2004 SUZUKI SWIFT Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-5
4) Pass parking brake cable (1) through bracket (3) of caliper.
5) Hang parking brake cable on lever (2) as follows.
NOTE
Make sure that lever (4) contacts pin (5).

6) Install brake pads and caliper referring to “Rear Disc Brake Pad Removal and Installation”.
7) Connect flexible hose (1) with new washers to caliper (2).
WARNING!
Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.

Tightening torque
Flexible hose joint bolt (a): 23 N·m (2.3 kgf-m,
17.0 lb-ft) 8) Install brake cable clip (1) securely to bracket (2).
9) After reassembling brake lines, bleed air from them
referring to “Air Bleeding of Brake System in Section
4A”.
10) Check to make sure that system is free from fluid
leakage.
11) Start engine and then depress brake pedal with about 300 N (30 kg, 66 lbs) load 3 times or more so
as to obtain proper disc to pad clearance.
12) Check to make sure that parking brake lever stroke is as specified. Refer to “Parking Brake Inspection
and Adjustment in Section 4D”.
13) Tighten wheel nuts to specified torque.
Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
14) Remove vehicle from hoist and perform brake test (foot brake and parking brake).
1
23
45
I6RS0C430010-01
1 (a)2
I6RS0C430011-01
1
2
I6RS0C430012-01

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 Rear Brakes: 4C-7
Assembly
CAUTION!
• Wash each part cleanly before installation in the same fluid as the one used in master
cylinder reservoir.
• Never use other fluid or thinner.
• Before installing caliper to brake caliper carrier, install slide pins with grease
applied into carrier hole and check for its
smooth movement in thrust direction.
• Before installing piston seal to cylinder, apply fluid to them.
• Install a piston seal into groove in cylinder securely making sure that it is not twisted.

1) Apply thread lock cement to shaft thread (6) of caliper.
“A”: Thread lock cement 99000–32110 (Thread
Lock Cement Super 1322)
2) Apply grease to inside of new shaft cover (1).
3) Install new shaft cover, leve r (2), washer (3), parking
nut (4) and return spring (5) to caliper.
Tightening torque
Parking nut (a): 27 N·m (2.7 kgf-m, 19.5 lb-ft) 4) Install bleeder plug and cap to caliper.
5) Install new piston seal to caliper.
6) Before inserting piston (2) into cylinder, install boot
(1) onto piston as shown.
7) Fit boot as it is in figure into boot groove in cylinder with fingers.
8) Turn brake caliper piston clockwise to obtain clearance between brake disc and pads.
NOTE
Check that boot is fitted in boot groove
securely all around piston.

Special tool
(A): 09945–16060
5
4, (a)
2
3
1
6, “A”
I6RS0C430016-01
[A]: Cylinder side
[B]: Brake pad side
[A] [B]
I6RS0B431017-01
I6RS0B431033-01
I6RS0B431018-01

Downloaded from www.Manualslib.com manuals search engine 4C-8 Rear Brakes:
Rear Disc Brake Caliper InspectionS7RS0B4306006
Pin Boot and Cylinder Boot
Check boots (1) for breakage, crack and damage.
If defective, replace.
Disc Brake Piston
Check all around piston for rust, corrosion and any other
damage.
If it is found faulty, replace.
Caliper
Push in adjusting bolt (1) by hand and move lever to
check that adjusting bolt (1) moves smoothly in the
arrow direction.
Also, check adjusting bolt (1) for any damage. If it is
found faulty, replace.
Slide Pin
Check guide pin for smooth movement.
If it is found faulty, correct or replace.
Apply rubber grease to guide pin outer surface. Rubber
grease should be the one whose viscosity is less
affected by such low temperature as –40 °C (–40 ° F).
Rear Flexible Hose Removal and InstallationS7RS0B4306007
Removal
1) Hoist vehicle and remove tire and wheel.
2) Remove caliper (4) assembly referring to “Rear Disc Brake Caliper Disassembly and Assembly”.
3) Loosen brake pipe flare nut (1) using by flare nut wrench.
4) Remove clip (2).
5) Remove brake flexible hose (3) from brake pipe.
Installation
Install reverse order of removal nothing the following.
• Tighten brake pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0 lb-ft)
1 1
1
I6RS0B431019-01
I6RS0B431020-01
1
I6RS0B431021-01
1
2
3
4
I6RS0C430013-01

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-9
Rear Brake Disc Removal and InstallationS7RS0B4306008
Removal1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper
carrier bolts (1) (2 pcs).
CAUTION!
During removal, be ca reful not to damage
brake flexible hose and not to depress brake
pedal.

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.
Don’t operate brake pedal with brake pads
removed.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs). Installation
Install in reverse order of removal nothing the following.
• Tighten brake disc screws and caliper carrier bolts to
specified torque.
Tightening torque
Caliper carrier bolt (a): 60 N·m (6.0 kgf-m, 43.5 lb-
ft)
• Tighten wheel nuts to specified torque. Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
• Upon completion of installation, perform brake test.
Rear Brake Disc InspectionS7RS0B4306009
• Using magnetic stand and with dial gauge positioned at about 10 mm (0.39 in.) inward from periphery of
disc, measure deflection of disc.
If limit value is exceeded, replace correct or replace.
Rear brake disc deflection
Limit: 0.10 mm (0.004 in.) max.
Special tool
(A): 09900–20607
(B): 09900–20701
1
I6RS0C430014-01
1 1I6RS0C430017-01
(a)
I6RS0C430015-01
(B)
(A)
I6RS0B431031-01

Downloaded from www.Manualslib.com manuals search engine 4C-10 Rear Brakes:
• Using micrometer, measure thickness of brake disc.If limit value is exceeded, replace brake disc.
Rear brake disc thickness
Standard: 9 mm (0.354 in.)
Limit: 8 mm (0.315 in.)
Specifications
Tightening Torque SpecificationsS7RS0B4307001
NOTE
The specified tightening torque is also described in the following.
“Rear Disc Brake Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I6RS0B431032-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Caliper pin bolt 23 2.3 17 )
Wheel bolt 85 8.5 61.5 ) / ) / )
Brake caliper carrier bolt 60 6.0 43.5 )
Flexible hose joint bolt 23 2.3 17.0 )
Parking nut 27 2.7 19.5 )
Brake pipe flare nut 16 1.6 12.0 )
Caliper carrier bolt 60 6.0 43.5 )

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-11
Special Tools and Equipment
Recommended Service MaterialS7RS0B4308001
NOTE
Required service material is also described in the following.
“Rear Disc Brake Components”

Special ToolS7RS0B4308002
Material SUZUKI recommended product or Specification Note
Thread lock cement Thread Lock Cement Super 1322 P/No.: 99000–32110 )
09900–2060709900–20701
Dial gauge Magnetic stand
))
09945–16060
Piston installer handle
) / ) / )

Downloaded from www.Manualslib.com manuals search engine 4D-1 Parking Brake:
Brakes
Parking Brake
General Description
Parking Brake Cable ConstructionS7RS0B4401001
I6RS0B440001-01
T: Top side3. Equalizer8. Lever [C]: View [C]
F: Front side 4. Parking cable bracket9. Parking cable clamp bolt [D]: View [D]
R: Right side 5. Parking cable bracket bolt 10. Vehicle body : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
1. Parking brake lever assembly 6. Grommet [A]: View [A]: 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
2. Parking brake lever bolt 7. E-ring[B]: View [B]