Front SUZUKI SWIFT 2006 2.G Service Manual Online

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

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-3
2) Set brake pad springs (1), shim (2) and install brake pads (3).
NOTE
Install right side brake pad with wear
indicator (4) to vehicle center side.

3) Install caliper and tighten caliper pin bolts (a) to specified torque.
Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
4) Install wheel and lower lift.
5) Tighten wheel nuts to specified torque. Tightening torque
Wheel nut (a): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
6) After completion of installation, check for brake effectiveness.
Front Disc Brake Pad InspectionS7RS0B4206004
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.

Front brake pad thickness (lining thickness)
Standard: 10 mm (0.40 in.)
Limit: 2 mm (0.08 in.)
NOTE
When pads are removed, visually inspect
caliper for brake fluid leak. Correct leaky
point, if any.

Front Disc Brake Caliper Removal and
Installation
S7RS0B4206005
Removal
1) Hoist vehicle and remove wheel.
2) Loosen flexible hose joint bolt (1) a little at caliper.
CAUTION!
Be careful not to twist flexible hose while
loosening the bolt.

3) Remove caliper pin bolts (1).
4) Remove caliper fr om caliper carrier.
5) Disconnect flexible hose fr om caliper using care not
to twist it. As this will allow brake fluid to flow out of
flexible hose, have a container ready beforehand.
I6RS0C420002-01
(a)
I4RS0A420002-01
I2RH01420005-01
I6RS0C420003-01
1
I2RH01420010-01

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)
I4RS0A420003-01
I6RS0C420004-01
I2RH01420011-01
I2RH01420013-01

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.

I2RH01420016-01
1
I2RH01420017-01
“A”: 1 grooved side directed cylinder side
“B”: 2 grooved side directed pad side
I4RS0A420006-01
I2RH01420019-01
I2RH01420020-01

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).
I4RS0A420004-01
I2RH01420014-01
I2RH01420015-01
I2RH01420024-01
I2RH01420025-01

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-7
Installation1) Install disc to wheel hub.
2) Install caliper assemb ly to steering knuckle.
3) Torque caliper carrier bolts to specification.
Tightening torque
Caliper carrier bolt (a): 85 N·m (8.5 kgf-m, 61.5
lb-ft)
4) Torque front wheel nuts to specification. Tightening torque
Wheel nut (b): 85 N·m (8.5 kgf-m, 61.5 lb-ft)
5) Upon completion of installation, perform brake test.Front Brake Disc InspectionS7RS0B4206009
• Install wheel nuts to hub bolts and fasten to fix the brake disc.
Using magnetic stand and with dial gauge positioned
at about 10 mm (0.39 in.) inward from periphery of
disc, measure deflection of disc.
If limit value is exceeded, replace correct or replace.
Front brake disc deflection
Limit: 0.10 mm (0.004 in.) max.
Special tool
(A): 09900–20607
(B): 09900–20701
• Using micrometer, measure thickness of brake disc. If it is less than limit, replace brake disc.
Front brake disc thickness
Standard: 20.0 mm (0.79 in.)
Limit: 18.0 mm (0.71 in.)
I2RH01420028-01
I2RH01420026-01
I2RH01420027-01

Downloaded from www.Manualslib.com manuals search engine 4B-8 Front Brakes:
Specifications
Tightening Torque SpecificationsS7RS0B4207001
NOTE
The specified tightening torque is also described in the following.
“Front Disc Brake Components”

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 MaterialS7RS0B4208001
NOTE
Required service material is also described in the following.
“Front Disc Brake Components”

Special ToolS7RS0B4208002
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Caliper pin bolt 26 2.6 19.0 ) / )
Wheel nut 85 8.5 61.5 ) / ) / )
Flexible hose joint bolt 23 2.3 17.0 )
Bleeder plug 8.0 0.8 6.0 )
Caliper carrier bolt 85 8.5 61.5 )
09900–2060709900–20701
Dial gauge Magnetic stand
))

Downloaded from www.Manualslib.com manuals search engine 4C-4 Rear Brakes:
5) Remove caliper pin bolts (1).
6) Remove caliper (2) from brake caliper carrier (3).
7) Disconnect parking brake cable (1) from lever (2) while rotating lever in direction of arrow.
8) Remove brake pads, slide pins and slide pin boots from brake caliper carrier.
9) Remove brake caliper carrier (1) from spindle (2). Installation
1) Install brake caliper ca rrier (1) to spindle (2).
Tightening torque
Brake caliper carrier bolt (a): 60 N·m (6.0 kgf-m,
43.5 lb-ft)
2) Install new slide pin boots (1) to brake caliper carrier.
3) Apply rubber grease to slide pins, then install slide pin to front side and slide pin to rear side of brake
caliper carrier.
NOTE
Be sure not to install wrongly because the
shape of slide pins are different as below.

1 3
2
I6RS0C430008-01
1
2
I6RS0B431011-01
1 2
I6RS0B431012-01
F: Vehicle front
1
2
(a)
I6RS0B431023-01
I6RS0C430009-02

Downloaded from www.Manualslib.com manuals search engine 4D-1 Parking Brake:
Brakes
Parking Brake
General Description
Parking Brake Cable ConstructionS7RS0B4401001
I6RS0B440001-01
T: Top side3. Equalizer8. Lever [C]: View [C]
F: Front side 4. Parking cable bracket9. Parking cable clamp bolt [D]: View [D]
R: Right side 5. Parking cable bracket bolt 10. Vehicle body : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1. Parking brake lever assembly 6. Grommet [A]: View [A]: 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
2. Parking brake lever bolt 7. E-ring[B]: View [B]

Downloaded from www.Manualslib.com manuals search engine ABS: 4E-2
General Description
ABS DescriptionS7RS0B4501001
The ABS (Antilock Brake System) controls the fluid
pressure applied to the wheel cylinder of each brake
from the master cylinder so that each wheel is not locked
even when hard braking is applied.
This ABS has also the following function.
While braking is applied, but before ABS control
becomes effective, braking force is distributed between
the front and rear so as to prevent the rear wheels from
being locked too early for better stability of the vehicle.
The main component parts of this ABS include the
following parts in addition to those of the conventional
brake system.
• Wheel speed sensor which senses revolution speed of each wheel and outputs its signal.
• ABS warning light which light s to inform abnormality
when system fails to operate properly.
• ABS hydraulic unit / cont rol module assembly is
incorporated ABS co ntrol module, ABS hydraulic unit
(actuator assembly), solenoid valve power supply
driver (transistor), solenoid valve driver (transistor),
pump motor driver (transistor).
– ABS control module which sends operation signal to ABS hydraulic unit to control fluid pressure
applied to each wheel cylinder based on signal
from each wheel speed sensor so as to prevent
wheel from locking.
– ABS hydraulic unit which operates according to signal from ABS control module to control fluid
pressure applied to wheel cylinder of each 4
wheels.
– Solenoid valve power supp ly driver (transistor)
which supplies power to solenoid valve in ABS
hydraulic unit.
– Solenoid valve driver (transistor) which controls each solenoid valves in ABS hydraulic unit.
– Pump motor driver (transistor) which supplies power to pump motor in ABS hydraulic unit.
This ABS is equipped with Electronic Brake force
Distribution (EBD) system that controls a fluid pressure
of rear wheels to best condition, which is the same
function as that of proportion ing valve, by the signal from
wheel sensor independently of change of load due to
load capacity and so on. An d if the EBD system fails to
operate properly, the brake warning light lights to inform
abnormality.
ABS Hydraulic Unit / Control Module Assembly
Description
S7RS0B4501002
ABS control module is a component of ABS hydraulic
unit / control module asse mbly and has the following
functions.
Self-Diagnosis Function
ABS control module diagnose s conditions of the system
component parts (whether or not there is any
abnormality) all the time and indicates the results
(warning of abnormality occurrence and DTC) through
the ABS warning light as described.
• When ignition switch is turned ON, ABS warning light lights for 2 seconds to check its circuit.
• When no abnormality has been detected (the system is in good condition), ABS warning light turns OFF
after 2 seconds.
• When an abnormality in th e system is detected, ABS
warning light lights and the area where that
abnormality lies is stored in the memory of EEPROM
in ABS control module.
1
I4RS0A450001-01