2006 SUZUKI SWIFT Clutch cylinder

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-5
Oil Pan and Oil Pump Strainer ComponentsS7RS0B1506004
Oil Pan and Oil Pump Strainer Removal and
Installation
S7RS0B1506005
Removal1) Remove oil level gauge.
2) Drain engine oil by removing drain plug.
3) Remove exhaust No.1 pipe (1), exhaust manifold stiffener (2) and heated oxygen sensor No.2
(connector color: green) (3) referring to “Exhaust
System Components in Section 1K”. 4) Remove clutch housing lower plate (1).
5) Remove oil pan and then oil pump strainer (1) from
cylinder block.
I4RS0A150002-01
1. Oil pan : Apply sealant 99000-31260 to mating surface. 6. Strainer bolt 11. Transaxle stiffener bolt
2. Strainer 7. Bracket bolt : 35 N ⋅m (3.5 kgf-m, 25.5 lb-ft)
3. O-ring 8. Oil pan nut : Tighten 11 N ⋅m (1.1 kgf-m, 8.0 lb-ft) by the specified
procedure.
4. Gasket 9. Oil pan bolt (M6) : 55 N ⋅m (5.5 kgf-m, 40.0 lb-ft)
5. Drain plug 10. Oil pan bolt (M10) : Do not reuse.
2
1
3
I4RS0A150003-01
1I4RS0A150004-01
I2RH0B150010-01

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System: 1E-7
6) After fitting oil pan to cylinder block, run in securing bolts and start tightening at the center: move wrench
outward, tightening one bolt at a time. Tighten bolts
and nuts to specified torque.
Tightening torque
Oil pan bolt (M6) (a): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
Oil pan bolt (M10) (c): 55 N·m (5.5 kgf-m, 40.0 lb-
ft)
Oil pan nut (e): 11 N·m (1.1 kgf-m, 8.0 lb-ft)
7) Install new gasket and drain plug to oil pan. Tighten drain plug to specified torque.
Tightening torque
Oil pan drain plug (b): 35 N·m (3.5 kgf-m, 25.5 lb-
ft)
8) Tighten transaxle stiffener bolts to specified torque. Tightening torque
Transaxle stiffener bolt (d): 55 N·m (5.5 kgf-m,
40.0 lb-ft)
9) Install exhaust manifold stiffener (2) and exhaust No.1 pipe (1) and heated oxygen sensor No.2
(connector color: green) (3) referring to “Exhaust
System Components in Section 1K”. 10) Install clutch housing lower plate (1).
11) Install oil level gauge.
12) Refill engine with engine oil referring to “Engine Oil
and Filter Change in Section 0B”.
13) Verify that there is no en gine oil leakage and exhaust
gas leakage at each connection.
Oil Pan and Oil Pump Strainer CleaningS7RS0B1506006
• Clean sealing surface between oil pan and cylinder block.
Remove oil, old sealant, and dust from sealing
surface.
• Clean oil pump strainer screen (1).(a)
(b)
(c)(e)
(d)I4RS0A150008-01
2
1
3
I4RS0A150003-01
1I4RS0A150004-01
I2RH0B150016-01

Downloaded from www.Manualslib.com manuals search engine 4A-12 Brake Control System and Diagnosis:
Master Cylinder Assembly Removal and
Installation
S7RS0B4106011
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) Clean outside of master cylinder.
2) Drain brake fluid in reservoir.
3) Remove clutch reservoir hose clamp (1) and disconnect clutch reservoir hose (3) from reservoir
(2) (M/T model).
4) Disconnect fluid level switch coupler (1) on reservoir.
5) Disconnect brake pipes (2) connected to master cylinder.
6) Remove master cylinder fixing nuts (1). 7) Remove master cylinder and master cylinder seal.
Installation 1) Install new master cylinder seal.
2) Apply small amount of silic on grease (included in
spare parts) to piston rod.
3) Install master cylinder to booster and tighten master cylinder fixing nuts (a) to specified torque.
Tightening torque
Master cylinder fixing nut (a): 15 N·m (1.5 kgf-
m, 11.0 lb-ft)
4) Connect brake pipe to master cylinder and tighten flare nuts (a) to specified torque.
Tightening torque
Brake pipe flare nut for M10 (a): 16 N·m (1.6 kgf-
m, 11.5 lb-ft)
Brake pipe flare nut for M12 (a): 19 N·m (1.9 kgf-
m, 14.0 lb-ft)
5) Connect fluid level switch connector (1) of reservoir.
3
2
1
I4RS0A410026-01
1
2
I4RS0A410013-01
1
I4RS0A410014-01
(a)I4RS0A410015-01
1
(a)
I4RS0A410016-01

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-13
6) Connect clutch reservoir hose (1) to reservoir (2) and install reservoir hose clamp (3) (M/T model).
7) Fill reservoir with specified brake fluid up to its MAX
mark.
8) After completing the work, bleed air from brake and clutch system referring to “Air Bleeding of Brake
System” and “Air Bleeding of Clutch System in
Section 5C” (M/T model).
9) Check each installed parts for fluid leakage
10) Check brake pedal for play referring to “Brake Pedal Play Inspection”.
11) Perform brake test and check fluid leakage.
Master Cylinder Reservoir Removal and
Installation
S7RS0B4106020
CAUTION!
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted
surfaces.

Removal 1) Remove windshield wiper referring to “Windshield Wiper Removal and Insta llation in Section 9D”.
2) Remove cowl top panel referring to “Cowl Top Components in Section 9K”.
3) Disconnect fluid level s witch coupler on reservoir.
4) Clean outside of reservoir.
5) Take out fluid with syringe or such.
6) Disconnect clutch reservoir hose clamp (2) and hose (3) from reservoir (1) (M/T model). 7) Remove reservoir bolt (1).
8) Remove reservoir (2) and grommets (3).
Installation 1) When using new grommets, lubricate them with the same fluid as the one to fill reservoir with. Then
press-fit grommets (1) to reservoir (2). Grommets
must be seated in place.
2) Install reservoir (2) to master cylinder with bolt (a).
Tightening torque
Reservoir bolt (a): 2.5 N·m (0.25 kgf-m, 2.0 lb-ft)
3) Connect fluid level switch coupler on reservoir.
4) Connect clutch reservoir hose (1) to reservoir (2) (M/ T model).
5) Install clutch reservoir hose clamp (3) (M/T model).
1
2
3
I4RS0A410023-01
3
1
2
I4RS0A410010-01
1 2
3I4RS0A410011-01
1 2
(a)
I4RS0A410012-01
1
2
3
I4RS0A410023-01

Downloaded from www.Manualslib.com manuals search engine 4A-14 Brake Control System and Diagnosis:
6) Fill reservoir with specified fluid.
7) After completing the work, bleed air from brake and clutch system referring to “Air Bleeding of Brake
System” and “Air Bleeding of Clutch System in
Section 5C” (M/T model).
8) Install cowl top panel referring to “Cowl Top Components in Section 9K”.
9) Install windshield wiper referring to “Windshield
Wiper Removal and Insta llation in Section 9D”.
10) Perform brake test and check each installed part for fluid leakage.
Master Cylinder Assembly Disassembly and
Assembly
S7RS0B4106013
Disassembly
1) Push in primary piston (1) to remove secondary
piston stopper pin (2) from master cylinder as
shown.
2) Remove circlip (1).
3) Remove piston guide and primary piston. Then remove secondary piston by blowing compressed air
(2) into hole. Be cautions during removal as
secondary piston jumps out.
WARNING!
Do not apply too highly compressed air
which will cause piston to jump out of
cylinder. Place a cloth to prevent piston from
damage. It should be taken out gradually with
moderately compressed air. Do not place
your fingers in front of piston when using
compressed air.

Assembly
CAUTION!
• Never use any mineral oil such as kerosene oil and gasoline when washing
and assembling parts.
• Check inside of cylinder wall, pistons and cup seals are free from any foreign objects
such as dust and dirt and use case not to
cause any damage with a tool during
assembly.
• Do not drop parts. Do not use any part which has been dropped.

1) Apply brake fluid to inside of cylinder and contact surface of piston assembly (new piston cups, new O-
ring and piston guide).
2) Install secondary return spring and secondary piston (1) into cylinder body (4).
NOTE
Align oblong hole in secondary piston (2)
with stopper pin hole (3) in master cylinder
body (4) when installing it.

3) Install primary piston assembly into cylinder body.
4) Install piston stopper pin (2) with pistons pushed in all the way and install it.
I2RH01410025-01
I4RS0A410017-01
I2RH01410027-01
I4RS0A410018-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 5-iii
Gear Shift Control Lever and Cable Components...................................................... 5B-5
Gear Shift Control Le ver and Cable Removal
and Installation .................................................. 5B-6
Gear Select Control Cable Adjustment ............... 5B-6
Back Up Light Switch Removal and Installation ......................................................... 5B-7
Back Up Light Switch Inspection ......................... 5B-7
Manual Transaxle Unit Components ................... 5B-8
Manual Transaxle Unit Dismounting and Remounting....................................................... 5B-9
Gear Shift and Sele ct Shaft Assembly
Components.................................................... 5B-11
Gear Shift and Sele ct Shaft Assembly
Removal and Installation................................. 5B-11
Gear Shift and Select Shaft Disassembly and Assembly ........................................................ 5B-12
Manual Transaxle Assembly Components........ 5B-13
Fifth Gear Disassembly and Assembly ............. 5B-14
Manual Transaxle Assembly Disassembly and Reassembly ............................................. 5B-16
Transaxle Right Case Disassembly and Assembly ........................................................ 5B-23
Transaxle Left Case Disassembly and Assembly ........................................................ 5B-24
Input Shaft and Countershaft Components....... 5B-25
Input Shaft Assembly Disassembly and Reassembly .................................................... 5B-26
Countershaft Assembly Disassembly and Reassembly .................................................... 5B-28
Synchronizer Parts Inspec tion .......................... 5B-31
Gear Shift Shaft Components ........................... 5B-31
5th and Reverse Gear Shift Shafts Disassembly and Assembly ............................ 5B-32
Gear Shift Shaft and Fork Inspection ................ 5B-32
Differential Components ................................... 5B-33
Differential Disassembly and Assembly ............ 5B-33
Specifications ..................................................... 5B-35
Tightening Torque Specifications ...................... 5B-35
Special Tools and Equipmen t ........................... 5B-36
Recommended Service Material ....................... 5B-36 Special Tool ...................................................... 5B-36
Clutch ................
.............................. ......... 5C-1
General Description .............................................5C-1
Clutch Construction .............................................5C-1
Diagnostic Information and Procedures ............5C-2 Clutch System Symptom Diagnosis ....................5C-2
Repair Instructions ........... ...................................5C-2
Clutch Pedal Inspection ......................................5C-2
Clutch Fluid Level Inspection ..............................5C-3
Air Bleeding of Clutch System.............................5C-3
Clutch Pedal Position (CPP) Switch Removal and Installation ..................................................5C-4
Clutch Pedal Position (CPP) Switch Inspection and Adjustment ................................5C-5
Clutch Fluid Pipe and Hose Components ...........5C-5
Clutch Fluid Pipe Removal and Installation.........5C-6
Clutch Fluid Pipe Inspection................................5C-6
Clutch Master Cylinder Removal and Installation .........................................................5C-6
Clutch Operating Cylinder Removal and Installation .........................................................5C-7
Clutch Operating Cylinder Inspection..................5C-7
Clutch Pedal and Clutch Pedal Bracket Components ......................................................5C-7
Clutch Cover, Clutch Disc and Flywheel Components ......................................................5C-8
Clutch Cover, Clutch Disc and Flywheel Removal and Installation ...................................5C-8
Clutch Cover, Clutch Disc and Flywheel Inspection ........................................................5C-10
Clutch Release Syst em Removal and
Installation .......................................................5C-11
Clutch Release System Inspection ...................5C-13
Specifications .................... .................................5C-13
Tightening Torque Specifications ......................5C-13
Special Tools and Equipmen t ...........................5C-14
Recommended Service Material .......................5C-14
Special Tool ......................................................5C-14

Downloaded from www.Manualslib.com manuals search engine Manual Transmission/Transaxle: 5B-3
Diagnostic Information and Procedures
Manual Transaxle Symptom DiagnosisS7RS0B5204001
Repair Instructions
Manual Transaxle Oil ChangeS7RS0B5206001
1) Before changing or inspecting oil, be sure to stop engine and lift vehicle horizontally.
2) With vehicle lifted up, check oil level and leakage. If leakage exists, correct it.
NOTE
Whenever vehicle is hoisted for any other
service work than oil change, also be sure to
check for oil leakage.

3) Remove oil filler plug (2).
4) Remove drain plug (1), and drain old oil. 5) Apply sealant to thread of drain plug (1), and tighten
it to specified torque.
“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)
Tightening torque
Transaxle oil drain plug (a): 21 N·m (2.1 kgf-m,
15.5 lb-ft)
6) Pour new specified oil unt il oil level reaches bottom
of oil filler plug hole (3) as shown in figure.NOTE
It is highly recommended to use API GL-4
75W-90 gear oil.

Transaxle oil specification
: API GL-4 (For SAE classification, refer to
viscosity chart [A] in figure.)
Manual transaxle oil capacity
Reference: 2.0 liters (4.2/3.5 US/Imp. pt)
Condition Possible cause Correction / Reference Item
Gears slipping out of
mesh Worn shift fork shaft
Replace.
Worn shift fork or synchronizer sleeve Replace.
Weak or damaged locating springs Replace.
Worn bearings on input shaft or
countershaft Replace.
Worn chamfered tooth on sleeve and
gear Replace sleeve and gear.
Hard shifting Maladjusted gear select control cable Adjust.
Inadequate or insufficient lubricant Replenish.
Improper clutch pedal free travel Replace clutch master cylinder or clutch pedal
arm.
Distorted or broken clutch disc Replace.
Damaged clutch pressure plate Replace clutch cover.
Worn synchronizer ring Replace.
Worn chamfered tooth on sleeve or gear Replace sleeve or gear.
Worn gear shift / select control cables
joint Replace.
Distorted shift shaft Replace.
Worn gear shift / select control cables Replace.
Noise Inadequate or insufficient lubricant Replenish.
Damaged or worn bearing(s) Replace.
Damaged or worn gear(s) Replace.
Damaged or worn synchronizer parts Replace.

Downloaded from www.Manualslib.com manuals search engine 5B-8 Manual Transmission/Transaxle:
Manual Transaxle Unit ComponentsS7RS0B5206008
13
6(a)
5
14(c)
114 7
(b)
12
7(b)
8
2
5 [A]
1
10
6
(a)
(a)
(b)3
9
9
(b)
(d)
I6RS0C520004-03
[A]: Forward
7. Engine left mounting bracket bolt and nuts 14. Clutch operating cylinder bolt
1. Engine 8. Clutch housing lower plate : 85 N⋅m (8.5 kgf-m, 61.5 lb-ft)
2. Transaxle 9. Engine rear mounting bracket bolts : 55 N⋅m (5.5 kgf-m, 40.0 lb-ft)
3. Engine rear mounting and bracket 10. Transaxle to engine nut : 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
4. Back up light switch connector 11. Ground cable : 11 N⋅m (1.1 kgf-m, 8.0 lb-ft)
5. Clutch operating cylinder 12. Engine left mounting bracket
6. Transaxle to engine bolt 13. Gear shift & select control cables