king SUZUKI JIMNY 2005 3.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine 5-34 BRAKES
INSTALLATION
1) Apply sealant to wheel cylinder. Then take off bleeder plug
cap from brake pipe and connect pipe (for pipes) (3) to wheel
cylinder just enough to prevent fluid from leaking.
“A” : Sealant 99000-31090
2) Tighten wheel cylinder to brake back plate (1) to specified
torque.
3) Torque flare nut (or nuts) (2) of brake pipe which was con-
nected in step 1) to specification.
Tightening torque
Wheel cylinder mounting bolts
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
Brake pipe flare nut
(b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
4) Install breather plug cap taken off from pipe back to breather
plug.
5) For procedure hereafter, refer to “Brake Shoe” in this sec-
tion.
Brake back plate
REMOVAL
1) Remove brake drum referring to “Brake Drum” in this sec-
tion.
2) Remove brake shoe referring to “Brake Shoe” in this section.
3) Remove wheel cylinder referring to “Wheel Cylinder” in this
section.
4) Drain rear differential gear oil.
5) Remove cable from brake back plate (2) by squeezing park-
ing brake cable stopper ring (1).
6) Remove brake back plate nuts (3) from rear axle housing.
4. Wheel cylinder bolts
NOTE:
Be sure to bleed brake system.

Downloaded from www.Manualslib.com manuals search engine 5-52 BRAKES
Parking Brake Lever/Cable
Parking brake lever
REMOVAL
1) Hoist vehicle and release parking brake lever.
2) Disconnect negative cable at battery.
3) Remove parking brake lever cover.
4) Disconnect lead wire of parking brake switch at coupler.
5) Remove adjusting nut.
6) Loosen bracket nut (3) and disconnect parking brake cables
(2) from equalizer (4).
7) Remove parking brake lever bolts and then remove parking
brake lever assembly (1).
INSTALLATION
1) Install in reverse order of REMOVAL procedure.
Equalizer angle “a” : within 15 degrees
Tightening torque
Parking brake lever bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
2) After all parts are installed, parking brake lever needs to be
adjusted. Refer to “Parking Brake Inspection and Adjust-
ment” in this section.
3) Check brake drum for dragging and brake system for proper
performance. NOTE:
Don’t disassemble parking brake lever switch. It must be
removed and installed as a complete switch assembly.
1. Parking brake lever
2. Parking brake cable
3. Adjusting nut
4. Equalizer

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-53
Parking Brake Cable
REMOVAL
1) Raise, suitably support vehicle and remove wheel if necessary.
2) Remove parking brake cable.
INSTALLATION
1) Install it by reversing removal procedure, noting the following points.
Install clamps properly referring to figure below.
Tighten bolts and nuts to specified torque.
2) Upon completion of installation, adjust cable. (Refer to “Parking Brake Inspection and Adjustment” in this
section.) Then check brake drum for dragging and brake system for proper performance. After removing
vehicle from hoist, brake test should be performed.
E : View E J : View J 2. Floor Tightening torque
G : View G K : View K 3. Cross member
H : View H 1. Bracket 4. Clamp

Downloaded from www.Manualslib.com manuals search engine 5-54 BRAKES
Tightening Torque Specifications
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Brake caliper carrier bolt 85 8.5 61.5
Brake caliper pin bolt 22 2.2 16.0
Front brake flexible hose bolt 23 2.3 17.0
Rear brake back plate nut 23 2.3 17.0
Master cylinder nut 13 1.3 9.5
Booster nut 13 1.3 9.5
Brake pipe 5-way 4-way joint bolt 11 1.1 8.0
Brake pipe flare nut 16 1.6 12.0
LSPV bolt/P valve bolt 25 2.5 18.0
Brake bleeder plugFront caliper 11 1.1 8.0
Rear wheel cylinder, LSPV 8 0.8 6.0
Wheel nut 95 9.5 69.0
Hose bracket bolt 11 1.1 8.0
Booster clevis nut 25 2.5 18.0
Stop light switch lock nut 6.5 0.65 4.7
Parking brake lever bolt 23 2.3 17.0
Wheel cylinder mounting bolt 9 0.9 6.5
Piston stopper bolt 10 1.0 7.5
LSPV adjust bolt 25 2.5 18.0
Material Recommended SUZUKI products Use
Brake fluid Indicated on reservoir tank cap or
described in owner’s manual of vehi-
cleTo fill master cylinder reservoir.
To clean and apply to inner parts of master
cylinder caliper and wheel cylinder when they
are disassembled.
Water tight sealant SEALING COMPOUND 366E
99000-31090To apply to mating surfaces of brake back
plate and rear wheel cylinder.
Sealant SUZUKI BOND NO. 1215
99000-31110To apply to mating surfaces of brake back
plate and rear axle housing.
To apply to mating surfaces of brake back
plate and rear wheel bearing retainer.

Downloaded from www.Manualslib.com manuals search engine 5E-2 ANTILOCK BRAKE SYSTEM (ABS)
General Description
The ABS (Antilock Brake System) is a system to prevent each wheel to lock during hard braking or braking on a
slippery road by controlling the fluid pressure from master cylinder to each brake (either brake caliper or wheel
cylinder).
The ABS of this vehicle monitors all four wheels (four sensors) and controls all four wheels when the system is
active.
The component parts of this ABS includes following parts in addition to those of the conventional brake system.
Wheel speed sensor senses revolution speed of each wheel and sends outputs to ABS control module.
In this ABS, ABS hydraulic unit (actuator assembly), ABS control module, pump motor transistor and fail-
safe transistor are combined as one component.
ABS control module sends operation signal to ABS hydraulic unit to control fluid pressure applied to each
wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking.
ABS hydraulic unit operates according to signal from ABS control module and controls fluid pressure applied
to wheel cylinder of each of 4 wheels.
Fail-safe transistor which supplies power to solenoid valve in ABS hydraulic unit.
Pump motor transistor supplies power to pump motor in ABS hydraulic unit.
“ABS” warning lamp lights to inform abnormality when system fails to operate properly.
G sensor which detects body deceleration speed.
1. Front disc brake 5. Brake master cylinder / booster
2. Proportioning valve [A] : For LH steering vehicle
3. Rear drum brake [B] : For RH steering vehicle
4. ABS hydraulic unit / control module assembly

Downloaded from www.Manualslib.com manuals search engine 5E-6 ANTILOCK BRAKE SYSTEM (ABS)
Diagnosis
To ensure that the trouble diagnosis is done accurately and smoothly, observe “Precautions in Diagnosing Trou-
bles” and follow “ABS Diagnostic Flow Table”.
Precaution in Diagnosing Troubles
If the vehicles was operated in any of the following ways, “ABS” warning lamp 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 Electronic Circuit Service” in Section 0A before inspection and observe
what is written there.
Be sure to use the trouble diagnosis procedure as described in the flow table. Failure to follow the flow table
may result in incorrect diagnosis. Some other diag. trouble code may be stored by mistake in the memory of
ABS control module during inspection.
ABS Diagnostic Flow Table
Refer to the following for the details of each step.
Step Action Yes No
1 Perform customer complaint analysis, problem symptom confir-
mation and diagnostic trouble code check record and clear-
ance.
Is there any trouble code?Go to Step 2. Go to Step 5.
2 Perform driving test.
Is trouble symptom identified?Go to Step 3. Go to Step 6.
3 Check diagnostic trouble code.
Is it malfunction code?Go to Step 4. Go to Step 5.
4 Inspect and repair referring to applicable diagnostic trouble
code table in this section. Then perform final confirmation test
after clearing diagnostic trouble code.
Is trouble recur?Go to Step 7. End.
5 Inspect and repair referring to “Diagnosis Table” in Section 5.
Then perform final confirmation test after clearing diagnostic
trouble code.
Is trouble recur?Go to Step 7. End.
6 Check for intermittent problems referring to “Intermittent and
Poor Connection” in Section 0A and related circuit of trouble
code recorded in Step 3. Then perform final confirmation test
after clearing diagnostic trouble code.
Is trouble recur?Go to Step 7. End.
7 Perform diagnostic trouble code check record and clearance.
Is there any trouble code?Go to Step 4. Go to Step 5.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-21
DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right Front Wheel Speed Sensor
Circuit
DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left Front Wheel Speed Sensor
Circuit
DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right Rear Wheel Speed Sensor
Circuit
DTC C1035 (DTC 35), DTC C1036 (DTC 36) – Left Rear Wheel Speed Sensor
Circuit
DESCRIPTION
The ABS control module monitors the voltage at the positive (+) terminal of each sensor while the ignition switch
is ON. When the voltage is not within the specified range, an applicable DTC will be set. Also, when no sensor
signal is inputted at starting or while running, an applicable DTC will be set.
1. Ignition switch 4. Right front wheel speed sensor 7. ABS hydraulic unit / control module connector of harness
2. ABS hydraulic unit / control module assembly 5. Left rear wheel speed sensor
3. Left front wheel speed sensor 6. Right rear wheel speed sensor
NOTE:
When the vehicle was operated in any of the following ways, one of these DTC’s may be set even when
the sensor is in good condition. If such possibility is suspected, repair the trouble (dragging of brake,
etc.) of the vehicle, clear DTC once and then after performing the driving test as described in Step 2 of
“ABS DIAG. FLOW TABLE” in this section, check whether or not any abnormality exists.
The vehicle was driven with parking brake pulled.
The vehicle was driven with brake dragging.
Wheel spin occurred while driving.
Wheel(s) was turned while the vehicle was jacked up.
The vehicle was stuck.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-29
On-Vehicle Service
Precaution
When connectors are connected to ABS hydraulic unit / control
module assembly, do not disconnect connectors of sensors, fuse
etc. and turn ignition switch ON. Then DTC will be set in ABS con-
trol module.
ABS Hydraulic Unit Operation Check
1) Check that basic brake system other than ABS is in good
condition.
2) Check that battery voltage is 11 V or higher.
3) With ABS warning lamp, check that no abnormality is
detected in ABS. Refer to “Diagnostic Trouble Code (DTC)
Check” in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake drag-
ging occurs. If it does, correct.
7) With diag. switch terminal (3) of monitor connector (1) con-
nected to ground terminal (2) by using service wire (4), turn
ignition switch ON and check if ABS warning lamp indicates
DTC 12.
When other DTC’s appear on display, refer to “ABS Diagnos-
tic Flow Table” in this section.
8) Turn ignition switch OFF.
9) Perform following checks with help of another person.
Brake pedal (1) should be depressed and then ignition
switch (2) turned ON by one person and wheel (3) should be
turned by another person’s hand. At this time, check that:
Operation sound of solenoid is heard and wheel turns only
about 0.5 sec (Brake force is depressurized).
Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF → ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace
hydraulic unit.
11) Turn ignition switch OFF.
12) Remove service wire from monitor connector.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-35
Front Wheel Sensor Ring
REMOVAL
1) Remove wheel hub with sensor ring. Refer to “Wheel Hub /
Bearing / Oil Seal” in Section 3D.
2) Remove sensor ring (1) from wheel hub (2) as shown.
INSPECTION
Check ring teeth for being missing, damaged or deformed.
Check sensor ring (1) for being deformed.
Check that no foreign material is attached.
If any malcondition is found, repair or replace.
INSTALLATION
1) Install sensor ring (3) as shown.
2) Install wheel hub, brake disc, brake caliper, locking hub and
wheel.
Refer to “Wheel Hub / Bearing / Oil Seal” in Section 3D. CAUTION:
Pull out sensor ring (1) from wheel hub (2) gradually and
evenly. Attempt to pull it out partially may cause it to be
deformed.
3. Vise
4. Lever
NOTE:
Pipe (2) used here should have inner diameter of 90
mm (3.55 in) – 96 mm (3.77 in) and its outside should
not contact teeth of sensor ring.
Use care not to insert wheel hub diagonally.
1. Steel plate
4. Wheel hub
5. Hydraulic press

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-39
G Sensor
REMOVAL
1) Turn ignition switch “OFF” and disconnect battery negative
cable.
2) Remove rear center console box.
3) Disconnect connector from G sensor (2).
4) Remove G sensor (2) from floor.
INSPECTION
Connect positive cable of 12 volt battery to “A” terminal of sensor
and ground cable to “C” terminal. Then using voltmeter, check
voltage between “B” terminal and “C” terminal.
If measured voltage is not as specified, replace sensor with
bracket.
G sensor specification
When placed horizontally : 2 – 3V
When placed upright with arrow upward : 3 – 4V
When placed upright with arrow downward : 1 – 2V
INSTALLATION
1) Connect connector to sensor securely.
2) Install sensor onto floor so that arrow mark directs vehicle
forward.
Tightening torque
G sensor bolts
(a) : 23 N·m (2.3 Kg-m, 17.0 lb-ft)
3) Install rear console box.CAUTION:
Sensor must not be dropped or shocked. It will affect its
original performance.
1. Parking brake lever assembly
3. Bolt
[A] : Horizontal
[B] : Upright with arrow upward
[C] : Upright with arrow downward