (A/T model) 10. Oil seal
: Apply grease 99000-25011 to oil seal lip.
[D]: Left side drive shaft assembly (A/T model) 11. Center bearing support circlip
[E]: Center shaft assembly (A/T model) 12. Center bearing support
[F]: Center shaft assembly (M/T model) 13. Center bearing
1. Circlip 14. Center shaft
2. Differential side joint (Constant velocity tripod joint) : Apply dark gray grease included in spare part to joint. 15. Cage
3. Snap ring 16. Tripod joint spider
: Never disassemble.
4. Boot band (Large) 17. O-ring
: Apply grease 99000-25011 to all round of O-ring.
5. Boot (Differential or center shaft side) 18. Differential side joint (Constant velocity tripod joint)
: Apply dark gray grease included in spare part to joint.
6. Boot band (Small) 19. Center shaft side joint (Constant velocity tripod joint)
: Apply dark gray grease included is spare part to joint.
7. Boot (Wheel side) : Do not reuse.
I6RS0C310004-01
F: Vehicle front
I3RM0A310003-01
I6RS0C310005-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-5
8) Disconnect front suspension control arm ball joint
stud from steering knuckle.
9) Pull out drive shaft joint as follows. • For differential sideUsing tire lever (1), pull out drive shaft joint (2) so
as to release snap ring fitting of joint spline at
differential side.
• For center shaft side Using plastic hammer (3), drive out drive shaft
joint (2) so as to release snap ring fitting of joint
spline at center shaft.
10) Remove drive shaft assembly. 11) Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from
differential side gear. Installation
CAUTION!
• Be careful not to damage oil seals and
boots when installing drive shaft.
• Do not hit joint boot with hammer. Inserting joint only by hands is allowed.
• Make sure that differential side joint is inserted fully and its snap ring is seated as
it was.

Install drive shaft assemb ly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as sp ecified referring to “A/T
Fluid Change in Section 5A” or “Manual Transaxle Oil
Change in Section 5B”.
• Check toe setting referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B” and adjust
as required.
[A]: Differential side
[B]: Center shaft side
I6RS0C310006-01
3
2
1I2RH01310007-01

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-15
Specifications
Tightening Torque SpecificationsS7RS0B3107001
NOTE
The specified tightening torque is also described in the following.
“Front Drive Shaft Assembly Components Location”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B3108001
NOTE
Required service material is also described in the following.
“Front Drive Shaft Components”

Special ToolS7RS0B3108002
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Brake hose mounting bolt 25 2.5 18.0 )
MaterialSUZUKI recommended product or Specification Note
Grease SUZUKI Super Grease A P/No.: 99000–25011)
09913–84510 09925–15410
Bearing installer Oil seal installer
))
09925–98221 09943–57010
Bearing installer Band compressor
)) / ) / )
09943–57021
Pliers, Low-Profile Clamp
) / )

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1 Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System Construction ...................................................... 4A-2
Front Brake Hose / Pipe Co nstruction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4 Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7 Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-8
Brake Fluid Level Inspection ............................... 4A-8
Stop Light Switch Adjustment ............................. 4A-8
Air Bleeding of Brake System ............................. 4A-9
Front Brake Hose / Pipe Removal and Installation ....................................................... 4A-10
Rear Brake Hose / Pipe Removal and Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-11
Master Cylinder Components............................ 4A-11
Master Cylinder Assembly Removal and Installation ....................................................... 4A-12
Master Cylinder Rese rvoir Removal and
Installation ....................................................... 4A-13
Master Cylinder Assemb ly Disassembly and
Assembly ........................................................ 4A-14
Master Cylinder Assembly Inspection ............... 4A-15
Brake Booster Components .............................. 4A-15
Booster Operation Inspection ........................... 4A-16
Brake Booster Removal and Installation ........... 4A-17
Brake Booster Inspection and Adjustment ........ 4A-18
Specifications ..................................................... 4A-18
Tightening Torque Specifications ...................... 4A-18
Special Tools and Equipmen t ........................... 4A-18 Recommended Service Material ....................... 4A-18
Front Brakes .......
..................................... 4B-1
Repair Instructions ........... ...................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Ca liper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and Assembly........................................................... 4B-4
Front Disc Brake Caliper In spection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .................... ...................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipmen t .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes................... ........................... 4C-1
Repair Instructions ........... ...................................4C-1
Rear Disc Brake Components.............................4C-1
Rear Disc Brake Pad Removal and Installation .........................................................4C-2
Rear Disc Brake Caliper Removal and Installation .........................................................4C-3
Rear Disc Brake Pad Inspection .........................4C-6
Rear Disc Brake Caliper Disassembly and Assembly...........................................................4C-6
Rear Disc Brake Caliper Inspection ....................4C-8
Rear Flexible Hose Remova l and Installation .....4C-8
Rear Brake Disc Removal and Installation..........4C-9
Rear Brake Disc Inspection.................................4C-9
Specifications .................... .................................4C-10
Tightening Torque Specifications ......................4C-10
Special Tools and Equipmen t ...........................4C-11
Recommended Service Material .......................4C-11
Special Tool ......................................................4C-11
Parking Brake ................. ......................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1