brake SUZUKI SWIFT 2017 5.G Service Manual

INSPECTION AND MAINTENANCE
INSPECTION AND MAINTENANCE
Maintenance Schedule ....................................................... 7-2
Periodic Maintenance Schedule ........................................ 7-2
Drive Belt ............................................................................. 7-6
Engine Oil and Filter ........................................................... 7-6
Engine Coolant .................................................................... 7-10
Air Cleaner ........................................................................... 7-11
Spark Plugs (Petrol Engine)................................................ 7-11
Gear Oil ................................................................................ 7-13
Clutch Pedal ........................................................................ 7-14
Fuel Filter (Diesel Engine) .................................................. 7-15
Brakes .................................................................................. 7-16
7
Steering ................................................................................ 7-17
Tires ...................................................................................... 7-18
Battery .................................................................................. 7-20
Fuses .................................................................................... 7-22
Bulb Replacement ............................................................... 7-24
Wiper Blades ....................................................................... 7-28
Windshield Washer Fluid ................................................... 7-30
Air Conditioning System .................................................... 7-30
74LH0-74E

7-1INSPECTION AND MAINTENANCE
74LH0-74E
60B128S
WA R N I N G
You should take extreme care when
working on your vehicle to prevent
accidental injury. Here are a few pre-
cautions that you should be espe-
cially careful to observe:
To prevent damage or unintended
activation of the air bag system or
seat belt pretensioner system, be
sure the battery is disconnected and
the ignition switch has been in the
“LOCK” position for at least 90 sec-
onds before performing any electri-
cal service work on your vehicle. Do
not touch air bag system compo-
nents, seat belt pretensioner system
components or wires.
The wires are wrapped with yellow
tape or yellow tubing, and the cou-
plers are yellow for easy identifica-
tion.
Do not leave the engine running in
garages or other confined areas.
(Continued)
WA R N I N G
(Continued)
When the engine is running, keep
hands, clothing, tools, and other
objects away from the fan and drive
belt. Even though the fan may not
be moving, it can automatically
turn on without warning.
When it is necessary to do service
work with the engine running, make
sure that the parking brake is set
fully and the transmission is in
Neutral.
Do not touch ignition wires or other
ignition system parts when starting
the engine or when the engine is
running, or you could receive an
electric shock.
Be careful not to touch a hot
engine, exhaust manifold and
pipes, muffler, radiator and water
hoses.
Do not allow smoking, sparks, or
flames around fuel or the battery.
Flammable fumes are present.
Do not get under your vehicle if it is
supported only with the portable
jack provided in your vehicle.
Be careful not to cause accidental
short circuits between the positive
and negative battery terminals.
(Continued)
WA R N I N G
(Continued)
Keep used oil, coolant, and other
fluids away from children and pets.
Dispose of used fluids properly;
never pour them on the ground,
into sewers, etc.

7-4
INSPECTION AND MAINTENANCE
74LH0-74E
4-3.
Transmission Oil (Manual / Auto Gear Shift)
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Replace at 1,60,000 km or 10 years whichever comes first
4-4. Automatic Transmission Fluid (Level, Leakage) Replace at 1,65,000 km or 11years whichever comes first
4-5.
Hose, Automatic Transmission Fluid
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Drive shaft
5-1.
Drive shaft boot (boot damage)
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BRAKE
6-1.
Brake Fluid (Level, Leakage)
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R
6-2. Brake pedal (pedal - carpet clearance) I I I I I I I I I I
6-3.
Parking brake lever and cable (Play, damage)
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6-4. Brake disc and pad (Wear) – I I I I I I I I I
6-5.
Brake drum and shoes (Wear)
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–
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6-6.Master cylinder, wheel cylinder, caliper piston
(Fluid leakage, boot/seal damage)IIIIIIIIII
6-7.
Brake hoses and pipes (Fluid leakage, damage)
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WHEEL
7-1.
Tires (air pressure, abnormal wear, crack and rotation)
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I&O
I&O
I&O
I&O
I&O
I&O
I&O
I&O
I&O
7-2. Wheels (Damage) I I I I I I I I I I
7-3.
Front/Rear wheel bearing (Loose, damage)
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FRONT / REAR SUSPENSION
8-1.
Suspension strut (Oil leakage, damage)
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8-2. Suspension arms / Knuckle support (Loose, damage) – I I I I I I I I I
8-3.
Rear spring (Damage)
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8-4. Shock absorbers (Oil leakage, damage) I I I I I I I I I I
8-5.
All bolts and nuts (Loose)
–
T
T
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T
T
T
T
T
T
8-6. Suspension arms and torsion rods – I I I I I I I I I
STEERING
9-1. Steering wheel (Play, loose) I I I I I I I I I IInterval: This interval should be judged by odometer reading
or months, whichever comes first.
FREE INSPECTION
PERIODIC MAINTENANCE AT COST
km (x1000)
1
5
10
20
30
40
50
60
70
80
months
1
6
12
24
36
48
60
72
84
96
Drive Belt: 1, 2
Engine Oil and Filter: 1, 2

7-5INSPECTION AND MAINTENANCE
74LH0-74E
9-2.
All rods and arms (Loose, damage, wear)
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10-1. Battery electrolyte (Level, leakage) I I I I I I I I I I
ELECTRICAL
10-2. Wiring harness connection (Loose, damage)
–
I I I I I I I I I10-3.
Lightening system (Operation, stains, damage)
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10-4. Horn (Operation) I I I I I I I I I I
10-5.
System Voltage
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BODY
11-1.
All chassis bolts and nuts (Tighten)
–
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T
T
11-2. All latches, hinges and locks (Function)) I I&L I&L I&L I&L I&L I&L I&L I&L I&L
ROAD TEST12-1.
Operation of Brakes, gear shifting and speedometer
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12-2.
Body and chassis noise
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AIR CONDITIONER (If equipped)
13-1.
Check belt tension
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13-2. Tighten compressor mounting bolt
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T T T T T T T T T
13-3.
All hose joint (Check, tighten)
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13-4. Check functioning of Recirc flap I I I I I I I I I I
13-5.
Clean condenser with low pressure water
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C
C
C
C
C
C
C
C
C
13-6. Check belt for frayed edges I I I I I I I I I I
13-7.
Check all mounting bolts
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13-8. Air conditioner filter element (if equipped) I I I I R I I R I I
Interval: This interval should be judged by odometer reading
or months, whichever comes first.
FREE INSPECTION
PERIODIC MAINTENANCE AT COST
km (x1000)
1
5
10
20
30
40
50
60
70
80
months
1
6
12
24
36
48
60
72
84
96
Engine Oil and Filter: 1, 2

7-13INSPECTION AND MAINTENANCE
74LH0-74E
60D204
NOTE:
If your engine is equipped with the high
tension cord type ignition wiring and you
experience some firing problem of spark
plugs, such as, hard engine-starting, mis-
fire etc., the cause may be located not only
on spark plugs but also on deteriorated
ignition wirings (generally, used for more
than 80,000 km or five years). If spark plug
replacement does not solve the problem,
have the ignition wiring and other ignition
system inspected by your MARUTI
SUZUKI dealer.Gear OilManual Transaxle Oil / Auto Gear
Shift OilWhen adding gear oil, use gear oil with the
appropriate viscosity and grade.
We highly recommend you use:
"MARUTI SUZUKI GEAR OIL 75W-80" for
manual transaxle gear oil or Auto Gear
Shift Oil.
Gear Oil Level CheckManual transmission
74LHT0714
(1) Oil filler and level plug
(for Petrol engine model)
(2) Oil filler and level plug
(for diesel engine model)
To check the gear oil level, use the fol-
lowing procedure:
1) Park the vehicle on a level surface with
the parking brake applied. Then, stop
the engine.
2) Remove the oil filler plug (1) or (2) .
3) Check the inside of the hole with your
finger. If the oil level comes up to the
bottom of the plug hole, the oil level is
correct. If so, reinstall the plug.
4) If the oil level is low, add gear oil
through the oil filler plug hole (1) or (2)
until the oil level reaches the bottom of
the filler hole, then reinstall the plug.
Tightening torque for oil filler plug
(1) or (2)
21 Nm (2.1 kg-m, 15.2 lb-ft)
Gear Oil ChangeSince special procedures, materials and
tools are required, it is recommended that
you trust this job to your MARUTI SUZUKI
authorized dealer.
(1)
(2)
EXAMPLE
CAUTION
After driving the vehicle, the trans-
mission oil temperature may be high
enough to burn you. Wait until the oil
filler plug is cool enough to touch
with your bare hands before inspect-
ing transmission oil level.
NOTICE
When tightening the plug, apply the
following sealing compound or
equivalent to the plug threads to pre-
vent oil leakage.
SUZUKI Bond No. “1216E” or “1217G”
Engine Coolant: 1, 2

7-14
INSPECTION AND MAINTENANCE
74LH0-74E
Clutch Pedal
Cable Control Clutch (For Petrol
Engine Model)
54G274
Clutch pedal play “d”:
10 - 15 mm (0.4 - 0.6 in.)
Measure the clutch pedal play by moving
the clutch pedal with your hand and mea-
suring the distance it moves until you feel
slight resistance. The play in the clutch
pedal should be between the specified val-
ues. If the play is more or less than the
above, or clutch dragging is felt with the
pedal fully depressed, have the clutch
inspected by your MARUTI SUZUKI autho-
rized dealer.
Fluid Control Clutch (For Diesel
Engine Model)
68LM703
Check the clutch pedal for smooth opera-
tion and clutch fluid level from time to time.
If clutch dragging is felt with the pedal fully
depressed, have the clutch inspected by
your MARUTI SUZUKI dealer. If the clutch
fluid level is near the “MIN” line, fill it up to
the “MAX” line with Maruti Genuine Brake
Fluid (MGBF) or DOT 3.
We highly recommend to use “Maruti Gen-
uine Brake Fluid” (MGBF).
Automatic Transaxle (AT) Fluid
Specified Fluid
Use an automatic transaxle fluid SUZUKI
ATF 3317 or Mobil ATF 3309.
Fluid Level Check
You must check the fluid level with the
automatic transaxle fluid at normal operat-
ing temperature.
To check the fluid level:
1) To warm up the transaxle fluid, drive the
vehicle or idle the engine until the tem-
perature gauge indicates normal oper-
ating temperature.
2) Then drive for ten more minutes.NOTE:
Do not check the fluid level if you have just
driven the vehicle for a long time at high
speed, if you have driven in city traffic in
hot weather, or if the vehicle has been pull-
ing a trailer. Wait until the fluid cools down
(about 30 minutes), or the fluid level indi-
cation will not be correct.
3) Park your vehicle on level ground.
4) Apply the parking brake and then start
the engine in “P” (Park). Let it idle for
two minutes and keep it running during
the fluid level check.
5) With your foot on the brake pedal, move
the gearshift lever through each range,
pausing for about three seconds in
each range. Then move it back to the
“P” (Park) position.
EXAMPLE
NOTICE
Driving with too much or too little
fluid can damage the transaxle.
NOTICE
Be sure to use the specified auto-
matic transaxle fluid. Using auto-
matic transaxle fluid other than
SUZUKI ATF 3317 or Mobil ATF 3309
may damage the automatic transaxle
of your vehicle.
EXAMPLE
Windshield Washer Fluid: 3
Air Cleaner: 1, 2

7-15
INSPECTION AND MAINTENANCE
74LH0-74E
6) The handle of the A/T fluid dipstick is
colored red for easy identification.
Remove the dipstick, clean it and push
it back in until the cap seats. Then pull
out the dipstick.
7) 7) Check both sides of the dipstick, and
read the lowest level. The fluid level
should be between the two marks in the
“HOT” range on the dipstick.(1) FULL HOT
(2) LOW HOT
(3) The lowest point = Fluid level
8) Add just enough specified fluid through
the dipstick hole to fill the transaxle oil
to the proper level.
Changing Oil
Since special procedures, materials, and
tools are required to change the automatic
transaxle oil, it is recommended that you
trust this job to your authorized MARUTI
SUZUKI dealer.
Fuel Filter (Diesel Engine)
74LHT0703
The fuel filter works as a water sedimentor
as well.
Drain water according to the Periodic
Maintenance Schedule. To drain water:
1) Remove the battery. (Refer to “Battery”
in this section.)
2) Place a pan or ample rag under the fuel
filter drain nozzle.
3) Loosen the drain knob. The water will
be drained.
4) Tighten the drain knob when the water
changes to the diesel fuel.
5) Tighten the drain knob.
Tightening torque for drain knob
1.5 Nm (0.15 kg-m, 1.1 lb-ft)
NOTE:
Trust this job to be carried out at Maruti
Suzuki authorized dealer.
WA R N I N G
Be sure to depress the brake pedal
when moving the gearshift lever, or
the vehicle can move suddenly.
EXAMPLE
(1)(2) (3)(1)
(2)(3)
EXAMPLE
NOTICE
After checking or adding oil, be sure
to insert the dipstick securely.
Air Cleaner: 1, 2
Spark Plugs: 1, 2

7-16
INSPECTION AND MAINTENANCE
74LH0-74E
Brakes
Brake Fluid
68LM703
Check the brake fluid level by looking at
the reservoir in the engine compartment.
Check that the fluid level is between the
“MAX” and “MIN” lines. If the brake fluid
level is near the “MIN” line, fill it up to the
“MAX” line with Maruti Genuine Brake
Fluid (MGBF) or DOT 3.
We highly recommend to use “Maruti Gen-
uine Brake Fluid” (MGBF).NOTE:
With disc brakes, the fluid level can be
expected to gradually fall as the brake
pads wear.
Brake PedalCheck if the brake pedal stops at the regu-
lar height without “spongy” feeling when
you depress it. If not, have the brake sys-
tem inspected by your MARUTI SUZUKI
dealer. If you doubt the brake pedal for the
regular height, check it as follows:
54G108
WA R N I N G
Failure to follow the guidelines below
can result in personal injury or seri-
ous damage to the brake system.
If the brake fluid in the reservoir
drops below a certain level, the
brake warning light on the instru-
ment panel will come on (the
engine must be running with the
parking brake fully disengaged).
Should the light come on, immedi-
ately ask your MARUTI SUZUKI
dealer to inspect the brake system.
A rapid fluid loss indicates a leak in
the brake system which should be
inspected by your MARUTI SUZUKI
dealer immediately.
Do not use any fluid other than
Maruti Genuine Brake Fluid (MGBF)
or DOT 3. Do not use reclaimed
fluid or fluid that has been stored in
old or open containers. It is essen-
tial that foreign particles and other
liquids are kept out of the brake
fluid reservoir.
CAUTION
Brake fluid can harm your eyes and
damage painted surfaces. Use cau-
tion when refilling the reservoir.
WA R N I N G
Brake fluid is harmful or fatal if swal-
lowed, and harmful if it comes in con-
tact with skin or eyes. If swallowed,
do not induce vomiting. Immediately
contact a poison control center or a
physician. If brake fluid gets in eyes,
flush eyes with water and seek medi-
cal attention. Wash thoroughly after
handling. Solution can be poisonous
to animals. Keep out of the reach of
children and animals.
Spark Plugs: 1, 2

7-17INSPECTION AND MAINTENANCE
74LH0-74E
Pedal to floor carpet minimum dis-
tance “a”: 68 mm (2.7 in.)
With the engine running, measure the dis-
tance between the brake pedal and floor
carpet when the pedal is depressed with
approximately 30 kg (66 lbs) of force. The
minimum distance required is as specified.
Since your vehicle’s brake system is self-
adjusting, there is no need for pedal
adjustment.
If the pedal to floor carpet distance as
measured above is less than the minimum
distance required, have your vehicle
inspected by your MARUTI SUZUKI
dealer.
NOTE:
When measuring the distance between the
brake pedal and floor carpet, be sure not to
include the floor mat or rubber on the floor
carpet in your measurement.
60G104S
Parking Brake
54G109
Ratchet tooth specification “b”:
4th – 9th
Lever pull force (1):
200 N (20 kg, 44 lbs)
Check the parking brake for proper adjust-
ment by counting the number of clicks
made by the ratchet teeth as you slowly
pull up on the parking brake lever to thepoint of full engagement. The parking
brake lever should stop between the speci-
fied ratchet teeth and the rear wheels
should be securely locked. If the parking
brake is not properly adjusted or the
brakes drag after the lever has been fully
released, have the parking brake inspected
and/or adjusted by your MARUTI SUZUKI
dealer.
Steering
68LM708
Steering wheel play “c”:
0 – 30 mm (0.0 – 1.2 in.)
Check the play of the steering wheel by
gently turning it from left to right and mea-
suring the distance that it moves before
you feel slight resistance. The play should
be between the specified values.
WA R N I N G
If you experience any of the following
problems with your vehicle’s brake
system, have the vehicle inspected
immediately by your MARUTI SUZUKI
dealer.
Poor braking performance
Uneven braking (brakes not work-
ing uniformly on all wheels.)
Excessive pedal travel
Brake dragging
Excessive noise
EXAMPLE
“c”
EXAMPLE
Fuel Filter (diesel engine):
Brakes: 6

7-18
INSPECTION AND MAINTENANCE
74LH0-74E
Check that the steering wheel turns easily
and smoothly without rattling by turning it
all the way to the right and to the left while
driving very slowly in an open area. If the
amount of free play is outside the specifi-
cation or you find anything else to be
wrong, an inspection must be performed
by your MARUTI SUZUKI dealer.Tires
74LHT0704
The front and rear tire pressure specifica-
tions for your vehicle are listed on the Tire
Information Label. Both the front and rear
tires should have the specified tire pres-
sure.Tire InspectionInspect your vehicle’s tires at least once a
month by performing the following checks:
1) Measure the air pressure with a tire
gauge. Adjust the pressure if neces-
sary. Remember to check the spare
tire, too.
54G136
(1) Tread wear indicator
(2) Indicator location mark2) Check that the depth of the tread
groove is more than 1.6 mm (0.06 in.).
To help you check this, the tires have
molded-in tread wear indicators in the
grooves. When the indicators appear
on the tread surface, the remaining
depth of the tread is 1.6 mm (0.06 in.)
or less and the tire should be replaced.
3) Check for abnormal wear, cracks and
damage. Any tires with cracks or other
damage should be replaced. If any tires
show abnormal wear, have them
inspected by your MARUTI SUZUKI
dealer.
4) Check for loose wheel nuts.
5) Check that there are no nails, stones or
other objects sticking into the tires.
EXAMPLE
WA R N I N G
Air pressures should be checked
when the tires are cold or you may
get inaccurate readings.
Check the inflation pressure from
time to time while inflating the tire
gradually, until the specified pres-
sure is obtained.
Never underinflate or overinflate
the tires.
Underinflation can cause unusual
handling characteristics or can
cause the rim to slip on the tire
bead, resulting in an accident or
damage to the tire or rim.
Overinflation can cause the tire to
burst, resulting in personal injury.
Overinflation can also cause
unusual handling characteristics
which may result in an accident.EXAMPLE
CAUTION
Hitting curbs and running over rocks
can damage tires and affect wheel
alignment. Be sure to have tires and
wheel alignment checked periodi-
cally by your MARUTI SUZUKI dealer.
Brakes: 6