front SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 5-28 BRAKES
CHECK FOR FRONT BRAKE AFTER INSTALLATION
Mount tires and make certain that they rotate smoothly, with a
force of less than 3.0 kg (6.6 Ib).
If tire rotation is heavy, check the following:
Piston, piston seal and cylinder slide bush of caliper for
installation.
Wheel bearings for breakage.
Disc for flatness (Improper flatness brings disc into contact
with lining during rotation and makes rotation heavy).
To check this, measure disc deflection.NOTE:
For above check the following must be observed.
Jack up front wheels, both right and left, off the
ground.
Shift transfer shift lever to 2H (rear wheel) position (if
equipped) and start engine for a few seconds then
stop.
Side figure shows outer periphery of tire.
Be careful not to depress brake pedal when checking
tire for rotation.
1. String
2. Spring measure

Downloaded from www.Manualslib.com manuals search engine 5-48 BRAKES
Brake Hose/Pipe
Front brake hose/pipe
For left-hand steering vehicle
[A] : For vehicle without ABS X : View X 5. Brake caliper 12. To front left brake caliper
[B] : For vehicle with ABS Y : View Y 6. 4 way joint 13. To rear brake
F : Front side Z : View Z 7. 5 way joint a-d: Clamp
R : Right side 1. E-ring 8. ABS hydraulic unit/control mod-
ule assemblyTightening torque
T : Top side 2. Flexible hose 9. P valve
V : View V 3. Hose washer 10. Hose bracket
W : View W 4. Hose bolt 11. To front right brake caliper

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-49
For right-hand steering vehicle
[A] : For vehicle without ABS X : View X 5. Brake caliper 12. To front left brake caliper
[B] : For vehicle with ABS Y : View Y 6. 4 way joint 13. To rear brake
F : Front side Z : View Z 7. 5 way joint 14. Front brake master cylinder
R : Right side 1. E-ring 8. ABS hydraulic unit a-f: Clamp
T : Top side 2. Flexible hose 9. P valve Tightening torque
V : View V 3. Hose washer 10. Hose bracket
W : View W 4. Hose bolt 11. To front right brake caliper

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 BRAKES 5-55
Special Tool
09900-20205 09900-20602 09900-20701 09956-02210
Micrometer (0 – 25 mm) Dial gauge (1/1000 mm) Magnetic stand Brake circuit plug
09922-85811 09942-15510 09943-35511 09950-78220
Connector pin remover Sliding hammer Brake drum remover
(Front wheel hub
remover)Flare nut wrench (10 mm)
09950-96010 09952-16010 09956-02310
Booster piston rod gauge Booster piston rod
adjusterFluid pressure gauge

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8E
5E
9
10
10A
10B
10
10A
10B
SECTION 5E
ANTILOCK BRAKE SYSTEM (ABS)
CONTENTS
General Description ....................................... 5E-2
System Schematic ....................................... 5E-3
ABS Component Parts Location .................. 5E-4
ABS Control Module ..................................... 5E-5
Self-diagnosis function ............................. 5E-5
Fail-safe function ...................................... 5E-5
Diagnosis ........................................................ 5E-6
Precaution in Diagnosing Troubles .............. 5E-6
ABS Diagnostic Flow Table .......................... 5E-6
“ABS” Warning Lamp Check ........................ 5E-9
Diagnostic Trouble Code (DTC) Check ........ 5E-9
DTC Check (Using SUZUKI Scan Tool) ..... 5E-10
Diagnostic Trouble Code (DTC)
Clearance ................................................... 5E-10
Diagnostic Trouble Code (DTC) Table ....... 5E-11
System Circuit ............................................ 5E-12
Table – A “ABS” Warning Lamp Circuit
Check – Lamp Does Not Come “ON”
at Ignition Switch ON .................................. 5E-14
Table – B “ABS” Warning Lamp Circuit
Check – Lamp Comes “ON” Steady ........... 5E-15
Table – C “ABS” Warning Lamp Circuit
Check – Lamp Flashes Continuously
While Ignition Switch is ON ........................ 5E-16
Table – D Code (DTC) is Not Outputted
Even With Diag. Switch Terminal
Connected to Ground. ................................ 5E-17
DTC C1015 (DTC 15) – G Sensor
Circuit ......................................................... 5E-18
DTC C1016 (DTC 16) – Stop Lamp
Circuit ......................................................... 5E-20
DTC C1021 (DTC 21), DTC C1022
(DTC 22) – Right Front Wheel Speed
Sensor Circuit ............................................. 5E-21
DTC C1025 (DTC 25), DTC C1026
(DTC 26) – Left Front Wheel Speed
Sensor Circuit ............................................. 5E-21DTC C1031 (DTC 31), DTC C1032
(DTC 32) – Right Rear Wheel Speed
Sensor Circuit ............................................ 5E-21
DTC C1035 (DTC 35), DTC C1036
(DTC 36) – Left Rear Wheel Speed
Sensor Circuit ............................................ 5E-21
DTC C1041 (DTC 41), DTC C1042
(DTC 42) – Right Front Solenoid Circuit .... 5E-24
DTC C1045 (DTC 45), DTC C1046
(DTC 46) – Left Front Solenoid Circuit....... 5E-24
DTC C1055 (DTC 55), DTC C1056
(DTC 56) – Rear Solenoid Circuit .............. 5E-24
DTC C1057 (DTC 57) – Power Source
Circuit ......................................................... 5E-25
DTC C1061 (DTC 61) – ABS Pump
Motor Circuit............................................... 5E-26
DTC C1063 (DTC 63) – ABS Fail Safe
Circuit ......................................................... 5E-27
DTC C1071 (DTC 71) – ABS Control
Module ....................................................... 5E-28
On-Vehicle Service ...................................... 5E-29
Precaution .................................................. 5E-29
ABS Hydraulic Unit Operation Check ........ 5E-29
ABS Hydraulic Unit / Control Module
Assembly ................................................... 5E-30
Front Wheel Speed Sensor........................ 5E-32
Front Wheel Sensor Ring........................... 5E-35
Rear Wheel Speed Sensor ........................ 5E-36
Rear Wheel Sensor Ring ........................... 5E-38
G Sensor .................................................... 5E-39
Tightening Torque Specification ................ 5E-40
Special Tool .................................................. 5E-40 NOTE:
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
same part number or with an equivalent part if replacement part of lesser quality or substitute design.
Torque values must be used as specified during reassembly to assure proper retention of all parts.
There is to be no welding as it may result in extensive damage and weakening of the metal.

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 ANTILOCK BRAKE SYSTEM (ABS) 5E-3
System Schematic
1. Wheel speed sensor (Right front) 7. Wheel speed sensor (Left rear) 13. ABS hydraulic unit
2. Stop lamp switch 8.“ABS” warning lamp 14. G sensor
3. ABS control module 9. ABS pump motor transistor 15. Data link connector
4. Wheel speed sensor (Right rear) 10. ABS solenoid valve transistor 16. ABS hydraulic unit / control module assembly
5. Monitor connector 11. Proportioning valve 17. 4WD switch (for 4WD model only)
6. ABS lamp driver module 12. Wheel speed sensor (Left front)
INPUTOUTPUT
ABS control
module Wheel speed sensor (RF)
Wheel speed sensor (RR)
Wheel speed sensor (LR)
Wheel speed sensor (LF)
Stop lamp switch
Diag. switch terminal
Battery voltage
4WD switch (for 4WD model only) G sensor
Pump motor
transistor
Fail-safe
transistor
Pump motor
LF hold solenoid
LF release solenoid
RF hold solenoid
RF release solenoid
Rear hold solenoid
Rear release solenoid
“ABS” warning lamp
Idle-up
ECM
Data link connector
ABS hydraulic unit/control
module assembly

Downloaded from www.Manualslib.com manuals search engine 5E-4 ANTILOCK BRAKE SYSTEM (ABS)
ABS Component Parts Location
1. Wheel speed sensor (Right front) 6. ABS hydraulic unit / control module assembly 11. Proportioning valve
2. Stop lamp switch 7. Monitor connector [A] : For LH steering vehicle
3.“ABS” warning lamp 8. Wheel speed sensor (Left front) [B] : For RH steering vehicle
4. Wheel speed sensor (Right rear) 9. Wheel speed sensor ring
5. Wheel speed sensor (Left rear) 10. G sensor

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-9
“ABS” Warning Lamp Check
Turn ignition switch ON and check that “ABS” warning lamp
comes ON for about 2 seconds and then goes OFF. If any faulty
condition is found, advance to Diagnostic Flow Table-A, B or C.
Diagnostic Trouble Code (DTC) Check
1) Test drive vehicle at 40 km/h for more than a minute.
2) Stop vehicle and while IG switch OFF, connect diagnosis
switch terminal (3) and ground terminal (2) of monitor con-
nector (1) with service wire (4).
3) Turn IG switch ON, read the flashing “ABS” warning lamp
which represents DTC as shown in example below and write
it down. When more than 2 DTC’s are stored in memory,
flashing for each DTC is repeated three times starting with
the smallest DTC number in increasing order.
For details of DTC, refer to “DTC Table”.
Example : When right front wheel speed sensor circuit opens (DTC 21)
4) After completing the check, turn ignition switch off, discon-
nect service wire from monitor connector.
NOTE:
“ABS” warning lamp indicates only following DTCs, DTC
12 which means that no malfunction DTC is stored and
history DTC which indicates history trouble area. When
there is current trouble, “ABS” warning lamp remains ON
and therefore DTC is not indicated.