Clé SUZUKI SWIFT 2007 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 2C-2 Rear Suspension:
Repair Instructions
Rear Wheel Alignment InspectionS7RS0B2306017
Measure toe and camber referring to “Front Wheel
Alignment Inspection and Adjustment in Section 2B”.
NOTE
Rear suspension is not adjustable structure.

Rear toe (total)
: IN 3.8 ± 3.8 mm (IN 0.1969 ± 0.1969 in)
Rear camber
: –1 ° ± 1
If measured value is out of specified value, check
following items for damage, deformation and crack.
• Rear axle (torsion beam)
• Spindle, wheel hub or wheel bearing
• Vehicle body
Rear Shock Absorber Removal and InstallationS7RS0B2306001
Removal 1) Hoist vehicle and remove rear wheels.
2) Remove tail end member trim (1) and quarter inner trim (2).
3) Support rear axle by using floor jack to prevent it from lowering.
4) Remove shock absorber lower nut.
5) Remove shock absorber upper nut. Then remove shock absorber, a pair of upper washers and lower
washer. Installation
1) Install shock absorber (1), a pair of upper washers (2) and lower washer.
Tighten new rear shock absorber upper nut (4) and
lower nut temporarily at this step.
CAUTION!
Never reuse the removed rear shock
absorber upper nut.

NOTE
A pair of upper washers (2) are installed as
shown in figure.

3. Clip
3
3 2
3
1
3
I7RS0B230001-01
3. Body panel
14
3 2
I6RS0C230005-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-3
2) Remove floor jack (2) from rear axle.
3) Install rear wheels and tighten wheel nuts specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
4) Lower hoist and vehicle in unloaded condition, tighten shock absorber nuts to specified torque.
Tightening torque
Rear shock absorber upper nut (a): 28 N·m (2.8
kgf-m, 20.0 lb-ft)
Rear shock absorber lower nut (b): 90 N·m (9.0
kgf-m, 65.0 lb-ft)
5) Install tail end member trim and quarter inner trim.Rear Shock Absorber InspectionS7RS0B2306002
• Inspect for deformation or damage.
• Inspect bushings for wear or damage.
• Inspect for evidence of oil leakage.
Replace any defective parts.
WARNING!
When handling rear shock absorber (1) in
which high-pressure gas is sealed, make
sure to observe the following precautions.
• Don’t disassemble it.
• Don’t put it into the fire.
• Don’t store it where it gets hot.
• Before disposing it, be sure to drill a hole (approximately 3 mm (0.12 in.) diameter)
(2) in it where indicated by arrow in the
figure and let gas and oil out.
Be sure to wear eye shield since the gas
itself is harmless but the absorber drill
hole debris maybe blown out.

(a)
1
(b) 2
I4RS0B230003-01
I4RS0A230005-01

Downloaded from www.Manualslib.com manuals search engine 2C-4 Rear Suspension:
Rear Shock Absorber Bush Removal and
Installation
S7RS0B2306003
Removal1) Remove rear shock absorber referring to “Rear Shock Absorber Remova l and Installation”.
2) Remove rear shock absorber bushes (1).
Installation 1) Install rear shock absorber bushes (1).
NOTE
For proper installing direction of shock
absorber bushes (1), refer to the figure.

2) Install rear shock absorber referring to “Rear Shock Absorber Removal and Installation”.
Rear Shock Absorber Bush InspectionS7RS0B2306004
Inspect for cracks, deformation or damage. Replace any
defective parts.
Rear Coil Spring Removal and InstallationS7RS0B2306005
Removal
1) Hoist vehicle and remove rear wheels.
2) Support rear axle (1) by using two floor jacks (2) to prevent it from lowering.
3) Detach shock absorbers (1) lower side (right & left) from rear axle.
4) Lower rear axle gradually as far down as the coil spring (2) can be removed.
CAUTION!
Be careful not to lowe r rear axle down too
much.
It may cause damage to brake flexible hose,
wheel speed sensor lead wire and parking
brake cable.

5) Remove coil spring (2).
2. Body panel
1
1
I4RS0A230006-01
1
2
I4RS0A230007-01
I4RS0A230008-01
1
2
2
I6RS0C230006-01
1
2
I4RS0A230010-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-5
Installation1) Install coil spring (1) on spring seat (2) of rear axle and mate spring open end with stepped part (3) of
spring lower seat and raise rear axle.
2) Install shock absorbers (1) lower side (right & left) to rear axle.
Install washers and tighten shock absorber lower
nuts (2) temporarily by hand at this step. 3) Remove floor jacks from rear axle.
4) Install wheels and tighten wheel nuts to specified
torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
5) Lower hoist and vehicle in unloaded condition, tighten shock absorber lower nuts (a) to specified
torque.
Tightening torque
Rear shock absorber lower nut (a): 90 N·m (9.0
kgf-m, 65.0 lb-ft)
Spring Upper Seat / Spring Lower Seat
Inspection
S7RS0B2306006
Inspect for cracks, deformation or damage.
Replace any defective part.
F: Vehicle front
I4RS0A230011-01
1
2
I4RS0A230012-01
(a)
I4RS0A230013-01
I4RS0A230015-01

Downloaded from www.Manualslib.com manuals search engine 2C-6 Rear Suspension:
Spring Upper Seat and Lower Seat Removal and
Installation
S7RS0B2306007
Removal1) Remove coil spring referring to “Rear Coil Spring Removal and Installation”.
2) Remove spring upper seat (1) and lower seat (2).
Installation 1) Install spring upper seat (1) and lower seat (2).
NOTE
For proper installing direction of spring
upper seat (1) and lower seat (2), refer to the
figure.

2) Install coil spring referr ing to “Rear Coil Spring
Removal and Installation”.
Rear Axle Removal and InstallationS7RS0B2306008
Removal
1) Hoist vehicle and remove rear wheels (right & left).
2) Disconnect rear brake caliper flexible hoses (1) (right & left) from brake pipes (2) and put bleeder plug cap
(3) onto pipe (2) prevent fluid from spilling.
CAUTION!
Do not drop brake fluid onto painted surface.

1
2
I4RS0A230016-01
I3RM0A230021-01
A: Vehicle body side (Upper side)
F: Vehicle front3. Stepped part
I4RS0A230017-01
1
2
2 3
I6RS0B230002-01

Downloaded from www.Manualslib.com manuals search engine Rear Suspension: 2C-9
12) Fill reservoir with brake fluid and bleed brake system. For bleeding operation, see “Air Bleeding of
Brake System in Section 4A”.
13) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Adjust parking brake cable. For adjustment, refer to “Parking Brake Inspection and Adjustment in Section
4D”.
15) Lower hoist and bounce vehicle up and down several times to stabilize suspension.
16) Tighten shock ab sorber lower nuts (1) and trailing
arm bolts (2) to specified torque.
NOTE
When tightening these nuts and bolts, be
sure that vehicle is not on hoist and in
unloaded condition.

Tightening torque
Rear shock absorber lower nut (a): 90 N·m (9.0
kgf-m, 65.0 lb-ft)
Trailing arm bolt (b): 73 N·m (7.3 kgf-m, 53.0 lb-
ft)
17) Perform brake test (foot brake and parking brake).
18) Check each installed part for fluid leakage.
Trailing Arm, Rear Axle and Coil Spring
Inspection
S7RS0B2306009
• Inspect for cracks, deformation or damage.
• Inspect bushing for damage, wear or breakage.
Replace any defective part.
Rear Axle Bush InspectionS7RS0B2306010
Inspect for cracks, deformation or damage. Replace any
defective part.
1, (a)
2, (b)
I6RS0B230008-01
I4RS0A230031-01

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 2D-1 Wheels and Tires:
Suspension
Wheels and Tires
Precautions
Precaution for Emergency Flat Tire Repair KitS7RS0B2400001
WARNING!
Flat tire repair sealant including in kit is
harmful. Be sure to observe the following.
Otherwise, your health may be ruined.
• If swallowed, get medical attention immediately.
• Keep out of reach of children.
• Select place where there is good ventilation for this work.
• If it enters eye or contacts skin, wash thoroughly with water. If anything
abnormal still rema ins, get medical
attention immediately.
• Do not discard tire containing sealant as it is. Make sure to remove sealant from tire,
referring to “Tire Repair for Emergency
Repaired-Tire with Sealant”.
• Dispose of sealant as waste oil.

CAUTION!
• When tire repaired with Emergency Flat Tire Repair Kit is brought in, remove flat
tire repair sealant from tire and repair flat
tire referring to “Tire Repair for Emergency
Repaired-Tire with Sealant”.
• Sealant expiration date is printed on bottle label. if it expires, sealant should be
replaced with a new one to ensure
emergency flat tire repair.

General Description
Tires DescriptionS7RS0B2401001
The tire is of tubeless type. The tire is designed to
operate satisfactorily with loads up to the full rated load
capacity when inflated to the recommended inflation
pressures.
Correct tire pressures and driving habits have an
important influence on tire life. Heavy cornering,
excessively rapid acceleration, and unnecessary sharp
braking increase tire wear.
Tire Placard
The “Tire Placard” is located on the left or right door lock
pillar and should be referred to tire information.
The placard lists the maximum load, tire size and cold
tire pressure where applicable.
NOTE
Whether rim size and/or maximum load are
listed or not depends on regulations of each
country.

Inflation of Tires
The pressure recommended for any model is carefully
calculated to give a satisfacto ry ride, stability, steering,
tread wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for 3
hours or more, or driven less than one mile) should be
checked monthly or before any extended trip. Set to the
specifications on the “Tire Placard” located on the left
door lock pillar.
It is normal for tire pressure to increase when the tires
become hot during driving.
Do not bleed or reduce tire pressure after driving.
Bleeding reduces the “Cold Inflation Pressure”.
Higher than recommended pressure can cause:
• Hard ride
• Tire bruising or carcass damage
• Rapid tread wear at center of tire
Unequal pressure on same axle can cause:
• Uneven braking
• Steering lead
• Reduced handling
• Swerve on acceleration

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 Wheels and Tires: 2D-4
Radial Tire Waddle DescriptionS7RS0B2401005
Waddle is side to side movement at the front and/or rear
of the vehicle. It is caused by the steel belt not being
straight within the tire. It is most noticeable at a low
speed, 8 to 48 kph (5 to 30 mph).
It is possible to locate the f aulty tire by road testing the
vehicle. If it is on the rear , the rear end of the vehicle
shakes from side to side or “waddles”. To the driver in
the seat, it feels as though someone is pushing on the
side of vehicle.
If the faulty tire is on the front, waddling is more visual.
The front sheet metal appears to be moving back and
forth and the driver feels as though he is at the pivot
point in vehicle.
Waddle can be quickly diagnosed by using Tire Problem
Detector (TPD) and following the equipment
manufacture’s recommendations.
If TPD is not available, an alternative method of
substituting known-good tire / wheel assemblies can be
used as follows, although it takes a longer time. 1) Ride vehicle to determine whether the front or rear
waddles.
2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on waddling end
of vehicle. If waddling end cannot be identified,
substitute rear ones.
3) Road test again. If improvement is noted, reinstall originals one at a time till w addle causal tire is found.
If no improvement is noted, install known-good tires
in place of all four. Then reinstall originals in the
same manner.
Equipment manufacture’s recommendations
I2RH01240006-01
Inflate tires to recommended pressure
Road test vehicle on level unrouned road in both directions
Switch front tires side to side and road test again
Lead corrected,
if roughness results, replace tiresLeads in same directionLeads reverses direction
Put tires back in original position
and check alignmentInstall a known-good tire on one front side
Lead remains install a known-good
tire in place of other front tire
Lead remains known-good tires are not goodLead corrected replace tire
Lead corrected replace tire
I2RH01240007-01