Lining SUZUKI SWIFT 2008 2.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 0B-12 Maintenance and Lubrication:
HVAC Air Filter (If Equipped) InspectionS7RS0B0206032
1) Remove HVAC air filter from HVAC unit referring to
“HVAC Air Filter Removal and Installation (If
Equipped) in Section 7A”.
2) Check for dirt and dust. If HVAC air filter is excessively dirty, replace HVAC air filter with new
one. If not, go to next step.
3) Blow compressed air on the air outlet side of HVAC air filter for removing dust.
4) Install HVAC air filter in to HVAC unit referring to
“HVAC Air Filter Removal and Installation (If
Equipped) in Section 7A”.
HVAC Air Filter (If Equipped) ReplacementS7RS0B0206033
Replace HVAC air filter with new one referring to “HVAC
Air Filter Removal and Installation (If Equipped) in
Section 7A”.
Final Inspection for Maintenance ServiceS7RS0B0206034
WARNING!
When carrying out road tests, select a safe
place where no man or no running vehicle is
seen so as to prevent any accident.

Seats
Check that seat slides smoot hly and locks securely at
any position. Also check that reclining mechanism of
front seat back allows it to be locked at any angle.
Seat Belt
Inspect belt system including webbing, buckles, latch
plates, retractors and anchors for damage or wear.
Check that seat belt is securely locked. If “REPLACE
BELT” label on seat belt is visible, replace belt.
Battery Electrolyte Level Check
Check that the electrolyte le vel of all battery cells is
between the upper and lower level lines on the case. If
battery is equipped with built-in indicator, check battery
condition by the indicator. Accelerator Pedal Operation
Check that pedal operates
smoothly without getting
caught or interfered by any other part.
Engine Start
Check engine start for readiness.
WARNING!
Before performing th e following check, be
sure to have enough room around the
vehicle. Then, firmly apply both the parking
brake and the regular brakes. Do not use the
accelerator pedal. If the engine starts, be
ready to turn off the ignition promptly. Take
these precautions because the vehicle could
move without warning and possibly cause
personal injury or property damage.

On automatic transaxle vehicles, try to start the engine in
each select lever position. The starting motor should
crank only in “P” (Park) or “N” (Neutral).
On manual transaxle vehicles, place the shift lever in
“Neutral,” depress clutch pedal fully and try to start.
On Automated Manual Transaxl e vehicles, try to start
the engine in each select le ver position. The starting
motor should crank only when select lever is in “N”
(Neutral) and brake pedal is depressed.
Exhaust System Check
Check for leakage, cracks or loose supports.
Clutch (for Manual Transaxle)
Check for the following.
• Clutch is completely released when depressing clutch pedal,
• No slipping clutch occurs when releasing pedal and accelerating.
• Clutch itself is free fr om any abnormal condition.
Gearshift or Select Lever (Transaxle)
Check gear shift or select lever for smooth shifting to all
positions and for good performance of transaxle in any
position.
With automatic transaxle or Automated Manual
Transaxle equipped vehicle, also check that shift
indicator indicates properly according to which position
select lever is shifted to.
With automatic transaxle equipped vehicle, make sure
that vehicle is at complete stop when shifting select lever
to “P” range position and release all brakes.
I4RS0A020018-01

Downloaded from www.Manualslib.com manuals search engine 4A-4 Brake Control System and Diagnosis:
Rear Brake Hose / Pipe ConstructionS7RS0B4101003
Diagnostic Information and Procedures
Brakes Diagnosis NoteS7RS0B4104001
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both light
and heavy pedal forces at vari ous speeds to determine if
the vehicle stops evenly and effectively. Also drive
vehicle to see if it leads to one side or the other without
brake application. If it does, check the tire pressure, front
wheel alignment and front suspension attachments for
looseness. See diagnosis table for other causes. Brake Fluid Leaks
Check the master cylinder fl
uid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low leve l indicates a leak in the
system. In such a case, chec k the entire brake system
for leakage. If even a slight ev idence of leakage is noted,
the cause should be corrected or defective parts should
be replaced.
Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may
cause the brake fluid to boil or the rubber components in
the hydraulic system to deteriorate.
[A]: ABS model 6. Master cylinder13. ESP® hydraulic unit
[B]: ESP ® model 7. From hydraulic unit to 4-way joint right : 11 N⋅m (11.0 kgf-m, 8.0 lb-ft)
1. From master cylinder primary to hydraulic unit 8. From hydraulic unit to 4-way joint left: 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
2. From master cylinder secondary to hydraulic unit 9. 4-way joint: 16 N⋅m (1.6 kgf-m, 11.5 lb-ft)
3. From hydraulic unit to right front brake 10.4-way joint to left rear brake hose : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft)
4. From hydraulic unit to left front brake 11. 4-way joint to right rear brake hose
5. ABS hydraulic unit 12. Master cylinder fixing nut
I6RS0C410003-01
A: View A4. Right rear brake hose8. Flexible hose joint bolt
1. To left rear brake hose 5. Left rear brake hose to left brake9. Caliper
2. To right rear brake hose 6. Right rear brake hose to right brake: 16 N⋅m (1.6 kgf-m, 12.0 lb-ft)
3. Left rear brake hose 7. Brake flexible hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-5
If deterioration of rubber is evident, disassemble all
hydraulic parts and wash with alcohol. Dry these parts
with compressed air before assembly to keep alcohol out
of the system. Replace all rubber parts in the system,
including hoses. Also, when working on the brake
mechanisms, check for fluid on the linings.
If excessive fluid is found, replace the pads. If master cylinder piston seals
are satisfactory, check for
leakage or excessive heat co nditions. If leakage is not
found, drain fluid, flush with brake fluid, refill and bleed
system.
The system must be flushed if there is any doubt as to
the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to
contaminated fluid.
Brakes Symptom DiagnosisS7RS0B4104002
Condition Possible cause Correction / Reference Item
Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair.
Brake disc or brake pad stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Badly worn brake pad Replace.
Malfunctioning caliper assembly Repair or replace.
Malfunctioning brake booster Check system and replace assembly.
Malfunctioning brake master cylinder Check system and replace as necessary.
Air in system Bleed system.
Malfunctioning ABS (ESP ®). Check system and replace as necessary.
Brake pull (Brakes not
working in unison) Brake pad and disc are wet with water or
stained with oil in some brakes Clean or replace.
Disc is out of round in some brakes Replace.
Tires are inflated unequally Inflate equally.
Disturbed front wheel alignment Adjust as prescribed.
Unmatched tires on same axle Tires with approximately the same amount of
tread should be used on the same axle.
Restricted brake pipes or hoses Check for soft hoses and damaged lines.
Replace with new hoses and new double-
walled steel brake tubing.
Malfunctioning caliper assembly Caliper should slide.
Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifications.
Noise (High pitched
squeak without brake
applied) Contact wear indicator to brake disc
Replace brake pads.
Worn brake pad Replace brake pads.
Excessive pedal travel
(Pedal stroke too large) Partial brake system failure
Check brake systems and repair as necessary.
Brake fluid leaking Repair the leaking point and bleed air.
Air in system (soft / spongy pedal) Bleed system.
Brake locked Malfunctioning ABS (ESP®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
Dragging brakes (A very
light drag is present in all
brakes immediately after
pedal is released.) Master cylinder pistons not returning
correctly
Replace master cylinder.
Restricted brake pipes or hoses Check for soft hoses or damaged pipes and
replace with new hoses and/or new brake
piping.
Incorrect parking brake adjustment on
rear brakes Check and adjust to correct specifications.
Weakened or broken return springs in
rear brakes. Replace.
Sluggish parking brake cables or linkage Repair or replace.
Brake caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Improper brake pedal free height Check brake pedal free height.

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 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-6 Front Brakes:
5) To confirm that boot is fitted in its groove in cylinder
properly, pull piston out of cylinder a little but do not
take it all out.
NOTE
Boot’s face (1) should be at the same level
from cylinder’s face (2) all around.

6) Insert piston into cylinder by hand.
Front Disc Brake Caliper InspectionS7RS0B4206007
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage.
If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate
unsmooth return of piston.
In such case, replace rubber seal.
Front Brake Disc Removal and InstallationS7RS0B4206008
CAUTION!
During removal, be care ful not to damage
brake flexible hose and not to depress brake
pedal.

Removal
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper carrier bolts (2 pcs).
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.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
I4RS0A420004-01
I2RH01420014-01
I2RH01420015-01
I2RH01420024-01
I2RH01420025-01

Downloaded from www.Manualslib.com manuals search engine 4C-6 Rear Brakes:
Rear Disc Brake Pad InspectionS7RS0B4306004
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.

Rear brake pad thickness (lining thickness)
Standard: 9.0 mm (0.354 in.)
Limit: 1.0 mm (0.039 in.)
NOTE
When pads are removed, visually inspect
caliper for brake fluid leak. Correct leaky
point, if any.

Rear Disc Brake Caliper Disassembly and
Assembly
S7RS0B4306005
Disassembly
CAUTION!
Clean around caliper with brake fluid before
disassembly.

1) Remove disc brake piston (1) by turning piston counterclockwise with special tool.
CAUTION!
Be careful not to damage inside (bore side) of
cylinder.

Special tool
(A): 09945–16060 2) Remove cylinder boot and piston seal (1).
CAUTION!
Be careful not to damage inside (bore side) of
cylinder.

3) Remove bleeder plug and cap from caliper.
4) Remove return spring (1), parking nut (2), washer
(3), lever (4) and shaft cover (5).
I6RS0B431034-01
(A)
1
I6RS0B431013-01
1
I6RS0B431014-01
1
2
3
4
5
I6RS0B431015-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-127
Direct Clutch Assembly InspectionS7RS0B5106040
Clutch Discs, Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
NOTE
• If disc lining is exfoliated, discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Direct Clutch Return Spring Subassembly
Measure free length of direct clutch return spring.
Direct clutch return spring free length
“a”: 36.04 mm (1.419 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Direct Clutch Piston
Shake direct clutch piston lightly and check that check
ball (1) is not stuck.
Blow in low pressure air (Max. 100 kPa, 1 kg/cm
2, 15 psi)
to check ball to check that there is no leakage.
I2RH0B510172-01
I2RH0B510173-01
I2RH0B510174-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-133
Forward and Reverse Clutch Assembly
Inspection
S7RS0B5106044
Clutch, Discs, Separator Plates and Retaining Plate
Check that sliding surfaces of discs, separator plates
and retaining plate are not worn hard or burnt. If
necessary, replace.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Forward Clutch Return Spring Subassembly
Measure free length of fo rward clutch return spring.
Forward clutch return spring free length
24.04 mm (0.946 in.)
NOTE
Do not apply excessive force when
measuring spring free length. Perform
measurement at several points.

Forward Clutch Piston Lip and Forward Clutch
Balancer Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
Forward Clutch Drum Lip
Check each lip for wear, deformation, cut and/or
hardening. If necessary, replace.
I2RH0B510192-01
I2RH0B510193-01
I2RH0B510194-01
I2RH0B510195-01

Downloaded from www.Manualslib.com manuals search engine Automatic Transmission/Transaxle: 5A-147
3) Install new differential side oil seal to transaxle case by using special tools.
Special tool
(A): 09924–74510
(B): 09944–88220
Differential side oil seal installing depth
“a”: 3.8 – 4.8 mm (0.15 – 0.19 in.)
4) Apply grease to oil seal lip. : Grease 99000–25030 (SUZUKI Super Grease C)
Automatic Transaxle Unit Inspection and
Adjustment
S7RS0B5106059
Inspection
Brake discs
Dry and inspect them for pitting, burn flaking, significant
wear, glazing, cracking, charring and chips or metal
particles imbedded in lining.
If discs show any of the ab ove conditions, replacement
is required.
NOTE
• If disc lining is exfoliated or discolored, replace all discs.
• Before assembling new discs, soak them in A/T fluid for at least two hours.

Brake separator plates and retaining plates
Dry plates and check for discol oration. If plate surface is
smooth and even color smear is indicated, plate should
be reused. If severe heat spot discoloration or surface
scuffing is indicated, plate must be replaced.
Brake return spring subassembly
Measure free length of each brake return spring
subassembly.
Evidence of extreme heat or burning in the area of clutch
may have caused springs to take heat set and would
require their replacement.
Free length of 1st & reverse brake return spring
subassembly
“a”: 21.71 mm (0.855 in.)
Free length of 2nd brake return spring subassembly
“a”: 15.85 mm (0.624 in.)
NOTE
• Do not apply excessive force when measuring spring free length.
• Perform measurement at several points.

I2RH0B510252-01
I2RH01510147-01
I2RH0B510253-01
I2RH0B510173-01