306 SUZUKI SWIFT 2008 2.G Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-5
Clutch Pedal Position (CPP) Switch Inspection
and Adjustment
S7RS0B5306005
Inspection
Check for resistance between terminals under each
condition below. If check result is not satisfactory,
replace.
CPP switch resistance
When switch shaft is pushed (1): Continuity
When switch shaft is free (2): No continuityAdjustment
With clutch pedal depressed,
adjust switch (1) position
so that clearance between end of thread and clutch
pedal arm is within specification, and then tighten lock
nut to specified torque.
Clearance between end of thread and clutch pedal
arm
“a”: 3.5 – 4.0 mm (0.14 – 0.16 in.)
Tightening torque
CPP switch lock nut (a): 7.5 N·m (0.75 kgf-m, 5.5 lb-
ft)
Clutch Fluid Pipe and Hose ComponentsS7RS0B5306006
I5JB0A530006-01
(a)
1
“a”
I6RS0C530002-01
6
1
5
2 5
4(a)
3
I6RS0C530003-01
1. Master cylinder
: Apply grease 99000-25100 to push rod end. 5. Clamp
2. Pipe 6. Clutch reservoir hose
3. Operating cylinder : Apply grease 99000-25100 to rod tip. : 23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Operating cylinder bolt

Downloaded from www.Manualslib.com manuals search engine 5C-6 Clutch:
Clutch Fluid Pipe Removal and InstallationS7RS0B5306007
Removal
CAUTION!
Do not allow fluid to get on painted surface. It
may cause painted surface damage.

1) Remove dust and dirt from each joint of pipe to be disconnected and clean around brake master
cylinder reservoir cap.
2) Take out fluid with syringe or such from brake master cylinder reservoir.
3) Pull clamp (1) of clutch master cylinder (3) and push clamp (5) of clutch operating cylinder (4) and then
disconnect clutch fluid pipe (2).
Installation
Reverse removal procedure for installation noting the
following.
CAUTION!
• Do not allow fluid to get on painted surface.
• Do not allow pipe to contact hard against vehicle body or other parts.

• Install each clamp securely.
• After installation, check clutch pedal free travel and bleed air from system referring to “Clutch Pedal
Inspection” and “Air Blee ding of Clutch System”.
• Check fluid leakage.
• Add fluid to MAX level of reservoir.
Clutch Fluid Pipe InspectionS7RS0B5306008
Check pipe (1) for dent, kink, crack, dirt and dust.
Replace if check result is not satisfactory.
Clutch Master Cylinder Removal and
Installation
S7RS0B5306009
Removal 1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe from clutch master cylinder (1) referring to “C lutch Fluid Pipe Removal
and Installation”.
3) Disconnect clutch reservoir hose (2).
4) Remove push rod from clutch pedal.
5) Turn clutch master cylinder (1) clockwise as shown in figure, and then remove it.
Installation
Reverse removal procedure for installation noting the
following.
• Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
31
2
5
4
I4RS0B530003-01
3. Brake booster
1
I6RS0C530004-01
1
2
3
I4RS0B530005-01
“A”
I4RS0B530006-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-7
Clutch Operating Cylinder Removal and
Installation
S7RS0B5306010
Removal1) Clean around brake master cylinder reservoir cap and take out fluid with syringe or such from brake
master cylinder reservoir.
2) Disconnect clutch fluid pipe (2) from operating cylinder referring to “Clutch Fluid Pipe Removal and
Installation”.
3) Remove clutch operating cylinder (1).
Installation
Reverse removal procedure for installation noting the
following. • Apply grease to push rod tip.
“A”: Grease 99000–25100 (SUZUKI Silicone
Grease)
• Tighten clutch operating cylinder bolt to specified torque.
Tightening torque
Clutch operating cylinder bolt: 23 N·m (2.3 kgf-
m, 17.0 lb-ft)
Clutch Operating Cylinder InspectionS7RS0B5306011
Check operating cylinder for damage and fluid leakage.
If malfunction is found, repl ace clutch operating cylinder.
Clutch Pedal and Clutch Pedal Bracket ComponentsS7RS0B5306012
2
1I4RS0A530010-01
“A”
I4RS0A530011-01
I6RS0C530005-01
1. Clutch pedal bracket 9. Pedal pad
2. Pedal bracket nut 10. Cushion
3. Pedal bracket bolt : Pedal bracket bolt must be tighten after pedal bracket nut. 11. Return spring
: Apply grease 99000-25011 to inside of spring.
4. Pedal shaft bolt 12. Pedal cover plate
5. Pedal bush : Apply grease 9900-25011 to outside of bush. 13. Pedal plate cushion
6. Pedal shaft spacer : 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
7. Pedal shaft nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 5C-8 Clutch:
Clutch Cover, Clutch Disc and Flywheel ComponentsS7RS0B5306013
Clutch Cover, Clutch Disc and Flywheel
Removal and Installation
S7RS0B5306014
Removal1) Dismount manual transaxle assembly referring to “Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
2) Hold flywheel with specia l tool and remove clutch
cover bolts (1), clutch cover (2) and clutch disc.
Special tool
(A): 09924–17811
8. Clutch pedal : Apply grease 99000-25011 to outside surface of pin.
(a)
(b)
(b)
A
A
A
12
115
6
A3
A4
710
2
98
1
I4RS0A530013-02
1. Flywheel 9. Clutch disc
2. Flywheel bolt 10. Clutch cover bolt
3. Clutch release shaft seal : Apply grease 99000-25011 to seal lip. 11. Release arm
4. Clutch release shaft No.2 bush : Apply grease 99000-25011 to bush inside. 12. Release arm bolt
5. Clutch release shaft : Apply grease 99000-25011 to the end of release shaft arm. :70 N
⋅m (7.0 kgf-m, 51.0 lb-ft)
6. Clutch release shaft No.1 bush : Apply grease 99000-25011 to bush inside. :23 N
⋅m (2.3 kgf-m, 17.0 lb-ft)
7. Release bearing : Apply grease 99000-25011 to joint of bearing and release shaft and also bearing inside. Do not reuse.
8. Clutch cover
I4RS0A530014-01

Downloaded from www.Manualslib.com manuals search engine 5C-10 Clutch:
3) Aligning clutch disc to flywheel center using special
tool, install clutch cover (1) and bolts (2). Then
tighten bolts (2) to specification.
NOTE
• While tightening clutch cover bolts, compress clutch disc with special tool
(clutch center guide) by hand so that disc
is centered.
• Tighten cover bolts little by little evenly in diagonal order.

Special tool
(A): 09924–17811
(B): 09923–36320
Tightening torque
Clutch cover bolt (a): 23 N·m (2.3 kgf-m, 17.0 lb-
ft)
4) Slightly apply grease to input shaft (1), then join manual transaxle assembly with engine referring to
“Manual Transaxle Unit Dismounting and
Remounting in Section 5B”.
“A”: Grease 99000–25210 (SUZUKI Super
Grease I)
NOTE
When inserting transaxle input shaft to clutch
disc, turn crankshaft li ttle by little to match
the splines.

Clutch Cover, Clutch Disc and Flywheel
Inspection
S7RS0B5306015
Input Shaft Bearing
Check bearing (1) for smooth ro tation and replace it if
abnormality is found.
Clutch Disc
Measure depth of rivet head depression, i.e. distance
between rivet head and facing surface.
If depression is found to hav e reached service limit at
any of rivet holes (2), repl ace clutch disc assembly (1).
Rivet head depth
Standard: 1.65 – 2.25 mm (0.06 – 0.09 in.)
Limit: 0.5 mm (0.02 in.)
I4RS0A530017-01
I4RS0A530018-01
I3RM0A530014-01
I4RS0A530019-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-11
Clutch Cover1) Check diaphragm spring (1) for abnormal wear or damage.
2) Inspect pressure plate (2) for wear or heat spots.
3) If abnormality is found, replace clutch cover. Do not disassemble it into diaphragm spring and
pressure plate.
Flywheel
Check surface contacting clutch disc for abnormal wear
or heat spots. Replace or repair as required.
Clutch Release System Removal and
Installation
S7RS0B5306016
Removal 1) Remove release arm by loosening its bolt.
2) Take out release bearing by turning release shaft (1).
3) Drive out No.2 bush usin g special tool and hammer.
Release shaft seal will also be pushed out.
Special tool
(A): 09922–46010
4) Remove release shaft (1). 5) Install tap (M16 X 1.5) (1) to clutch release shaft
No.1 bush.
6) Pull No.1 bush out using tap (1) and special tools. Special tool
(B): 09923–46020
(C): 09930–30104
Installation 1) Drive in a new No.1 bush using special tools and
hammer, and then apply grease to bush inside.
Special tool
(A): 09943–88211
(B): 09923–46030
“A”: Grease 99000–25011 (SUZUKI Super
Grease A)
I3RM0A530015-01
I4RS0A530020-01
IYSY01531016-01
IYSY01531017-01
I3RM0A530016-01

Downloaded from www.Manualslib.com manuals search engine Clutch: 5C-13
Clutch Release System InspectionS7RS0B5306017
Clutch Release Bearing
Check clutch release bearing for smooth rotation. If
abnormality is found, replace it.
CAUTION!
Do not wash release bearing. Washing may
cause grease leakage and consequential
bearing damage.

Clutch Release Shaft
Check clutch release shaft and its pin for deflection or
damage.
If abnormality is found, replace it.
Specifications
Tightening Torque SpecificationsS7RS0B5307001
NOTE
The specified tightening torque is also described in the following.
“Clutch Fluid Pipe and Hose Components”
“Clutch Pedal and Clutch Pedal Bracket Components”
“Clutch Cover, Clutch Disc and Flywheel Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I3RM0A530020-01
I3RM0A530021-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
CPP switch lock nut 7.5 0.75 5.5 )
Clutch operating cylinder bolt 23 2.3 17.0 )
Flywheel bolt 70 7.0 51.0 )
Clutch cover bolt 23 2.3 17.0 )
Release lever bolt 23 2.3 17.0 )

Downloaded from www.Manualslib.com manuals search engine Steering Wheel and Column: 6B-2
Diagnostic Information and Procedures
Checking Steering Column for Accident
Damage
S7RS0B6204001
NOTE
Vehicles involved in accidents resulting in
body damage, where steering column has
been impacted or air bag deployed may have
a damaged or misaligned steering column.

Checking Procedure
NOTE
The steering column used in each vehicle is
one of the two types as shown.

1) Check that two capsules (1) are attached to steering column bracket securely. If found loose, replace
steering column assembly.
2) Take measurement “a”, “b” and “c” as shown. If it is shorter than spec ified length, replace steering
column assembly with new one.
Ty p e A
Power steering column length
“a”: 459 ± 2 mm (18.1 ± 0.08 in.)
“b”: 64.1 ± 1 mm (2.5 ± 0.03 in.)
“c”: 306.7 ± 1 mm (12.0 ± 0.03 in.)
Ty p e B
Power steering column length
“a”: 466 ± 2 mm (18.3 ± 0.08 in.)
“b”: 60.0 ± 1 mm (2.4 ± 0.03 in.)
“c”: 300.5 ± 1 mm (11.8 ± 0.03 in.) 3) Check steering shaft joints and shaft for any
damages such as crack, breakage, malfunction or
excessive play.
If anything is found faulty, replace as lower shaft
assembly or steering column assembly.
4) Check steering shaft for smooth rotation. If found defective, replace as steering column
assembly.
5) Check steering shaft and steering column for bend, cracks or deformation.
If found defective, replace.
[A]: Type A [B]: Type B
[A] [B]
1
1
1
1
I6RS0C620004-01
I6RS0C620001-01
I4RS0A620003-01

Downloaded from www.Manualslib.com manuals search engine 6C-40 Power Assisted Steering System:
Repair Instructions
Steering Gear Case Assembly ComponentsS7RS0B6306001
3(a)
10
(c) 2
3
(a)
2 1
19
(g)
19 18(g) 6
11
8
9
(b) 7
(b)
22 23
24 4
5
14
15
16
(e)
17
(f)
12
(d) 21
(c)
20
4 6
5 7
(b)
9
(b)
8
13
22
23
24
A
A
1322
I7RS0B630013-02
1. Steering gear case 12. Steering gear case mounting No.3 bolt 23. Boot
2. Tie-rod lock washer 13. Gear rack side No.1 bracket 24. split pin
3. Tie-rod 14. Steering rack plunger
: Apply grease 99000-25050 to rack plunger. : 93 N
⋅m (9.3 kgf-m, 67.5 lb-ft)
4. Band 15. Steering rack plunger spring
: Apply grease 99000-25050 to spring end. : 45 N
⋅m (4.5 kgf-m, 32.5 lb-ft)
Refer to “Tie-Rod End Removal and
Installation”.
5. Boot 16. Steering rack damper screw
: Apply thread lock 99000-32110 to all around
thread part of rack damper screw. : 55 N
⋅m (5.5 kgf-m, 40.0 lb-ft)
6. Rack boot clip 17. Steering rack damper lock nut : 40 N⋅m (4.0 kgf-m, 29.0 lb-ft)
7. Tie-rod end lock nut 18. Heat insulator : Refer to “Steering Rack Plunger Removal
and Installation”.
8. Tie-rod end 19. Heat insulator bolt : 64 N⋅m (6.4 kgf-m, 46.5 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Power Assisted Steering System: 6C-41
Tie-Rod End Boot On-Vehicle InspectionS7RS0B6306002
Check boot for crack and damage.
If any defect is found, replace it with a new one.
Tie-Rod End Removal and InstallationS7RS0B6306003
Removal1) Hoist vehicle, and then remove wheel referring to “Wheel Removal and Installation in Section 2D”.
2) Remove split pin (2) and tie-rod end nut (1) from steering knuckle.
3) Disconnect tie-rod end (1) from knuckle (2) using puller (3). 4) For ease of adjustment after installation, make
marking (1) of tie-rod end lock nut (2) position on tie-
rod end thread. Then, loosen lock nut and remove
tie-rod end (3) from tie-rod (4).
Installation 1) Install tie-rod end lock nut (1) and tie-rod end (2) to tie-rod (3). Align lock nut with mark (4) on tie-rod
thread.
9. Tie-rod end nut 20. Gear rack side No.2 bracket : 9.5 N⋅m (0.95 kgf-m, 7.0 lb-ft)
10. Steering gear case mounting No.1 bolt 21. Steering gear case mounting No.2 bolt : Do not reuse.
11. Steering gear case grommet 22. Clip
I3RM0A630024-01
21
I7RS0A630016-01
2 1
3
I4RS0A630040-01
I4RS0A630041-01
I4RS0A630042-01