2006 SUZUKI SWIFT Vin

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Assembly
Assemble parts in reverse order of disassembly,
observing the following instructions.
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 piston seal or cylinder boot to cylinder, apply brake fluid to them.
• Install a new piston seal into groove in cylinder securely making sure that it is not
twisted.
• Before installing caliper to carrier, check for slid pin smooth movement in thrust
direction.
• After reassembling brake lines, bleed air from them.

• Install piston seal, boot and piston to caliper referring to the following instructions.
1) Replace with a new piston seal (1) at every overhaul. After applying rubber grease (included in repair kit)
or brake fluid, fit piston seal (1) into groove in
cylinder taking care not to twist it. 2) Before inserting piston (1) into cylinder, apply rubber
grease (included in repair kit) or brake fluid to new
boot “a” and install it onto piston as shown.
3) Fit boot as it is in figure into boot groove in cylinder with fingers.
4) Insert piston into cylinder by hand and fit boot in boot groove in piston.
NOTE
Check that boot is fitted in boot groove
securely all around piston and cylinder.

I2RH01420016-01
1
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“A”: 1 grooved side directed cylinder side
“B”: 2 grooved side directed pad side
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Downloaded from www.Manualslib.com manuals search engine 4B-6 Front Brakes:
5) To confirm that boot is fitted in its groove in cylinder
properly, pull piston out of cylinder a little but do not
take it all out.
NOTE
Boot’s face (1) should be at the same level
from cylinder’s face (2) all around.

6) Insert piston into cylinder by hand.
Front Disc Brake Caliper InspectionS7RS0B4206007
Pin Boot and Cylinder Boot
Check boots for breakage, crack and damage.
If defective, replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate
unsmooth return of piston.
In such case, replace rubber seal.
Front Brake Disc Removal and InstallationS7RS0B4206008
CAUTION!
During removal, be care ful not to damage
brake flexible hose and not to depress brake
pedal.

Removal
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by removing caliper carrier bolts (2 pcs).
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.

3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
I4RS0A420004-01
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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
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1 1I6RS0C430017-01
(a)
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(B)
(A)
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Installation1) Install in reverse order of removal procedure. Check equalizer inclined angle.
Tightening torque
Parking brake lever bolt (a): 25 N·m (2.5 kgf-m,
18.0 lb-ft) 2) After all parts are installed, parking brake lever
needs to be adjusted. Refer to “Parking Brake
Inspection and Adjustment”.
3) Check brake drum or disc for dragging and brake system for proper performance. After removing
vehicle from hoist, brake test should be performed.
Specifications
Tightening Torque SpecificationsS7RS0B4407001
NOTE
The specified tightening torque is also described in the following.
“Parking Brake Cable Construction”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
I4RS0A440006-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Parking brake lever bolt 25 2.5 18.0 ) / )
Parking cable clamp bolt 11 1.1 8.0 )
Parking cable bracket bolt 25 2.5 18.0 )

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Brakes
ABS
Precautions
Precautions in Diagnosing TroublesS7RS0B4500001
To ensure that the trouble diagnosis is done accurately
and smoothly, observe the following and follow “ABS
Check”.
• Diagnostic information stored in ABS cont rol module
memory can be cleared as well as checked by using
SUZUKI scan tool. Before us ing scan tool, read its
Operator’s (Instruction) Manual carefully to have good
understanding as to what functions are available and
how to use it.
• If the vehicles was operated in any of the following ways, ABS warning light may light momentarily but
this does not indicate anything abnormal in ABS.
– The vehicle was driven with parking brake pulled.
– The vehicle was driven with brake dragging.
– The vehicle was stuck in mud, sand, etc.
– Wheel spin occurred while driving.
– Wheel(s) was rotated while the vehicle was jacked up.
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe
what is written there.
• Be sure to use the trouble diagnosis procedure as described in “ABS Check”. Failure to follow it may
result in incorrect diagnosis. (Some other diagnosis
trouble code may be stored by mistake in the memory
of ABS control module during inspection.)
• When disconnecting ABS co ntrol module connector
(1), pull down lock lever (2) of connector.
When connecting, set the connector on ABS control
module assembly and pull up the lock lever (2) until it
locks. • Communication of ECM,
BCM, ABS control module,
keyless start control module (if equipped), and
combination meter is established by CAN (Controller
Area Network).
Therefore, be sure to read “Precautions for Installing
Mobile Communication Equipment in Section 00”
before inspection and handle CAN communication
line.
Precautions in On-Vehicle ServiceS7RS0B4500002
When connector is connected to ABS control module
assembly, do not disconnect connectors of sensors with
ignition switch ON. Otherwise, DTC will be set in ABS
control module.
Precautions in Hydraulic Unit Operation CheckS7RS0B4500003
ABS hydraulic unit / control module assembly function is
checked by correct wheel lock / release condition when
brake pressure is pressurized / depressurized using
SUZUKI scan tool. The hydraulic unit operation check
referring to “ABS Hydraulic Unit Operation Check”
should be performed to confirm the correct brake pipe
connection in the following cases.
• ABS hydraulic unit / cont rol module assembly was
replaced.
• Brake pipe and/or hose ware replaced.
[A]: Disconnect C: Pull down to disconnect
[B]: Connect D: Pull up to connect
21
C D
[A]
[B]
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Rear Wheel Speed Sensor Components LocationS7RS0B4503003
Diagnostic Information and Procedures
ABS CheckS7RS0B4504001
Refer to the following items for the details of each step.
12
3
4
[A]
[B]1
1
(a)
(a)
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[A]: OK
1. Rear wheel speed sensor 3. Connector: 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
[B]: NG 2. Sensor ring 4. Grommet
StepAction YesNo
1 ) Malfunction analysis
1) Perform “Customer complaint analysis: ”.
2) Perform “Problem symptom confirmation: ”.
3) Perform “DTC check, record and clearance: ” and recheck DTC.
Is there any malfunction DTC? Go to Step 4.
Go to Step 2.
2 ) Driving test
1) Perform “Step 2: Driving Test: ”.
Is trouble symptom identified? Go to Step 3.
Go to Step 6.
3 ) DTC check
1) Perform “DTC Check”.
Is it malfunction code? Go to Step 4.
Go to Step 5.
4 ) ABS check
1) Inspect and repair referring to applicable DTC flow.
Does trouble recur? Go to Step 5.
Go to Step 7.
5 ) Brakes diagnosis
1) Inspect and repair referring to “Brakes Symptom Diagnosis in Section 4A”.
Does trouble recur? Go to Step 3.
Go to Step 7.

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Problem symptom confirmation
Check if what the customer claimed in “Customer
Questionnaire” is actually found in the vehicle and if that
symptom is found, whether it is identified as a failure.
(This step should be shared with the customer if
possible.) Check warning lights related to brake system
referring to “EBD Warning Light (Brake Warning Light)
Check” and “ABS Warning Light Check”.
DTC check, record and clearance
Perform “DTC Check” proced ure, record it and then
clear it referring to “DTC Clearance”.
Recheck DTC referring to “DTC Check”.
When DTC which is recorded at DTC check procedure is
detected again after performi ng DTC clearance, go to
“Step 4: ABS Check: ” to proceed the diagnosis.
When DTC which is recorded at DTC check procedure is
not indicated anymore after performing DTC clearance,
ABS control module does not perform the system
diagnosis, or temporary abnormality may occur,
therefore go to “Step 2: Driving Test: ” to proceed the
diagnosis.
Step 2: Driving Test
Test drive the vehicle at 40 km/h for more than a minute
and check if any trouble symptom (such as abnormal
lighting of ABS warn ing light) exists.
If the malfunction DTC is co nfirmed again at ignition
switch ON, driving test as described is not necessary.
Proceed to Step 3.
Step 3: DTC Check
Recheck DTC referring to “DTC Check”.
Step 4: ABS Check
According to ABS Check for the DTC confirmation in
Step 3, locate the cause of the trouble, namely in a
sensor, switch, wire harness, connector, actuator
assembly or other part and repair or replace faulty parts.
Step 5: Brakes Diagnosis
Check the parts or system suspected as a possible
cause referring to “Brakes Symptom Diagnosis in
Section 4A” and based on symptoms appearing on the
vehicle (symptom obtained through Steps 1 and 2 and
repair or replace faulty parts, if any).
Step 6: Check for Intermittent Problem
Check parts where an intermittent trouble is easy to
occur (e.g., wire harness, con nector, etc.), referring to
“Intermittent and Poor Connection Inspection in Section
00” and related circuit of trouble code recorded in Step 1
to 3.
Step 7: Final Confirmation Test
Confirm that the problem symptom has gone and the
ABS is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear
the DTC once referring to “DTC Clearance” and perform
test driving and confirm that no DTC is indicated.ABS Warning Light CheckS7RS0B4504002
1) Turn ignition switch ON.
2) Check that ABS warning light (1) comes ON for
about 2 seconds and then goes off.
If any faulty condition is found, advance to “ABS
Warning Light Does Not Come ON at Ignition Switch
ON” or “ABS Warning Light Comes ON Steady”.
EBD Warning Light (Brake Warning Light)
Check
S7RS0B4504003
NOTE
Perform this check on a level place.

1) Turn ignition switch ON with parking brake applied.
2) Check that EBD warning lig ht (brake warning light)
(1) is turned ON.
3) Release parking brake with ignition switch ON and check that EBD warning lig ht (brake warning light)
goes off.
If it doesn’t go off, go to “EBD Warning Light (Brake
Warning Light) Comes ON Steady”.
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BRAKE
1
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DTC ClearanceS7RS0B4504006
WARNING!
When performing a driving test, select a safe
place where there is neither any traffic nor
any traffic accident possibility and be very
careful during testing to avoid occurrence of
an accident.

After repair or replace malfunction part(s), clear all DTCs
by performing the following procedure or using SUZUKI
scan tool.
1) Connect SUZUKI scan tool to data link connector in the same manner as when making this connection
for DTC check.
2) Turn ignition switch to ON position.
3) Erase DTC according to instructions displayed on scan tool. Refer to scan tool operator’s manual for
further derails.
NOTE
For DTC C 1021, C1022, C1025, C1026, C1031,
C1032, C1035, C1036 and C1061, confirm that
ABS warning light turns off after performing
Step 2 of “Test Driving” under “ABS Check”,
and then clear the DTCs.

4) After completing the clear ance, turn ignition switch
OFF and disconnect scan tool from data link
connector.
5) Perform “Driving Test” (S tep 2 of “ABS Check”) and
“DTC Check” and confirm that NO DTC is displayed
on scan tool.
Scan Tool DataS7RS0B4504007
The parameter data below are values measured with the
scan tool when the normally operating vehicle is under
the following conditions. When taking measurements for
comparison by using the scan tool, be sure to check that
the vehicle is under the following conditions.
• Apply parking brake and block wheels.
• Ignition switch ON.
• Turn OFF air conditioner (if equipped).
• Apply no load to power steering (if equipped). (Don’t turn it)
• Turn OFF all electric loads (except ignition).
• No DTC.
• ABS is not operated. (N ormal braking operation)
Scan Tool Data Definition
Battery Volt (V): Battery Voltage is an analog input
signal read by the ABS control module. Certain ABS
control module function s will be modified if the
battery voltage falls below or rises above
programmed thresholds.
Pump Motor Driver (V): This parameter indicates the
operational condition of the pump motor driver
(transistor).
RF Wheel Speed, LF Wheel Speed, RR Wheel Speed and LF Wheel Speed (km/h, MPH): Wheel speed
is an ABS control module inte rnal parameter. It is
computed by reference pulses from the wheel speed
sensor.
Brake Switch (ON, OFF): This switch signal informs
the ABS control modu le whether the brake is active
or not.
Scan Tool
Data Standards Condition
Battery
Voltage 10.0 – 18.0 V —
Pump Motor
Driver 0.0 V —
RF Wheel
Sp ee d 0 km/h, 0.0 MPH Vehicle stop
LF Wheel
Sp ee d 0 km/h, 0.0 MPH Vehicle stop
RR Wheel
Sp ee d 0 km/h, 0.0 MPH Vehicle stop
LR Wheel
Sp ee d 0 km/h, 0.0 MPH Vehicle stop
Brake Switch ONBrake pedal
depressed
OFF Brake pedal released