2006 SUZUKI SWIFT Adjust

Downloaded from www.Manualslib.com manuals search engine Wheels and Tires: 2D-2
Lower than recommended pressure can cause:
• Tire squeal on turns
• Hard Steering
• Rapid and uneven wear on the edges of the tread
• Tire rim bruises and rupture
• Tire cord breakage
• High tire temperature
• Reduced handling
• High fuel consumption
Replacement Tires
When replacement is necessary, the original equipment
type tire should be used. Refer to the Tire Placard.
Replacement tires should be of the same size, load
range and construction as those originally on the vehicle.
Use of any other size or type tire may affect ride,
handling, speedometer / odometer calibration, vehicle
ground clearance and tire or snow chain clearance to the
body and chassis.
It is recommended that new tires be installed in pairs on
the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to
equalize braking traction.
WARNING!
Do not mix different types of tires on the
same vehicle such as radial, bias and bias-
belted tires except in emergencies, because
handling may be seriously affected and may
result in loss of control.

The metric term for tire infl ation pressure is the kilo
pascal (kPa). Tire pressures is usually printed in both
kPa and kgf/cm
2 on the “Tire Placard”.
Metric tire gauges are available from tool suppliers.
The chart, shown the table, converts commonly used
inflation pressures from kPa to kgf/cm
2 and psi.
Wheels DescriptionS7RS0B2401002
Wheel Maintenance
Wheel repairs that use welding, heating, or peening are
not approved. All damaged wheels should be replaced.
Replacement Wheels
Wheels must be replaced if they are bent, dented, have
excessive lateral or radial runout, air leak through welds,
have elongated bolt holes, if lug wheel bolts won’t stay
tight, or if they are heavily rusted. Wheels with greater
runout than shown in the following may cause
objectional vibrations.
Replacement wheels must be equivalent to the original
equipment wheels in load capacity, diameter, rim with
offset and mounting configuration. A wheel of improper
size or type may affect wheel and bearing life, brake
cooling, speedometer / odometer calibration, vehicle
ground clearance and tire clearance to body and
chassis.
How to Measure Wheel Runout
To measure the wheel runout, it is necessary to use an
accurate dial indicator. The tire may be on or off the
wheel. The wheel should be installed to the wheel
balancer of the like for proper measurement.
Take measurements of both lateral runout “a” and radial
runout “b” at both inside an d outside of the rim flange.
With the dial indicator set in place securely, turn the
wheel one full revolution slowly and record every reading
of the indicator.
When the measured runout exceeds the specification
and correction by the balancer adjustment is impossible,
replace the wheel. If the reading is affected by welding,
paint or scratch, it should be ignored.
Lateral runout limit “a”
: 0.3 mm (0.012 in.)
Radial runout limit “b”
: 0.3 mm (0.012 in.)
kPa kgf/cm2psi
Conversion: 1 psi =
6.895 kPa 1 kgf/cm
2 =
98.066 kPa 160 1.6 23
180 1.8 26
200 2.0 29
220 2.2 32
240 2.4 35
260 2.6 38
280 2.8 41
300 3.0 44
I4RS0A240001-01

Downloaded from www.Manualslib.com manuals search engine 2D-9 Wheels and Tires:
2) Check tire if it can be repaired, referring to “Tire
Repair”. If it cannot be repaired, replace it with new
one.
3) Replace valve core of flat tire with new one if tire is reused after repairing.CAUTION!
Be sure to use new valve core. Otherwise, air
leak may occur due to sealant attached to
valve core.

4) Install tire to ri m of wheel, check that there is no air
leakage and adjust it to specified pressure shown on
tire placard.
Specifications
Wheels and Tires SpecificationsS7RS0B2407001
Tire size (Standard)
: 195/50R16 87V
Wheel size (Standard)
: 16x 6 J
Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
NOTE
• Tire inflation pressure should be checked when tires are cool.
• Specified tire inflation pressure should be found on tire placard or in owner’s manual which came
with the vehicle.

Tightening Torque SpecificationsS7RS0B2407002
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Fastening part
Tightening torque
Note
N ⋅mkgf-mlb-ft
Wheel nut 858.5 61.5 ) / )

Downloaded from www.Manualslib.com manuals search engine Drive Shaft / Axle: 3A-5
8) Disconnect front suspension control arm ball joint
stud from steering knuckle.
9) Pull out drive shaft joint as follows. • For differential sideUsing tire lever (1), pull out drive shaft joint (2) so
as to release snap ring fitting of joint spline at
differential side.
• For center shaft side Using plastic hammer (3), drive out drive shaft
joint (2) so as to release snap ring fitting of joint
spline at center shaft.
10) Remove drive shaft assembly. 11) Remove center bearing support bolts (3) and remove center bearing support (2) with center shaft (1) from
differential side gear. Installation
CAUTION!
• Be careful not to damage oil seals and
boots when installing drive shaft.
• Do not hit joint boot with hammer. Inserting joint only by hands is allowed.
• Make sure that differential side joint is inserted fully and its snap ring is seated as
it was.

Install drive shaft assemb ly by reversing removal
procedure and noting the following points.
• Tighten each bolt and nut to the specified torque referring to “Front Drive Shaft Assembly Components
Location”.
• Tighten brake hose mounting bolt to specified torque.
Tightening torque
Brake hose mounting bolt: 25 N·m (2.5 kgf-m,
18.0 lb-ft)
• Fill transaxle with oil as sp ecified referring to “A/T
Fluid Change in Section 5A” or “Manual Transaxle Oil
Change in Section 5B”.
• Check toe setting referring to “Front Wheel Alignment Inspection and Adjustment in Section 2B” and adjust
as required.
[A]: Differential side
[B]: Center shaft side
I6RS0C310006-01
3
2
1I2RH01310007-01

Downloaded from www.Manualslib.com manuals search engine 3A-10 Drive Shaft / Axle:
11) Fit boot (1) to grooves of shaft and housing (2) adjust
length to specification below.
12) Insert screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between housing end and small boot band)
Left side drive shaft “a”: 153.9 mm (6.05 in.)
Right side drive shaft “b”: 178.0 mm (7.00 in.)
CAUTION!
• Bend each boot band against forward rotation.
• Do not squeeze or distort boot when fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

13) Place differential side (or center shaft side) boot new big band (3) and new small band (4) onto boot
putting band outer end (1) against forward rotation
(2) as shown in figure. 14) Fasten differential side (or center shaft side) boot
band.
• For differential side (or center shaft side) boot big band (1) and small band (5).
Fasten band by drawing hooks (2) with special
tool and engage hooks (3) in slot and window (4).
Special tool
(A): 09943–57021
[A]: Drive shaft inserted into differential side
[B]: Drive shaft inserted into center shaft side
I4RS0B310004-01
I5JB0A311006-01
(A)
1 4
2 3
(A)
5 4
2 3
I6RS0B310005-02

Downloaded from www.Manualslib.com manuals search engine 3A-12 Drive Shaft / Axle:
10) Set new differential side (or center shaft side) small band and new differential side (or center shaft side)
boot on shaft temporarily.
11) Drive in the cage (1) by using special tool.
Special tool
(A): 09913–84510
12) Install circlip (1) by using snap ring pliers (2).
13) Apply grease to entire su rface of cage. Use specified
grease in tube included in spare parts.
14) Insert cage into joint housing (2) and fit snap ring (1) into groove of joint housing (2).
CAUTION!
Position opening of snap ring “c” so that it
will not be lined up with a ball.

15) Apply grease (including in spare parts) to inside of joint housing (1).
Grease color
“A”: Dark gray
Amount
“A”: 70 – 90 g (2.5 – 3.2 oz) 16) Fit boot (1) to grooves of shaft and housing (2) adjust
length to specification below.
17) Inset screw driver into boot and allow air to enter boot so that air pressure in boot becomes the same
as atmospheric pressure.
Drive shaft boot fixing position (distance
between boot end (housing side) and small boot
band center)
Left side and right side drive shafts “a”: 89.5 mm
(3.52 in.)
CAUTION!
• Band each boot band against forward rotation.
• Do not squeeze or distort boot when fastening it with bands. Distorted boot
caused by squeezing air may reduce its
durability.

(A)
1
I5RS0B310009-01
I5RS0B310010-01
I2RH01310036-01
[A]: Drive shaft inserted into differential side
[B]: Drive shaft inserted into center shaft side
I5RS0B310011-02
I5RS0B310012-01

Downloaded from www.Manualslib.com manuals search engine Table of Contents 4- i
4
Section 4
CONTENTS
Brakes
Precautions ................................................. 4-1
Precautions............................................................. 4-1
Precautions for Brakes .......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Precautions........................................................... 4A-1Precautions on Brake .......................................... 4A-1
General Description ............................................. 4A-1 Brakes Construction ............................................ 4A-1
Brake Pedal Foot Protection System Construction ...................................................... 4A-2
Front Brake Hose / Pipe Co nstruction................. 4A-3
Rear Brake Hose / Pipe Construction ................. 4A-4
Diagnostic Information and Procedures ............ 4A-4 Brakes Diagnosis Note ....................................... 4A-4
Brakes Symptom Diagnosis ................................ 4A-5
Repair Instructions .............................................. 4A-7 Brake Pedal Components ................................... 4A-7
Brake Pedal Free Height Inspection ................... 4A-7
Brake Pedal Play Inspection ............................... 4A-7
Excessive Pedal Travel Inspection ..................... 4A-8
Brake Fluid Level Inspection ............................... 4A-8
Stop Light Switch Adjustment ............................. 4A-8
Air Bleeding of Brake System ............................. 4A-9
Front Brake Hose / Pipe Removal and Installation ....................................................... 4A-10
Rear Brake Hose / Pipe Removal and Installation ....................................................... 4A-10
Brake Hose and Pipe Inspection ....................... 4A-11
Master Cylinder Components............................ 4A-11
Master Cylinder Assembly Removal and Installation ....................................................... 4A-12
Master Cylinder Rese rvoir Removal and
Installation ....................................................... 4A-13
Master Cylinder Assemb ly Disassembly and
Assembly ........................................................ 4A-14
Master Cylinder Assembly Inspection ............... 4A-15
Brake Booster Components .............................. 4A-15
Booster Operation Inspection ........................... 4A-16
Brake Booster Removal and Installation ........... 4A-17
Brake Booster Inspection and Adjustment ........ 4A-18
Specifications ..................................................... 4A-18
Tightening Torque Specifications ...................... 4A-18
Special Tools and Equipmen t ........................... 4A-18 Recommended Service Material ....................... 4A-18
Front Brakes .......
..................................... 4B-1
Repair Instructions ........... ...................................4B-1
Front Disc Brake Components ............................ 4B-1
Front Disc Brake Pad On-Vehicle Inspection ...... 4B-2
Front Disc Brake Pad Removal and Installation ......................................................... 4B-2
Front Disc Brake Pad Inspection......................... 4B-3
Front Disc Brake Ca liper Removal and
Installation ......................................................... 4B-3
Front Disc Brake Caliper Disassembly and Assembly........................................................... 4B-4
Front Disc Brake Caliper In spection.................... 4B-6
Front Brake Disc Removal and Installation ......... 4B-6
Front Brake Disc Inspection ................................ 4B-7
Specifications .................... ...................................4B-8
Tightening Torque Specifications ........................ 4B-8
Special Tools and Equipmen t .............................4B-8
Recommended Service Material ......................... 4B-8
Special Tool ........................................................ 4B-8
Rear Brakes................... ........................... 4C-1
Repair Instructions ........... ...................................4C-1
Rear Disc Brake Components.............................4C-1
Rear Disc Brake Pad Removal and Installation .........................................................4C-2
Rear Disc Brake Caliper Removal and Installation .........................................................4C-3
Rear Disc Brake Pad Inspection .........................4C-6
Rear Disc Brake Caliper Disassembly and Assembly...........................................................4C-6
Rear Disc Brake Caliper Inspection ....................4C-8
Rear Flexible Hose Remova l and Installation .....4C-8
Rear Brake Disc Removal and Installation..........4C-9
Rear Brake Disc Inspection.................................4C-9
Specifications .................... .................................4C-10
Tightening Torque Specifications ......................4C-10
Special Tools and Equipmen t ...........................4C-11
Recommended Service Material .......................4C-11
Special Tool ......................................................4C-11
Parking Brake ................. ......................... 4D-1
General Description .............................................4D-1
Parking Brake Cable Construction ......................4D-1

Downloaded from www.Manualslib.com manuals search engine 4-ii Table of Contents
Repair Instructions ..............................................4D-2Parking Brake Inspection and Adjustment ..........4D-2
Parking Brake Cable Removal and Installation ......................................................... 4D-3
Parking Brake Lever Removal and Installation ....4D-3
Specifications .... ...................................................4D-4
Tightening Torque Specifications ........................4D-4
ABS ........................................... .................4E-1
Precautions........................................................... 4E-1
Precautions in Diagnosing Troubles ................... 4E-1
Precautions in On-Vehicle Service...................... 4E-1
Precautions in Hydraulic Unit Operation Check ................................................................ 4E-1
General Description ............................................. 4E-2 ABS Description .................................................. 4E-2
ABS Hydraulic Unit / Control Module Assembly Description ....................................... 4E-2
CAN Communication System Description........... 4E-3
Schematic and Routing Diagram ........................ 4E-4 ABS Schematic ................................................... 4E-4
ABS Wiring Circuit Diagram ................................ 4E-5
Component Location ........... ................................ 4E-7
ABS Components Location ................................. 4E-7
Front Wheel Speed Sensor Components Location ............................................................ 4E-7
Rear Wheel Speed Sensor Components Location ............................................................ 4E-8
Diagnostic Information and Procedures ............ 4E-8 ABS Check .......................................................... 4E-8
ABS Warning Light Check................................. 4E-10
EBD Warning Light (Brake Warning Light) Check .............................................................. 4E-10
DTC Check........................................................ 4E-11
DTC Table ......................................................... 4E-11
DTC Clearance ................................................. 4E-12
Scan Tool Data ................................................. 4E-12
ABS Warning Light Does Not Come ON at Ignition Switch ON .......................................... 4E-13
ABS Warning Light Comes ON Steady ............. 4E-14
EBD Warning Light (Brake Warning Light) Comes ON Steady .......................................... 4E-15
Serial Data Link Circuit Check .......................... 4E-16
DTC C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-
Front / Right-Rear / Left-Rear Wheel Speed
Sensor Circuit or Sensor Ring ........................ 4E-18
DTC C1041 / C1045 / C1051 / C1055, DTC C1042 / C1046 / C1052 / C1056: Right-Front
/ Left-Front / Right-Rear / Left-Rear Inlet
Solenoid Circuit, Right-Front / Left-Front /
Right-Rear / Left-Rear Outlet Solenoid
Circuit .............................................................. 4E-20
DTC C1057: Power Source Circuit ................... 4E-21
DTC C1061: ABS Pump Motor and/or Motor Driver Circuit ................................................... 4E-22
DTC C1063: Solenoid Valve Power Supply Driver Circuit ................................................... 4E-23
DTC C1071: ABS Control Module..................... 4E-24 DTC U1073: Control Module Communication
Bus Off ............................................................ 4E-25
DTC U1100: Lost Communication with ECM (Reception Error)............................................. 4E-27
Repair Instructions ............ ................................ 4E-28
ABS Hydraulic Unit Operati on Check................ 4E-28
ABS Hydraulic Unit / Control Module
Assembly Components ...... ............................. 4E-29
ABS Hydraulic Unit / Control Module
Assembly On-Vehicle Inspection .................... 4E-29
ABS Hydraulic Unit / Control Module
Assembly Removal and Inst allation ................ 4E-29
Front / Rear Wheel Speed Sensor On-Vehicle Inspection ........................................................ 4E-31
Front Wheel Speed Sensor Removal and Installation ....................................................... 4E-32
Front Wheel Speed Sensor Inspection ............. 4E-32
Rear Wheel Speed Sensor Removal and Installation ....................................................... 4E-33
Rear Wheel Speed Sensor Inspection .............. 4E-34
Front Wheel Encoder On-Veh icle Inspection .... 4E-34
Front wheel Enco der Removal and
Installation ....................................................... 4E-34
Rear Wheel Encoder On-Veh icle Inspection..... 4E-34
Rear Wheel Encoder Removal and Installation ....................................................... 4E-34
Specifications ..................... ................................ 4E-35
Tightening Torque Specifications ...................... 4E-35
Special Tools and Equipmen t ........................... 4E-35
Special Tool ...................................................... 4E-35
Electronic Stability Prog ram ...................4F-1
Precautions ........................................................... 4F-1
Precautions in Diagnosing Troubles ................... 4F-1
Precautions in On-Vehicle Service...................... 4F-1
Precautions in Hydraulic Unit Operation Check ................................................................ 4F-1
Precautions in Sensor Calibration ....................... 4F-1
Precautions in Speedometer Test or Other Tests ................................................................. 4F-2
General Description ............................................. 4F-2 Electronic Stability Program Description ............. 4F-2
Electronic Stability Program Construction ........... 4F-3
ESP® Hydraulic Unit / Control Module
Assembly Description........................................ 4F-5
Warning Lamp, Indicator Lamp Description ........ 4F-6
CAN Communication System Description........... 4F-6
CAN Communication System For Electronic Stability Program Description ............................ 4F-7
Schematic and Routing Diagram ........................ 4F-8 Electronic Stability Program Schematic .............. 4F-8
Electronic Stability Program Wiring Circuit Diagram............................................................. 4F-9
Component Location ............ ............................. 4F-11
Electronic Stability Program Component
Location........................................................... 4F-11
Diagnostic Information and Procedures .......... 4F-12 Electronic Stability Program System Check ...... 4F-12
ESP® Warning lamp Check .............................. 4F-14

Downloaded from www.Manualslib.com manuals search engine Brake Control System and Diagnosis: 4A-5
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 co nditions. 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 Symptom DiagnosisS7RS0B4104002
Condition Possible cause Correction / Reference Item
Not enough braking force Brake oil leakage from brake lines Locate leaking point and repair.
Brake disc or brake pad stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Badly worn brake pad Replace.
Malfunctioning caliper assembly Repair or replace.
Malfunctioning brake booster Check system and replace assembly.
Malfunctioning brake master cylinder Check system and replace as necessary.
Air in system Bleed system.
Malfunctioning ABS (ESP ®). Check system and replace as necessary.
Brake pull (Brakes not
working in unison) Brake pad and disc are wet with water or
stained with oil in some brakes Clean or replace.
Disc is out of round in some brakes Replace.
Tires are inflated unequally Inflate equally.
Disturbed front wheel 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 tubing.
Malfunctioning caliper assembly Caliper should slide.
Check for stuck or sluggish pistons and proper
lubrication of caliper slide pin.
Loose suspension parts Check all suspension mountings.
Loose calipers Check and torque bolts to specifications.
Noise (High pitched
squeak without brake
applied) Contact wear indicator to brake disc
Replace brake pads.
Worn brake pad Replace brake pads.
Excessive pedal travel
(Pedal stroke too large) Partial brake system failure
Check brake systems and repair as necessary.
Brake fluid leaking Repair the leaking point and bleed air.
Air in system (soft / spongy pedal) Bleed system.
Brake locked Malfunctioning ABS (ESP®) Check system referri ng to “ABS Check in
Section 4E” or “Electronic Stability Program
System Check in Section 4F”.
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 brake
piping.
Incorrect parking brake adjustment on
rear brakes Check and adjust to correct specifications.
Weakened or broken return springs in
rear brakes. Replace.
Sluggish parking brake cables or linkage Repair or replace.
Brake caliper piston sticking Repair as necessary.
Badly worn piston seal in caliper Replace piston seal.
Improper brake pedal free height Check brake pedal free height.