brake fluid SUZUKI SWIFT 2007 2.G Service Owner's Manual

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Air Bleeding of Brake SystemS7RS0B4106006
CAUTION!
Brake fluid is extremely damaging to paint. If
fluid should accidentally touch painted
surface, immediately wipe fluid from paint
and clean painted surface.

Bleeding operation is necessary to remove air whenever
it entered hydraulic brake system.
Hydraulic lines of brake system are based on the
diagonal split system. When a brake pipe or hose was
disconnected at the wheel, bleeding operation must be
performed at both ends of the line of the removed pipe or
hose. When any joint part of the master cylinder of other
joint part between the master cylinder and each brake
(wheel) was removed, the hydraulic brake system must
be bled at all 4 wheel brakes.
NOTE
Perform bleeding operation starting with rear
brake caliper farthest from master cylinder
and then at front caliper of the same brake
line. Do the same on the other brake line.

1) Fill master cylinder rese rvoir with brake fluid and
keep at least one-half full of fluid during bleeding
operation.
Brake fluid
: Refer to reservoir cap (1) 2) Remove bleeder plug cap. Attach a vinyl tube (1) to
bleeder plug, and insert the other end into container
(2).
3) Depress brake pedal several times, and then while holding it depressed, loosen bleeder plug about one-
third to one-half turn.
4) When fluid pressure in cy linder is almost depleted,
retighten bleeder plug.
5) Repeat this operation until there are no more air bubbles in hydraulic line.
6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug referring to “Front Disc
Brake Components in Section 4B” and “Rear Disc
Brake Components in Section 4C”.
1. Right front brake caliper 3. Right rear brake caliper
2. Left front brake caliper 4. Left rear brake caliper
I6RS0C410007-01
1
I6RS0C410009-01
I2RH01410015-01
I2RH01410016-01
I2RH01410017-01

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7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
9) Replenish fluid into reserv oir up to specified level.
10) Check brake pedal for sponginess. If found spongy, repeat entire procedure of bleeding.
Front Brake Hose / Pipe Removal and
Installation
S7RS0B4106007
“Front Brake Hose / Pipe Construction”
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) Raise and support vehicle properly. Remove tire and wheel.
NOTE
This operation is not necessary when
removing pipes connecting master cylinder.

2) Clean dirt and foreign mate rial from both flexible
hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Make sure that steering wh eel is in straight-forward
position and flexible hose has not twist or kink.
• Check to make sure that flexible hose doesn’t contact any part of suspension, both in extreme right and
extreme left turn conditions. If it does at any point,
remove and correct. Fill and maintain brake fluid level
in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
• Perform brake test and check installed part for fluid leakage.
Rear Brake Hose / Pipe Removal and
Installation
S7RS0B4106008
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) Raise and support vehicle properly. Remove tire and wheel.
2) Clean dirt and foreign material from both flexible hose end and pipe end fittings.
3) Drain brake fluid in reservoir.
4) Remove brake flexible hose or pipe.
Installation
Reverse brake flexible hose removal procedure, noting
the following.
• Fill and maintain brake fluid level in reservoir.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
• Perform brake test and check each installed part for fluid leakage.
• Never reuse protector nut once removed. Be sure to use a new one.
• Install clamps properly referring to the figure and tighten bolts.
• When installing hose, make sure that it has no twist or
kink.
I4RS0B410006-01

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Brake Hose and Pipe InspectionS7RS0B4106009
Hose
The brake hose assembly should be checked for road
hazard damage, for cracks and chafing of outer cover,
for leaks and blisters. A light and mirror may be needed
for an adequate inspection. If any above conditions are
observed on brake hose, it is necessary to replace it.
Pipe
Inspect the pipe for damage, cracks, dents and
corrosion. If any defect is found, replace it.
Master Cylinder ComponentsS7RS0B4106010
I4RS0B410009-01
10
11
1
2 3
4
5 7
13
12
9
FLD
8FLD
6FLD
(b)
(a)
(c)FLD
I7RS0B410004-01
1. Reservoir cap 7. Master cylinder piston set13. Circlip
2. Filter 8. Primary piston assembly
: Apply brake fluid. :2.5 N
⋅m (0.25 kgf-m, 2.0 lb-ft)
3. Reservoir 9. Secondary piston assembly
: Apply brake fluid. : 15 N
⋅m (1.5 kgf-m, 11.0 lb-ft)
4. Grommet : Apply brake fluid. 10. Cup
: 16 N.m (1.6 kgf-m, 12.0 lb-ft) (flare nut for
M10)
19 N.m (1.9 kgf-m, 14.0 lb-ft) (flare nut for
M12)
5. Secondary piston stopper pin : Apply brake fluid. 11. Piston guide
: Do not reuse.
6. Master cylinder body : Apply brake fluid to inside of cylinder. 12. O-ring

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Master Cylinder Assembly Removal and
Installation
S7RS0B4106011
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) Clean outside of master cylinder.
2) Drain brake fluid in reservoir.
3) Remove clutch reservoir hose clamp (1) and disconnect clutch reservoir hose (3) from reservoir
(2) (M/T model).
4) Disconnect fluid level switch coupler (1) on reservoir.
5) Disconnect brake pipes (2) connected to master cylinder.
6) Remove master cylinder fixing nuts (1). 7) Remove master cylinder and master cylinder seal.
Installation 1) Install new master cylinder seal.
2) Apply small amount of silic on grease (included in
spare parts) to piston rod.
3) Install master cylinder to booster and tighten master cylinder fixing nuts (a) to specified torque.
Tightening torque
Master cylinder fixing nut (a): 15 N·m (1.5 kgf-
m, 11.0 lb-ft)
4) Connect brake pipe to master cylinder and tighten flare nuts (a) to specified torque.
Tightening torque
Brake pipe flare nut for M10 (a): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)
Brake pipe flare nut for M12 (a): 19 N·m (1.9 kgf-
m, 14.0 lb-ft)
5) Connect fluid level switch connector (1) of reservoir.
3
2
1
I4RS0A410026-01
1
2
I4RS0A410013-01
1
I4RS0A410014-01
(a)I4RS0A410015-01
1
(a)
I4RS0A410016-01

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6) Connect clutch reservoir hose (1) to reservoir (2) and install reservoir hose clamp (3) (M/T model).
7) Fill reservoir with specified brake fluid up to its MAX
mark.
8) 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).
9) Check each installed parts for fluid leakage
10) Check brake pedal for play referring to “Brake Pedal Play Inspection”.
11) Perform brake test and check fluid leakage.
Master Cylinder Reservoir Removal and
Installation
S7RS0B4106020
CAUTION!
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted
surfaces.

Removal 1) Remove windshield wiper referring to “Windshield Wiper Removal and Insta llation in Section 9D”.
2) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
3) Disconnect fluid level s witch coupler on reservoir.
4) Clean outside of reservoir.
5) Take out fluid with syringe or such.
6) Disconnect clutch reservoir hose clamp (2) and hose (3) from reservoir (1) (M/T model). 7) Remove reservoir bolt (1).
8) Remove reservoir (2) and grommets (3).
Installation 1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with. Then
press-fit grommets (1) to reservoir (2). Grommets
must be seated in place.
2) Install reservoir (2) to master cylinder with bolt (a).
Tightening torque
Reservoir bolt (a): 2.5 N·m (0.25 kgf-m, 2.0 lb-ft)
3) Connect fluid level switch coupler on reservoir.
4) Connect clutch reservoir hose (1) to reservoir (2) (M/ T model).
5) Install clutch reservoir hose clamp (3) (M/T model).
1
2
3
I4RS0A410023-01
3
1
2
I4RS0A410010-01
1 2
3I4RS0A410011-01
1 2
(a)
I4RS0A410012-01
1
2
3
I4RS0A410023-01

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.
I2RH01410025-01
I4RS0A410017-01
I2RH01410027-01
I4RS0A410018-01

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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)

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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
I2RH01410010-01
1
2 4
3
I6RS0C410006-02
(b)
(a)
I4RS0B410021-02

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10) Check pedal height and play referring to “Brake Pedal Free Height Inspection” and “Brake Pedal
Play Inspection”.
11) Check each installed part for fluid leakage and perform brake test.
12) Evacuate and charge refrigerant by referring to “Evacuating of A/C Syst em” and “Procedure of
Charging” under “Operation Procedure for
Refrigerant Charge in Section 7B” or “Operation
Procedure for Refrigerant Charge in Section 7B”.
Brake Booster Inspection and AdjustmentS7RS0B4106018
Installation Position of Push Rod
If push rod clevis (1) has b een removed, adjust distance
between booster installation surface (without including
packing) and the center of clevis pin hole to standard
value “a” and tighten nut (a) to specified torque. Distance “a” between center of booster clevis pin
hole and booster surface
Standard:
114.5 – 115.5 mm (4.51 – 4.54 in.)
Tightening torque
Clevis lock nut (a): 15 N·m (1.5 kgf-m, 11.0 lb-ft)
Specifications
Tightening Torque SpecificationsS7RS0B4107001
NOTE
The specified tightening torque is also described in the following.
“Front Brake Hose / Pipe Construction”
“Rear Brake Hose / Pipe Construction”
“Brake Pedal Components”
“Master Cylinder Components”
“Brake Booster 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 MaterialS7RS0B4108001
NOTE
Required service material is also described in the following.
“Master Cylinder Components”

I4RS0A410022-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Master cylinder fixing nut 15 1.5 11.0 )
Brake pipe flare nut for M10 16 1.6 11.5 )
Brake pipe flare nut for M12 19 1.9 14.0 )
Reservoir bolt 2.5 0.25 2.0 )
Booster mounting nut 13 1.3 9.5 )
Brake pedal bracket mounting bolt 13 1.3 9.5 )
Clevis lock nut 15 1.5 11.0 )

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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