MOUNT SUZUKI SWIFT 2008 2.G Service Manual Online

Downloaded from www.Manualslib.com manuals search engine 4A-6 Brake Control System and Diagnosis:
Pedal pulsation (Pedal
pulsates when depressed
for braking)Damaged or loose wheel bearings
Replace wheel bearings.
Distorted steering knuckle or rear wheel
spindle Replace knuckle or rear wheel spindle.
Excessive disc lateral runout Check per instructions. If not within
specifications, replace or machine disc.
Parallelism between brake pad and disc
not within specifications Check per instructions. If not within
specifications, replace or machine disc.
Brake caliper piston sticking Repair as necessary.
Braking noise Worn or distorted brake pad Replace pads.
Loose front wheel bearings Replace wheel bearings.
Distorted backing plates or loose
mounting bolts Replace or retighten securing bolts.
Contact wear indicator to brake disc Replace brake pad.
Brake warning light lights
after engine start Parking brake applied
Release parking brake and check that brake
warning light turns off.
Insufficient amount of brake fluid Investigate leaky point, correct it and add
brake fluid.
Brake fluid leaking Investigate leaky point, correct it and add
brake fluid.
Brake warning light circuit faulty Repair circuit.
Malfunctioning EBD system Check system referring to “EBD Warning Light
(Brake Warning Light) Comes ON Steady in
Section 4E”.
Brake warning light turns
on when brake is applied Brake fluid leaking
Investigate leaky point, correct it and add
brake fluid.
Insufficient amount of brake fluid Investigate leaky point, correct it and add
brake fluid.
Brake warning light fails
to turn on even when
parking brake is applied Brake warning light circuit faulty
Replace bulb or repair circuit.
ABS warning light or
ESP
® warning light turns
on after engine start Malfunctioning ABS (ESP
®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
ABS warning light or
ESP
® warning light turns
on when brake is applied Malfunctioning ABS (ESP
®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
ABS warning light or
ESP
® warning light does
not turn on for 2 sec. after
ignition switch has turned
ON Bulb burnt out
Replace bulb.
Malfunctioning ABS (ESP ®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
ABS warning light flashes New ABS hydraulic unit / control module
assembly installed. Perform “ABS Hydraulic
Unit Operation Check
in Section 4E”.
Condition Possible cause Correction / Reference Item

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-7
Repair Instructions
Brake Pedal ComponentsS7RS0B4106019
CAUTION!
Never disassemble brake pedalassembly.
Disassemble will spoil its originalfunction. If
faulty condition is found, replaceit with new
one.

Brake Pedal Free Height InspectionS7RS0B4106001
1) Check brake pedal free height. If it is not within specification, check and ad just following item 2) and
6).
Brake pedal free height “a” from carpet
130 – 150 mm (5.1 – 5.9 in.) 2) Check measurement between booster mounting
surface and center of clevis pin hole. When booster
push rod clevis has been reinstalled, it is important
that the measurement is adj usted (refer to “Brake
Booster Inspection and Adjustment”).
3) Check stop light switch position . Adjust it if it is out of
specification.
4) Check pedal for dent.
5) Check brake booster for installation.
6) Check brake booster push rod for length.
Brake Pedal Play InspectionS7RS0B4106002
Pedal play should be within the following specification. If
out of specification, check stop light switch for proper
installation position and adjust if necessary.
Also check pedal shaft bolt and booster clevis pin
installation for looseness and replace if defective.
Brake pedal play
“a”
: 1 – 8 mm (0.04 – 0.31 in.)
1. Brake pedal : 13 N⋅m (1,3 kgf-m, 9.5 lb-ft)
2. Brake pedal bracket
(a) 1
2
(a)
I7RS0B410002-01
I6RS0C410004-02
“a”I3RH0A410010-01

Downloaded from www.Manualslib.com manuals search engine 4A-12 Brake Control System and Diagnosis:
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

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-15
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)

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-17
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

Downloaded from www.Manualslib.com manuals search engine 4A-18 Brake Control System and Diagnosis:
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 )

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-1
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

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 Rear Brakes: 4C-1
Brakes
Rear Brakes
Repair Instructions
Rear Disc Brake ComponentsS7RS0B4306001
(d)
(c)
(a)
(a)
(a)16171413
2
1
15 2 19
12
117
7
3
7
4
20 20
5
10
9
8
(b)
18
6
24
23
22
21
I7RS0B430001-01
1. Caliper
11. Brake caliper carrier21. Shaft cover
: Apply rubber grease.
2. Caliper pin bolt 12. Caliper carrier bolt22. Lever
3. Boot 13. Rear caliper bleeder plug23. Washer
4. No.1 slide pin : Apply rubber grease. 14. Bleeder plug cap
24. Parking nut
5. Brake pad 15. Brake flexible hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
6. Return spring 16. Flexible hose joint bolt: 27 N⋅m (2.7 kgf-m, 19.5 lb-ft)
7. Pad spring 17. Hose washer: 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
8. Disk brake piston : Apply brake fluid to contact surface of cylinder. 18. Brake disc
: 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
9. Piston seal : Apply small amount of brake fluid to all around part of piston seal. 19. No.2 slide pin
: Apply rubber grease. : Do not reuse.
10. Cylinder boot : Apply small amount of brake fluid. 20. Pad shim

Downloaded from www.Manualslib.com manuals search engine 4C-2 Rear Brakes:
Rear Disc Brake Pad Removal and InstallationS7RS0B4306002
NOTE
When replacing brake pad, replace it on the
right and left.

Removal1) Hoist vehicle and remove wheel.
2) Release parking brake lever.
3) Remove caliper pin bolts (1).
4) Remove caliper (2) from caliper carrier.
NOTE
Hang removed caliper (2) 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.

5) Remove brake pads (1) and pad springs. Installation
1) Turn brake caliper piston clockwise to obtain clearance between brake disc and pads.
Special tool
(A): 09945–16060
2) Clean (and degrease) pad spring installation face (3) of caliper carrier (1).
3) Attach pad springs (2) to caliper carrier (1).
4) Before installing brake p ad shims (1), apply small
amount of grease (included in spare parts) to mating
surfaces of brake pad and pad shim.
5) Set pad shims (1) to brake pads (2).
1 2
I6RS0C430002-01
1
I6RS0C430003-01
(A)
I6RS0B431004-01
113
2
I6RS0B431005-03
2
1
1 2
I6RS0C430004-01