2000 SUZUKI SWIFT brake system

BRAKES 5-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
5
9
10
10A
10B
SECTION 5
BRAKES
CONTENTS
GENERAL DESCRIPTION ................................ 5-2
DIAGNOSIS ....................................................... 5-4
ROAD TESTING BRAKES ............................. 5-4
BRAKE FLUID LEAKS ................................... 5-4
SUBSTANDARD OR CONTAMINATED
BRAKE FLUID ................................................ 5-4
DIAGNOSIS TABLE ....................................... 5-5
BRAKE PEDAL FREE HEIGHT
ADJUSTMENT ............................................... 5-8
BRAKE PEDAL PLAY INSPECTION ............. 5-8
STOP LIGHT SWITCH ADJUSTMENT.......... 5-8
EXCESSIVE PEDAL TRAVEL
INSPECTION ................................................. 5-9
FRONT BRAKE PAD INSPECTION .............. 5-9
BRAKE DISC INSPECTION........................... 5-9
PARKING BRAKE INSPECTION AND
ADJUSTMENT ............................................. 5-10
BOOSTER OPERATION INSPECTION....... 5-11
FLUID PRESSURE TEST (IF EQUIPPED
WITH LSPV) ................................................ 5-12
MASTER CYLINDER AND BRAKE FLUID
LEVEL INSPECTION ................................... 5-14
BRAKE HOSE AND PIPE INSPECTION ..... 5-15
HOSE ....................................................... 5-15
PIPE ......................................................... 5-15
ON-VEHICLE SERVICE .................................. 5-15AIR BLEEDING OF BRAKE SYSTEM ......... 5-15
FRONT BRAKE ........................................... 5-17
BRAKE PAD............................................. 5-17
CALIPER ASSEMBLY ............................. 5-19
BRAKE DISC ........................................... 5-23
REAR BRAKE .............................................. 5-25
BRAKE DRUM ......................................... 5-26
BRAKE SHOE .......................................... 5-29
WHEEL CYLINDER ................................. 5-30
BRAKE BACK PLATE (FOR 2WD
VEHICLE)................................................. 5-31
BRAKE BACK PLATE (FOR 4WD
VEHICLE)................................................. 5-33
MASTER CYLINDER ................................... 5-33
MASTER CYLINDER RESERVOIR ......... 5-33
MASTER CYLINDER ASSEMBLY........... 5-34
BRAKE BOOSTER ...................................... 5-38
BRAKE HOSE/PIPE .................................... 5-41
FRONT BRAKE HOSE/PIPE ................... 5-41
REAR BRAKE HOSE/PIPE...................... 5-44
PARKING BRAKE CABLE ........................... 5-46
LSPV (LOAD SENSING PROPORTIONING
VALVE) ASSEMBLY (IF EQUIPPED).......... 5-48
REQUIRED SERVICE MATERIAL.................. 5-50
SPECIAL TOOL .............................................. 5-50

NOTE:
All front fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of same
part number or with an equivalent part if replacement becomes necessary. Do not use a replacement
part of lesser quality or substitute design. Torque values must be used as specified during reassem-
bly to assure proper retention of all parts. There is to be no welding as it may result in extensive dam-
age and weakening of the metal.

5-2 BRAKES
GENERAL DESCRIPTION
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pis-
tons (two in front and four in rear).
The master cylinder is a tandem master cylinder. Brake pipes are connected to the master cylinder and they
make two independent circuits. One connects front right & rear left brakes and the other connects front left &
rear right brakes.
The load sensing proportioning valve (LSPV) or the proportioning valve (P valve) is included in these circuits
between the master cylinder and the rear brake for the vehicle without ABS.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading/trailing
shoes) for the rear brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes are used for both parking and foot brakes.

5-4 BRAKES
DIAGNOSIS
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 various 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 end alignment and front suspension attachments for loose-
ness. See diagnosis table for other causes.
BRAKE FLUID LEAKS
Check the master cylinder fluid levels. While a slight drop in reservoir level does result from normal lining wear,
an abnormally low level indicates a leak in the system. In such a case, check the entire brake system for leak-
age. If even a slight evidence 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.
If primary piston cups are swollen, then rubber parts have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the drum brake wheels.
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 conditions. 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 5-5
DIAGNOSIS TABLE
Condition Possible Cause Correction
Not enough braking
forceBrake oil leakage from brake lines Locate leaking point and repair.
Brake disc or pads stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Poor contact of shoes on brake drum Repair for proper contact.
Brake shoes linings stained with oil or wet with
waterReplace.
Badly worn brake pad linings Replace.
Defective wheel cylinders Repair or replace.
Malfunctioning caliper assembly Repair or replace.
Air in system Bleed system.
Maladjusted sensor spring length of LSPV, if
equippedCheck or adjust.
Broken sensor spring of LSPV, if equipped Replace.
Defective LSPV, if equipped Replace.
Malfunctioning ABS (Antilock brake system), if
equippedCheck system and replace as nec-
essary.
Brake pull
(Brakes not working in
unison)Pad linings and/or shoe linings are wet with
water or stained with oil in some brakesReplace.
Drum-to-shoe clearance out of adjustment in
some brakes
(Malfunctioning auto adjusting mechanism)Check for inoperative auto adjust-
ing mechanism.
Disc and/or drum is out of round in some
brakesReplace.
Wheel tires are inflated unequally Inflate equally.
Malfunction in wheel cylinders Repair or replace.
Disturbed front end 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 tub-
ing.
Malfunctioning caliper assembly Check for stuck or sluggish pistons
and proper lubrication of caliper
slide bush.
Caliper should slide.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifica-
tions.
Noise (high pitched
squeak without brake
applied)Front lining worn out Replace linings.
Contact wear indicator to brake disc Replace pads.
Rear brake locked pre-
maturelyMaladjusted sensor spring length of LSPV, if
equippedCheck or adjust.
Malfunction LSPV assembly, if equipped Replace assembly.

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

BRAKES 5-7
Brake warning lamp
lights after engine
startParking brake applied Release parking brake and check
that brake warning lamp turns off.
Insufficient amount of brake fluid Add brake fluid.
Brake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Brake warning lamp circuit faulty Repair circuit.
Malfunctioning EBD system, if equipped with
ABS.Check system referring to Table-E
of Section 5E1.
Brake warning lamp
turns on when brake
is appliedBrake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Insufficient amount of brake fluid Add brake fluid.
Brake warning lamp
fails to turn on even
when parking brake is
appliedBrake warning lamp circuit faulty Replace bulb or repair circuit.
ABS warning lamp
turns on after engine
start (If equipped)Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
turns on when brake
is applied (If
equipped)Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
does not turn on for 2
sec. after ignition
switch has turned ONBulb burnt out Replace bulb.
Malfunctioning ABS Check system referring to DIAG-
NOSIS of Section 5E1.
ABS warning lamp
flashesNew ABS hydraulic unit/control module assem-
bly installed.Perform “ABS Hydraulic Unit Oper-
ation Check”. Condition Possible Cause Correction

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”

5-10 BRAKES
PARKING BRAKE INSPECTION AND
ADJUSTMENT
INSPECTION
Hold center of parking brake lever grip and pull it up with 200 N
(20 kg, 44 lbs) force.
With parking brake lever pulled up as shown, count ratchet
notches. There should be 4 to 9 notches.
Also, check if both right and left rear wheels are locked firmly.
To count number of notches easily, listen to click sounds that
ratchet makes while pulling parking brake lever without pressing
its button.
One click sound corresponds to one notch.
If number of notches is out of specification, adjust cable referring
to adjustment procedure so as to obtain specified parking brake
store.
ADJUSTMENT
After confirming that above conditions are all satisfied, adjust
parking brake lever stoke by loosening or tightening adjust nut
(1).NOTE:
Check tooth tip of each notch for damage or wear.
If any damage or wear is found, replace parking brake
lever.
NOTE:
Make sure for the following conditions before cable
adjustment.
No air is trapped in brake system.
Brake pedal travel is proper.
Brake pedal has been depressed a few times with
about 100 N (10 kg, 22 lbs) load.
Parking brake lever is pulled up a few times with about
500 N (50 kg, 110 lbs) load.
Rear brake shoes are not worn beyond limit, and self
adjusting mechanism operates properly.
If parking brake lever stroke is less than specification,
loosen adjusting nut (1) as far as end of bolt. Then
depress brake pedal repeatedly with about 300 N (30
kg, 66 lbs) load until adjuster actuator clicking sound
can not be heard from drum brake.
NOTE:
Check brake drum for dragging after adjustment.