2000 SUZUKI SWIFT Steering

5-6 BRAKES
Excessive pedal travel
(Pedal stroke too
large)Partial brake system failure Check brake systems and repair as
necessary.
Insufficient fluid in master cylinder reservoirs Fill reservoirs with approved brake
fluid.
Check for leaks and air in brake
system.
Check warning light. Bleed system
if required.
Air in system (soft/spongy pedal) Bleed system.
Rear brake system not adjusted
(malfunctioning auto adjusting mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoes Replace brake shoes.
Worn rear brake shoes Replace brake shoes.
Brake locked
(For vehicle equipped
with ABS)Malfunctioning ABS Check system referring to Section
5E1.
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 double-walled steel
brake piping.
Incorrect parking brake adjustment on rear
brakesCheck and adjust to correct specifi-
cations.
Weakened or broken return springs in the brake Replace.
Sluggish parking brake cables or linkage Repair or replace.
Wheel cylinder or caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Pedal pulsation
(Pedal pulsates when
depressed for brak-
ing)Damaged or loose wheel bearings Replace wheel bearings.
Distorted steering knuckle or rear wheel spindle Replace knuckle or rear wheel spin-
dle.
Excessive disc lateral runout Check per instructions. If not within
specifications, replace or machine
disc.
Parallelism between pad and disc not within
specificationsCheck per instructions. If not within
specifications, replace or machine
disc.
Rear drums out of round Check runout.
Repair or replace drum as neces-
sary.
Braking noise
Glazed shoe linings, or foreign matters stuck to
liningsRepair or replace shoe linings.
Worn or distorted shoe linings Replace shoe lining (or pad).
Loose front wheel bearings Replace wheel bearing.
Distorted backing plates or loose mounting
boltsReplace or retighten securing bolts.
Contact wear indicator to brake disc Replace pads. Condition Possible Cause Correction

5-8 BRAKES
BRAKE PEDAL FREE HEIGHT ADJUSTMENT
1) Check brake pedal free height.
If it is not within specification, check and adjust following
item 1) and 2).
Brake pedal free height “a” from dash silencer
LH steering vehicle : 205 – 225 mm (8.08 – 8.85 in.)
RH steering vehicle : 217 – 237 mm (8.55 – 9.33 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
adjusted (refer to BRAKE BOOSTER INSPECTION AND
ADJUSTMENT).
3) Check stop light switch position. Adjust it if it is out of specifi-
cation.
BRAKE PEDAL PLAY INSPECTION
Pedal play should be within specification below. If out of specifi-
cation, check stop light switch for proper installation position and
adjust if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Brake pedal play
“a” : 1 - 8 mm (0.04 - 0.31 in.)
STOP LIGHT SWITCH ADJUSTMENT
Adjustment should be made as follows when installing switch.
Pull up brake pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread and
brake pedal is as specified. Then adjust stop light switch assem-
bly position and lock it by turning clockwise.
Clearance between brake pedal and stop light switch
“a” : 0.5 - 1.5 mm (0.02 -0.06 in.)
“a”
“a”

BRAKES 5-9
EXCESSIVE PEDAL TRAVEL INSPECTION
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 30 kg (66
lbs) load, measure brake pedal to wall (dash panel silencer)
clearance “a”.
If clearance “a” is less than specification, the most possible
cause is either rear brake shoes are worn out beyond limit or
air is in lines.
Should clearance “a” remain less than specification even
after replacement of brake shoes and bleeding of system,
other possible but infrequent cause is malfunction of rear
brake shoe adjusters or booster push rod length out of
adjustment.
–Bleed brake system. Refer to “AIR BLEEDING OF BRAKE
SYSTEM”.
–Remove brake drums for adjuster inspection. (Refer to
“REAR BRAKE”.) If defective, correct or replace.
Clearance “a” between brake pedal and dash panel
silencer
LH steering vehicle : over 135 mm (5.32 in.)
RH steering vehicle : over 140 mm (5.52 in.)
FRONT BRAKE PAD INSPECTION
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 thickness (“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.)
BRAKE DISC INSPECTION
Refer to “BRAKE DISC” for inspection point and procedure.
“a”

BRAKES 5-17
FRONT BRAKE
BRAKE PAD
REMOVAL
1) Loosen wheel nuts and with vehicle lifted up, remove
wheels.
2) Remove caliper pin bolts (1).
1. Brake caliper carrier 9. Bleeder plug cap
2. Boot 10. Pad spring
3. Caliper 11. Anti noise shim
4. Disc brake piston 12. Caliper pin bolt
5. Piston seal
: Apply fluid (Brake, power steering or automatic transmission fluid).13. Brake disc
6. Cylinder boot
: Apply fluid (Brake, power steering or automatic transmission fluid).14. Slide pin
: Apply lithium grease (99000-25010).
7. Brake pad Tightening torque
8. Bleeder plugDo not reuse.
9
1
7
13
2
143
1226 N·m(2.6 kg-m)
85 N·m(8.5 kg-m)
8
8.5 N·m(0.85 kg-m)
10
5 4
6
11

5-24 BRAKES
INSPECTION
Using magnetic stand and with dial gauge positioned at
about 10 mm (0.39 in.) inward from periphery of disc, mea-
sure deflection of disc.
If limit value is exceeded, replace correct or replace.
Disc deflection
Limit : 0.10 mm (0.004 in.) max.
Special tool
(A) : 09900-20606
(B) : 09900-20701
Using micrometer, measure thickness of brake disc.
If limit value is exceeded, replace brake disc.
Brake disc thickness
Standard : 17.0 mm (0.67 in.)
Limit : 15.0 mm (0.59 in.)
INSTALLATION
1) Install disc to wheel hub.
2) Install caliper assembly to steering knuckle.
3) Torque caliper carrier bolts to specification.
Tightening torque
Caliper carrier bolts (a) : 85 N·m (8.5 kg-m, 61.5 Ib-ft)
4) Torque front wheel nuts to specification.
Tightening torque
Wheel nuts (b) : 85 N·m (8.5 kg-m, 61.5 Ib-ft)
5) Upon completion of installation, perform brake test.

BRAKES 5-39
3) Remove push rod clevis pin (1).
4) Remove wiper motor. (For right-hand steering vehicle only)
5) Remove booster mounting nuts (2) and then booster.
INSTALLATION
1) Install booster (4) to dash panel. Then connect push rod cle-
vis (5) to pedal arm with clevis pin (2) and clip (6).
2) Tighten booster mounting nuts (3) to specified torque.
Tightening torque
Booster mounting nuts (a) : 13 N·m (1.3 kg-m, 9.5 lb-ft)
3) Install new master cylinder gasket to booster.
4) Install master cylinder (7) to booster and tighten mounting
nuts (8) to specified torque.
Tightening torque
Master cylinder mounting nuts (b) :
13 N·m (1.3 kg-m, 9.5 lb-ft)
5) Connect brake pipes and tighten flare nuts to specified
torque.
Tightening torque
Brake pipe flare nuts : 16 N·m (1.6 kg-m, 11.5 lb-ft)
6) Connect reservoir lead wire connector and booster vacuum
hose (1).
7) Fill reservoir with specified fluid.
8) Bleed air from brake system.
9) Perform brake test and check each installed part for fluid
leakage.
1
2
2
NOTE:
Adjust clearance between booster piston rod and mas-
ter cylinder piston. (Refer to “INSPECTION AND
ADJUSTEMENT” of “BRAKE BOOSTER”.)
Check length of push rod clevis.

BRAKES 5-41
BRAKE HOSE/PIPE
FRONT BRAKE HOSE/PIPE
REMOVAL
1) Raise and support vehicle properly. Remove tire and wheel.
2) Clean dirt and foreign material from both flexible hose end and pipe end fittings.
3) Remove brake flexible hose or pipe.
INSTALLATION
Reverse brake flexible hose installation procedure, noting the followings.
Make sure that steering wheel is in straight-forward position and flexible hose has not twist or kink.
Check to make sure that flexible hose doesn’t contact any part of suspension, both in extreme right and
extreme left turn conditions. If it does at any point, remove and correct. Fill and maintain brake fluid level in
reservoir.
Bleed brake system. Refer to “AIR BLEEDING OF BRAKE SYSTEM”.
Perform brake test and check installed part for fluid leakage. NOTE:
This operation is not necessary when removing pipes connecting master cylinder.

5-42 BRAKES
For vehicle with ABS
T : Top side [A] : For left-hand steering vehicle 4. From ABS hydraulic unit to right front brake
F : Front side [B] : For right-hand steering vehicle 5. ABS hydraulic unit
R : Right side 1. From master cylinder primary to ABS hydraulic unit 6. Master cylinder
A : View A 2. From master cylinder secondary to ABS hydraulic unit 7. Front brake hose
a-f: Clamp 3. From ABS hydraulic unit to left front brake Tightening torque