wheel torque tightening SUZUKI SWIFT 2007 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4-iii
ABS Warning Lamp Check ............................... 4F-14
EBD Warning Lamp (Brake Warning Lamp) Check .............................................................. 4F-15
DTC Check ....................................................... 4F-15
DTC Table ......................................................... 4F-15
DTC Clearance ................................................. 4F-18
Fail-Safe Table ................ .................................. 4F-19
Scan Tool Data ................................................. 4F-20
Visual Inspection ............................................... 4F-21
ESP ® Warning Lamp Does Not Come ON at
Ignition Switch ON .......................................... 4F-21
ESP ® Warning Lamp Comes ON Steady......... 4F-22
ABS Warning Lamp Does Not Come ON at Ignition Switch ON .......................................... 4F-23
ABS Warning Lamp Comes ON Steady............ 4F-24
EBD Warning Lamp (Brake Warning Lamp) Comes ON Steady .......................................... 4F-24
Serial Data Link Circuit Check .......................... 4F-26
DTC C1016: Stop Lamp Swit ch Circuit Failure .. 4F-28
DTC C1017 / C1023: Yaw Rate / G Sensor Assembly Failure ............................................ 4F-29
DTC C1018: Brake Fluid Le vel Switch Failure .. 4F-30
DTC 1020: Master Cylinder Pressure Sensor Power Supply Failure ...................................... 4F-31
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Wheel Speed
Sensor Circuit or Encode r Failure ................... 4F-32
DTC C1024: Steering Angle Sensor Circuit
Failure ............................................................. 4F-34
DTC C1027: ESP ® OFF Switch Circuit
Failure ............................................................. 4F-34
DTC C1028: Master Cylinder Pressure Sensor Circuit Failure ....... .............................. 4F-35
DTC C1034: Yaw Rate / G Sensor Assembly Power Supply Failure ...................................... 4F-36
DTC C1037: Steering Angle Sensor Power Supply Failure ................................................. 4F-37
DTC C1038: Steering Angle Sensor Detect Rolling Counter Fa ilure from ESP® Control
Module ............................................................ 4F-38
DTC C1039: Yaw Rate / G Sensor Assembly Internal Failure .............. .................................. 4F-39
DTC C1040: Stability Control System Function Failure .............................................. 4F-39
DTC C1041 / C1042 / C1043 / C1044 / C1045 / C1046 / C1051 / C1052 / C1053 / C1054 /
C1055 / C1056: Solenoid Circuit Failure ......... 4F-40
DTC C1057: ESP ® Control Module Power
Supply Circuit Failure .... .................................. 4F-41
DTC C1061: Pump Motor and/or Motor Driver Circuit Failure .................................................. 4F-42
DTC C1063: Solenoid Valve Power Supply Driver Circuit Failure ....................................... 4F-43
DTC 1071: ESP ® Control Module Internal
Defect.............................................................. 4F-44 DTC C1073: Lost Communication With Yaw
Rate / G Sensor Assembly .............................. 4F-45
DTC C1075 / 1076 / 1078: Sensor Calibration Incomplete.......................... ............................. 4F-46
DTC C1090: Invalid Communication with
ECM ................................................................ 4F-47
DTC C1091 / C1094: ECM Data in CAN Line Failure / Invalid Torque Control
Communication with ECM .. ............................. 4F-48
DTC U1073: Control Module Communication Bus Off ............................................................ 4F-49
DTC U1100: Lost Communication with ECM (Reception Error)............................................. 4F-50
DTC U1126: Lost Communication with Steering Angle Sensor (Reception Error)........ 4F-51
DTC U1140: Lost Communication with BCM (Reception Error)............................................. 4F-52
Repair Instructions ........... ................................. 4F-54
ESP® Hydraulic Unit Operation Check ............. 4F-54
Sensor Calibration............................................. 4F-54
ESP® Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4F-55
ESP ® Hydraulic
Unit / Control Module
Assembly Removal and Inst allation ................ 4F-56
Front / Rear Wheel Speed Sensor On-Vehicle Inspection ........................................................ 4F-57
Front Wheel Speed Sensor Removal and Installation ....................................................... 4F-58
Front Wheel Speed Sensor Inspection ............. 4F-59
Rear Wheel Speed Sensor Removal and Installation ....................................................... 4F-59
Rear Wheel Speed Sensor Inspection .............. 4F-60
Front Wheel Encode r On-Vehicle Inspection .... 4F-61
Front Wheel Encoder Removal and Installation ....................................................... 4F-61
Rear Wheel Encoder On-Veh icle Inspection..... 4F-61
Rear Wheel Encoder Removal and Installation ....................................................... 4F-61
Master Cylinder Pressure Sensor On-Vehicle
Inspection ........................................................ 4F-61
Yaw Rate / G Sensor Assembly On-Vehicle Inspection ........................................................ 4F-62
Yaw Rate / G Sensor Assembly Removal and Installation ....................................................... 4F-63
Yaw Rate / G Sensor Inspection ....................... 4F-64
Steering Angle Sensor On-Vehicle Inspection .. 4F-64
Steering Angle Sensor Removal and Installation ....................................................... 4F-65
Steering Angle Sensor Inspection ..................... 4F-65
ESP® OFF Switch Removal an d Installation .... 4F-65
ESP® OFF Switch Inspection ........................... 4F-65
Specifications .................... ................................. 4F-66
Tightening Torque Specifications ...................... 4F-66
Special Tools and Equipmen t ........................... 4F-66
Special Tool ...................................................... 4F-66

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-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 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
I6RS0C430005-01
1
I6RS0C430006-01
1
I6RS0C430007-01

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-5
4) Pass parking brake cable (1) through bracket (3) of caliper.
5) Hang parking brake cable on lever (2) as follows.
NOTE
Make sure that lever (4) contacts pin (5).

6) Install brake pads and caliper referring to “Rear Disc Brake Pad Removal and Installation”.
7) Connect flexible hose (1) with new washers to caliper (2).
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.

Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft) 8) Install brake cable clip (1) securely to bracket (2).
9) After reassembling brake lines, bleed air from them
referring to “Air Bleeding of Brake System in Section
4A”.
10) Check to make sure that system is free from fluid
leakage.
11) Start engine and then depress brake pedal with about 300 N (30 kg, 66 lbs) load 3 times or more so
as to obtain proper disc to pad clearance.
12) Check to make sure that parking brake lever stroke is as specified. Refer to “Parking Brake Inspection
and Adjustment in Section 4D”.
13) Tighten wheel nuts to specified torque.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Remove vehicle from hoist and perform brake test (foot brake and parking brake).
1
23
45
I6RS0C430010-01
1 (a)2
I6RS0C430011-01
1
2
I6RS0C430012-01

Downloaded from www.Manualslib.com manuals search engine 4C-8 Rear Brakes:
Rear Disc Brake Caliper InspectionS7RS0B4306006
Pin Boot and Cylinder Boot
Check boots (1) for breakage, crack and damage.
If defective, replace.
Disc Brake Piston
Check all around piston for rust, corrosion and any other
damage.
If it is found faulty, replace.
Caliper
Push in adjusting bolt (1) by hand and move lever to
check that adjusting bolt (1) moves smoothly in the
arrow direction.
Also, check adjusting bolt (1) for any damage. If it is
found faulty, replace.
Slide Pin
Check guide pin for smooth movement.
If it is found faulty, correct or replace.
Apply rubber grease to guide pin outer surface. Rubber
grease should be the one whose viscosity is less
affected by such low temperature as –40 °C (–40 ° F).
Rear Flexible Hose Removal and InstallationS7RS0B4306007
Removal
1) Hoist vehicle and remove tire and wheel.
2) Remove caliper (4) assembly referring to “Rear Disc Brake Caliper Disassembly and Assembly”.
3) Loosen brake pipe flare nut (1) using by flare nut wrench.
4) Remove clip (2).
5) Remove brake flexible hose (3) from brake pipe.
Installation
Install reverse order of removal nothing the following.
• Tighten brake pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0 lb-ft)
1 1
1
I6RS0B431019-01
I6RS0B431020-01
1
I6RS0B431021-01
1
2
3
4
I6RS0C430013-01

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-9
Rear Brake Disc Removal and InstallationS7RS0B4306008
Removal1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper
carrier bolts (1) (2 pcs).
CAUTION!
During removal, be ca reful not to damage
brake flexible hose and not to depress brake
pedal.

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.
Don’t operate brake pedal with brake pads
removed.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs). Installation
Install in reverse order of removal nothing the following.
• Tighten brake disc screws and caliper carrier bolts to
specified torque.
Tightening torque
Caliper carrier bolt (a): 60 N·m (6.0 kgf-m, 43.5 lb-
ft)
• Tighten wheel nuts to specified torque. Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Upon completion of installation, perform brake test.
Rear Brake Disc InspectionS7RS0B4306009
• 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.
Rear brake disc deflection
Limit: 0.10 mm (0.004 in.) max.
Special tool
(A): 09900–20607
(B): 09900–20701
1
I6RS0C430014-01
1 1I6RS0C430017-01
(a)
I6RS0C430015-01
(B)
(A)
I6RS0B431031-01

Downloaded from www.Manualslib.com manuals search engine 4C-10 Rear Brakes:
• Using micrometer, measure thickness of brake disc.If limit value is exceeded, replace brake disc.
Rear brake disc thickness
Standard: 9 mm (0.354 in.)
Limit: 8 mm (0.315 in.)
Specifications
Tightening Torque SpecificationsS7RS0B4307001
NOTE
The specified tightening torque is also described in the following.
“Rear Disc Brake Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I6RS0B431032-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Caliper pin bolt 23 2.3 17 )
Wheel bolt 85 8.5 61.5 ) / ) / )
Brake caliper carrier bolt 60 6.0 43.5 )
Flexible hose joint bolt 23 2.3 17.0 )
Parking nut 27 2.7 19.5 )
Brake pipe flare nut 16 1.6 12.0 )
Caliper carrier bolt 60 6.0 43.5 )