2005 SUZUKI SWIFT caliper pin

Downloaded from www.Manualslib.com manuals search engine 4C-2 Rear Brakes:
Rear Disc Brake Pad Removal and InstallationS7RS0B4306002
NOTE
When replacing brake pad, replace it on the
right and left.

Removal1) Hoist vehicle and remove wheel.
2) Release parking brake lever.
3) Remove caliper pin bolts (1).
4) Remove caliper (2) from caliper carrier.
NOTE
Hang removed caliper (2) 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.

5) Remove brake pads (1) and pad springs. Installation
1) Turn brake caliper piston clockwise to obtain clearance between brake disc and pads.
Special tool
(A): 09945–16060
2) Clean (and degrease) pad spring installation face (3) of caliper carrier (1).
3) Attach pad springs (2) to caliper carrier (1).
4) Before installing brake p ad shims (1), apply small
amount of grease (included in spare parts) to mating
surfaces of brake pad and pad shim.
5) Set pad shims (1) to brake pads (2).
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(A)
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Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-3
6) With lug (1) of brake pad matched with dent (2) of brake piston, install caliper (3) to caliper carrier.
7) Tighten caliper pin bolts (4) to specified torque.
Tightening torque
Caliper pin bolt (a): 23 N·m (2.3 kgf-m, 17 lb-ft)
8) Tighten wheel bolts temporarily and lower lift.
9) Tighten wheel nuts to specified torque. Tightening torque
Wheel bolt: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
10) After completion of installation, check for brake effectiveness.Rear Disc Brake Caliper Removal and
Installation
S7RS0B4306003
CAUTION!
Do not allow brake fluid to get on painted
surfaces. Painted surfaces will be damaged
by brake fluid, flush it with water immediately
if any fluid is spilled.

Removal
1) Hoist vehicle and remove rear wheel.
2) Release parking brake lever.
3) Remove clip (1).
4) Disconnect flexible hose (1) from caliper.
4, (a) 21
3
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I6RS0C430006-01
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I6RS0C430007-01

Downloaded from www.Manualslib.com manuals search engine 4C-4 Rear Brakes:
5) Remove caliper pin bolts (1).
6) Remove caliper (2) from brake caliper carrier (3).
7) Disconnect parking brake cable (1) from lever (2) while rotating lever in direction of arrow.
8) Remove brake pads, slide pins and slide pin boots from brake caliper carrier.
9) Remove brake caliper carrier (1) from spindle (2). Installation
1) Install brake caliper ca rrier (1) to spindle (2).
Tightening torque
Brake caliper carrier bolt (a): 60 N·m (6.0 kgf-m,
43.5 lb-ft)
2) Install new slide pin boots (1) to brake caliper carrier.
3) Apply rubber grease to slide pins, then install slide pin to front side and slide pin to rear side of brake
caliper carrier.
NOTE
Be sure not to install wrongly because the
shape of slide pins are different as below.

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2
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2
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F: Vehicle front
1
2
(a)
I6RS0B431023-01
I6RS0C430009-02

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
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I6RS0C430012-01

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)
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3
4
I6RS0C430013-01

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 Parking Brake: 4D-2
Repair Instructions
Parking Brake Inspection and AdjustmentS7RS0B4406001
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 stroke.
NOTE
Check tooth tip of each notch for damage or
wear.
If any damage or wear is found, replace
parking brake lever.

Adjustment
NOTE
Make sure for the following conditions before
cable adjustment.
• No air is trapped in brake system.
• Brake pedal travel is proper.
• Start engine and then brake pedal has been depressed at least 3 times with about
160 N (16.0 kg, 35.3 lbs) load.
• Parking brake lever (1) has been pulled up a few times with about 200 N (20 kg, 44 lbs)
load.
If parking brake cable is replaced with new
one, pull up parking brake lever a few
times with about 500 N ⋅m (50 kg, 110 lbs)
force.

1) Release parking brake lever (1).
2) Loosen parking brake lever adjust nut (2) fully.
3) Make sure that lever (3) contacts pin (4).
4) Pull up parking brake lever 1 notch.
5) Rotate rear wheel by hand and fasten parking lever adjust nut until dragging rear wheel lightly.
I4RS0B440002-01
1. Parking brake cable 2. Brake caliper
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