2006 SUZUKI SWIFT Parts

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 4A-4 Brake Control System and Diagnosis:
Rear Brake Hose / Pipe ConstructionS7RS0B4101003
Diagnostic Information and Procedures
Brakes Diagnosis NoteS7RS0B4104001
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and
reasonably level roadway which is not crowned. Road
test brakes by making brake applications with both light
and heavy pedal forces at vari ous speeds to determine if
the vehicle stops evenly and effectively. Also drive
vehicle to see if it leads to one side or the other without
brake application. If it does, check the tire pressure, front
wheel alignment and front suspension attachments for
looseness. See diagnosis table for other causes. Brake Fluid Leaks
Check the master cylinder fl
uid levels. While a slight
drop in reservoir level does result from normal lining
wear, an abnormally low leve l indicates a leak in the
system. In such a case, chec k the entire brake system
for leakage. If even a slight ev idence of leakage is noted,
the cause should be corrected or defective parts should
be replaced.
Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may
cause the brake fluid to boil or the rubber components in
the hydraulic system to deteriorate.
[A]: ABS model 6. Master cylinder13. ESP® hydraulic unit
[B]: ESP ® model 7. From hydraulic unit to 4-way joint right : 11 N⋅m (11.0 kgf-m, 8.0 lb-ft)
1. From master cylinder primary to hydraulic unit 8. From hydraulic unit to 4-way joint left: 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)
2. From master cylinder secondary to hydraulic unit 9. 4-way joint: 16 N⋅m (1.6 kgf-m, 11.5 lb-ft)
3. From hydraulic unit to right front brake 10.4-way joint to left rear brake hose : 19 N⋅m (1.9 kgf-m, 14.0 lb-ft)
4. From hydraulic unit to left front brake 11. 4-way joint to right rear brake hose
5. ABS hydraulic unit 12. Master cylinder fixing nut
I6RS0C410003-01
A: View A4. Right rear brake hose8. Flexible hose joint bolt
1. To left rear brake hose 5. Left rear brake hose to left brake9. Caliper
2. To right rear brake hose 6. Right rear brake hose to right brake: 16 N⋅m (1.6 kgf-m, 12.0 lb-ft)
3. Left rear brake hose 7. Brake flexible hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)

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.

Downloaded from www.Manualslib.com manuals search engine 4A-8 Brake Control System and Diagnosis:
Excessive Pedal Travel InspectionS7RS0B4106003
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 300 N (30 kg, 66 lbs) load, measure brake pedal to wall
(dash panel silencer) clearance “a”. If clearance “a”
is less than specification, the most possible cause is
air in lines. Should clearance “a” remain less than
specification even after bleeding of system, other
possible infrequent cause is booster push rod length
out of adjustment.
• Bleed brake system. Refer to “Air Bleeding of Brake System”.
Brake arm pedal to wall clearance “a”
When pedal depressed at 300 N (30 kg, 66 lbs):
over 75 mm (2.95 in.)
Brake Fluid Level InspectionS7RS0B4106004
1) Check master cylinder, reservoir and reservoir hose (if equipped) for crack, damage and brake fluid
leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX and MIN marks on reservoir.
NOTE
Be sure to use particular brake fluid either as
indicated on reservoir cap of that vehicle or
recommended in owner’s manual which
comes along with that vehicle. Use of any
other fluid is strictly prohibited.
Fluid level should be between MIN and MAX
lines marked on reservoir.
When brake warning lamp lights sometimes
during driving, replenis h fluid to MAX level.
When fluid decreases quickly, inspect brake
system for leakage. Correct leaky points and
then refill to specified level.

CAUTION!
Do not use shock absorber fluid or any other
fluid which contains mineral oil. Do not use a
container which has been used for mineral oil
or a container which is wet from water.
Mineral oil will cause swelling and distortion
of rubber parts in hydraulic brake system and
water mixed into brake fluid will lower fluid
boiling point. Keep all fluid containers
capped to prevent contamination.

Stop Light Switch AdjustmentS7RS0B4106005
Adjustment should be made as follows. Pull up brake
pedal toward you and while holding it there, adjust
switch position so that clea rance between end of thread
and brake pedal is as specified. Then lock it by turning
clockwise.
Clearance between brake pedal and stop light switch
“a”: 1.2 – 2.2 mm (0.05 – 0.08 in.)
I6RS0C410005-02
I4RS0B410006-01
I4RS0A410007-01

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 Brake Control System and Diagnosis: 4A-15
5) Apply small amount of rubber grease (included in spare parts) to mating surface of “a” (piston cup (3)
and piston guide (1)) and “b” piston guide (1) and O-
ring (2)).
6) Apply small amount of s ilicon grease (included in
spare parts) to mating surfaces of “c” (rod seal (4)
and primary piston (5)).
7) Install piston guide (1) and circlip (6).Master Cylinder Assembly InspectionS7RS0B4106014
Inspect all disassembled parts for wear or damage, and
replace parts if necessary.
NOTE
• Wash disassembled parts with brake fluid.
• Do not reuse inner parts and rubber parts.

Inspect master cylinder bore for scoring or corrosion. It is
best to replace corroded cylinder. Corrosion can be
identified as pits or excessive roughness.
NOTE
Polishing bore of master cylinder with cast
aluminium body with anything abrasive is
prohibited, as damage to cylinder bore may
occur.

Rinse cylinder in clean brake fluid. Shake excess rinsing
fluid from cylinder. Do not use a cloth to dry cylinder, as
lint from cloth cannot be kept from cylinder bore
surfaces.
Brake Booster ComponentsS7RS0B4106015
CAUTION!
Never disassemble brake booster. Disassembly will spoi l its original function. If faulty condition is
found, replace it with new one.

I4RS0A410024-01
9
10 17
4
8
5
6
3
(b)
(a)
(b)
2
I6RS0C410010-01
1. Booster assembly 5. Clip 9. Brake master cylinder : Do not reuse.
2. Gasket 6. Booster nut 10. Master cylinder fixing nut
3. Brake vacuum hose 7. Clevis pin lock nut : Tighten 13 N⋅m (1.3 kgf-m, 9.5 lb-ft)
by the specified procedure.
4. Clevis pin 8. Push rod clevis : 15 N⋅m (1.5 kgf-m, 11.0 lb-ft)