2008 SUZUKI SWIFT 001

Downloaded from www.Manualslib.com manuals search engine 4B-4 Front Brakes:
Installation1) Torque caliper pin bolts (a) to specification.
NOTE
• Make sure that boots are fit into groove securely.
• If brake pads are replaced, use new caliper pin bolts included in repair kit. (if included)

Tightening torque
Caliper pin bolt (a): 26 N·m (2.6 kgf-m, 19.0 lb-ft)
2) Connect caliper to flexible hose.
3) Torque flexible hose jo int bolt to specification.
Tightening torque
Flexible hose joint bolt (b): 23 N·m (2.3 kgf-m,
17.0 lb-ft)
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.

4) Tighten bleeder plug to specified torque. Tightening torque
Bleeder plug (c): 8.0 N·m (0.8 kgf-m, 6.0 lb-ft)
5) Lower hoist and torque wheel nuts to specifications. Tightening torque
Wheel nut: 85 N·m (8.5 kgf-m, 61.5 lb-ft)
6) After completing installation, fill reservoir with brake
fluid and bleed air from brake system referring to “Air
Bleeding of Brake System in Section 4A”.
7) Check each installed part for fluid leakage.
8) Perform brake test and check fluid leakage.
Front Disc Brake Caliper Disassembly and
Assembly
S7RS0B4206006
Disassembly
CAUTION!
• Clean around caliper with brake fluid before disassembly.
• Be careful not to damage inside (bore side) of cylinder.

1) Remove piston with air blown into flexible hose bolt installation hole.
WARNING!
Do not apply too highly compressed air
which will cause piston to jump out of
cylinder. Place a cloth (1) 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.

2) Remove cylinder boot.
3) Remove piston seal using a thin blade like a thickness gauge, etc.
4) Remove bleeder plug and cap from caliper.
(a)
I4RS0A420003-01
I6RS0C420004-01
I2RH01420011-01
I2RH01420013-01

Downloaded from www.Manualslib.com manuals search engine Front Brakes: 4B-5
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
I2RH01420017-01
“A”: 1 grooved side directed cylinder side
“B”: 2 grooved side directed pad side
I4RS0A420006-01
I2RH01420019-01
I2RH01420020-01

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
I2RH01420014-01
I2RH01420015-01
I2RH01420024-01
I2RH01420025-01

Downloaded from www.Manualslib.com manuals search engine 4B-8 Front Brakes:
Specifications
Tightening Torque SpecificationsS7RS0B4207001
NOTE
The specified tightening torque is also described in the following.
“Front Disc Brake Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Service MaterialS7RS0B4208001
NOTE
Required service material is also described in the following.
“Front Disc Brake Components”

Special ToolS7RS0B4208002
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Caliper pin bolt 26 2.6 19.0 ) / )
Wheel nut 85 8.5 61.5 ) / ) / )
Flexible hose joint bolt 23 2.3 17.0 )
Bleeder plug 8.0 0.8 6.0 )
Caliper carrier bolt 85 8.5 61.5 )
09900–2060709900–20701
Dial gauge Magnetic stand
))

Downloaded from www.Manualslib.com manuals search engine Rear Brakes: 4C-1
Brakes
Rear Brakes
Repair Instructions
Rear Disc Brake ComponentsS7RS0B4306001
(d)
(c)
(a)
(a)
(a)16171413
2
1
15 2 19
12
117
7
3
7
4
20 20
5
10
9
8
(b)
18
6
24
23
22
21
I7RS0B430001-01
1. Caliper
11. Brake caliper carrier21. Shaft cover
: Apply rubber grease.
2. Caliper pin bolt 12. Caliper carrier bolt22. Lever
3. Boot 13. Rear caliper bleeder plug23. Washer
4. No.1 slide pin : Apply rubber grease. 14. Bleeder plug cap
24. Parking nut
5. Brake pad 15. Brake flexible hose: 23 N⋅m (2.3 kgf-m, 17.0 lb-ft)
6. Return spring 16. Flexible hose joint bolt: 27 N⋅m (2.7 kgf-m, 19.5 lb-ft)
7. Pad spring 17. Hose washer: 60 N⋅m (6.0 kgf-m, 43.5 lb-ft)
8. Disk brake piston : Apply brake fluid to contact surface of cylinder. 18. Brake disc
: 9 N⋅m (0.9 kgf-m, 6.5 lb-ft)
9. Piston seal : Apply small amount of brake fluid to all around part of piston seal. 19. No.2 slide pin
: Apply rubber grease. : Do not reuse.
10. Cylinder boot : Apply small amount of brake fluid. 20. Pad shim

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
I6RS0C430011-01
1
2
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)
1 1
1
I6RS0B431019-01
I6RS0B431020-01
1
I6RS0B431021-01
1
2
3
4
I6RS0C430013-01