AIR CON SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-13
CHECK AIR TIGHTNESS
1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same load as in
ordinary braking and observe pedal travel. If pedal goes
down deep the first time but its travel decreases as it is
depressed the second and more times, air tightness is
obtained.
4) If pedal travel doesn’t change, air tightness isn’t obtained.
CHECK OPERATION
1) With engine stopped, depress brake pedal several times with
the same load and make sure that pedal travel doesn’t
change.
2) Start engine while depressing brake pedal. If pedal travel
increases a little, operation is satisfactory. But no change in
pedal travel indicates malfunction.
1. 1st
2. 2nd
3. 3rd
NOTE:
If defective, inspect vacuum lines and sealing parts, and
replace any faulty part. When this has been done, repeat
the entire test.
1. 1st, 2nd, 3rd

Downloaded from www.Manualslib.com manuals search engine 5-14 BRAKES
CHECK AIR TIGHTNESS UNDER LOAD
1) With engine running, depress brake pedal. Then stop engine
while holding brake pedal depressed.
2) Hold brake pedal depressed for 30 seconds. If pedal height
does not change, condition is good. But it isn’t if pedal rises.
H : Hold
H : Hold
T : 30 seconds

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-15
Fluid Pressure Test (If Equipped with LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
1) Stop vehicle on level floor and place approximately about
140 kg (309 Ibs) weight on rear housing so that rear axle
weights 600 kg (1323 Ib).
Rear axle weight
“L” : 600 kg (1323 lb)
2) Install special tool to front and rear brake.
Special tool
Front brake
(A) : 09956-02310
(B) : 55473-82030 (Use the air bleeder plug supplied as a
spare part)
Rear brake
(A) : 09956-02310
(B) : 55473-82030 (Use the air bleeder plug supplied as a
spare part)
3) Depress brake pedal gradually till fluid pressure of front
brake becomes as specified below and check corresponding
pressure of rear brake. It should be within specification given
below.
As done above, apply 100 kg/cm
2 pressure to front brake and
check that rear brake pressure is within specification as given
below.NOTE:
Special tool should be connected to bleeder plug hole of
front (driver’s side brake) and rear brakes.
1. Air bleeder plug
2. Weight
3. Attachment
Front brake Rear brake
5000 kPa
50 kg/cm
2
711 psi3800 – 5100 kPa
38 – 51 kg/cm
2
540 – 725 psi
Front brake Rear brake
10000 kPa
100 kg/cm
2
1422 psi5100 – 6500 kPa
51 – 65 kg/cm
2
725 – 924 psi

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-17
On-Vehicle Service
Air Bleeding of Brake System
Bleeding operation is necessary to remove air whenever it
entered hydraulic brake system.
Hydraulic lines of brake system consists of two separate lines,
one for front wheel brakes and the other for rear wheel brakes. Air
bleeding is necessary at right and left front wheel brakes, left rear
wheel brake and LSPV (if equipped), i.e. 3 (4 for vehicle with
LSPV) places in all.
Be sure to bleed air of brake system according to following proce-
dure when its oil hydraulic circuit has been disconnected.
1) Fill master cylinder reservoir with brake fluid and keep at
least one-half full of fluid during bleeding operation.
2) Remove bleeder plug cap (1).
Attach a vinyl tube (2) to bleeder plug, and insert the other
end into container (3).
3) Depress brake pedal several times, and then while holding it
depressed, loosen bleeder plug about one-third to one-half
turn. CAUTION:
Brake fluid is extremely damaging to paint. If fluid should
accidentally touch painted surface, immediately wipe
fluid from paint and clean painted surface.

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4) When fluid pressure in the cylinder is almost depleted,
retighten bleeder plug.
5) Repeat this operation until there are no more air bubbles in
hydraulic line.
6) When bubbles stop, depress and hold brake pedal and
tighten bleeder plug.
Tightening torque
Front caliper bleeder plug
(b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Rear wheel cylinder and LSPV bleeder plug
(c) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
7) Then attach bleeder plug cap.
8) After completing bleeding operation, apply fluid pressure to
pipe line and check for leakage.
9) Replenish fluid into reservoir up to specified level.
10) Check brake pedal for “sponginess”. If found spongy, repeat
entire procedure of bleeding.
Brake Hose and Pipe Inspection
HOSE
The brake hose assembly should be checked for road hazard
damage, for cracks and chafing of the outer cover, for leaks and
blisters. A light and mirror may be needed for an adequate inspec-
tion. If any of the above conditions are observed on the brake
hose, it is necessary to replace it.

Downloaded from www.Manualslib.com manuals search engine 5-22 BRAKES
Caliper assembly
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove brake flexible hose mounting bolt from caliper. As
this will allow fluid to flow out of hose, have a container ready
beforehand.
3) Remove caliper pin bolts.
4) Remove caliper from carrier.
DISASSEMBLY
1) Before disassembly, clean all around caliper with brake fluid.
2) Remove piston set ring (1) and boot from caliper, pry off with
a flat-bladed tool. Be careful not to damage boot.
3) Blow compressed air into cylinder through bolt hole where
flexible hose was fitted. With this air pressure, piston can be
pushed out of cylinder.
4) Remove piston seal using a thin blade like a thickness
gauge, etc.
5) Remove bleeder plug and cap from caliper.
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 fin-
gers in front of piston when using compressed air.
NOTE:
Be careful not to damage inside (bore side) of cylinder.

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INSTALLATION
1) Install master cylinder as shown and torque attaching nuts to
specification.
Tightening torque
Master cylinder nuts
(a) : 13 N·m (1.3 kg-m, 9.5 Ib-ft)
2) Attach hydraulic lines and torque flare nuts to specification.
Tightening torque
Brake pipe flare nuts
(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
3) Connect reservoir lead wire.
4) Fill reservoir with specified brake fluid.
5) After installing, bleed air from system (refer to “Air Bleeding
of Brake System” in this section) and check brake pedal
height and play.
6) Perform brake test and check each installed part for fluid
leakage.
Master Cylinder
NOTE:
See NOTE at the beginning of this section.
Check clearance between booster piston rod and pri-
mary.
[A] : For vehicle without ABS 7. Piston cup
: Apply brake fluid confirm installing direction.
[B] : For vehicle with ABS 8. Secondary piston
1. Piston stopper circlip 9. Sealing
: Apply brake fluid confirm installing direction.
2. Piston stopper 10. Secondary piston return spring
3. Cylinder cup and plate
: Apply brake fluid confirm installing direction.11. Secondary piston stopper bolt
4. Primary piston 12. Master cylinder body
5. Piston cup
: Apply brake fluid confirm installing direction.Tightening Torque
6. Secondary piston pressure cup
: Apply brake fluid confirm installing direction.Do not reuse

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-39
DISASSEMBLY
1) Remove circlip (1).
2) Remove primary piston.
3) [For vehicle with ABS]
Pull out primary piston assembly straight so as not to cause
any damage to inside o cylinder wall.
Pull out secondary piston assembly straight so as not to
cause any damage to inside of cylinder wall and by tapping
flange with a piece of wood or something soft.
4) [For vehicle without ABS]
Remove piston stopper bolt (1). Then remove secondary pis-
ton by blowing compressed air (2) into hole from which pis-
ton stopper bolt was removed.
Be cautions during removal as secondary piston jumps out.
INSPECTION
Inspect all disassembled parts for wear or damage, and
replace parts if necessary.
Inspect master cylinder bore for scoring or corrosion. It is
best to replace corroded cylinder.
Corrosion can be identified as pits or excessive roughness.
2. Master cylinder
NOTE:
Wash disassembled parts with brake fluid.
Do not reuse piston cups.
NOTE:
Polishing bore of master cylinder with cast aluminum
body with anything abrasive is prohibited, as damage to
cylinder bore may occur.
[A]: Vehicle equipped with ABS
[B]: Vehicle not equipped with ABS

Downloaded from www.Manualslib.com manuals search engine 5-42 BRAKES
LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped)
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Hoist vehicle.
3) Disconnect brake pipes from LSPV.
4) Remove LSPV assembly from vehicle.
5) Remove spring and stay from LSPV.
INSTALLATION
Install by reversing removal procedure, noting the following.
1) Torque each bolt and nut to specification as indicated
respectively.
Tightening torque
LSPV bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Brake pipe flare nuts
(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
2) Upon completion of installation, fill reservoir tank with speci-
fied fluid and bleed air from brake system.
Tightening torque
LSPV bleeder plug
(a) : 8 N·m (8.0 kg-m, 6.0 lb-ft)
3) After bleeding air, check that LSPV is installed properly,
referring to following INSPECTION & ADJUSTMENT. CAUTION:
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted surface.
LSPV assembly must not be disassembled.
Replace with new one if defective.
NOTE:
As shown in figure, LSPV assembly should be removed
together with its spring and stay installed as they are.
NOTE:
Make sure to bleed air from LSPV bleeder without fail.

Downloaded from www.Manualslib.com manuals search engine 5-44 BRAKES
P (Proportioning) Valve
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Disconnect brake pipes from P valve.
3) Remove P valve.
INSTALLATION
1) Install P valve (2).
Tightening torque
P valve bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
2) Tighten flare nuts to specified torque.
Tightening torque
Brake pipe flare nuts
(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
3) Fill reservoir with specified brake fluid.
4) Bleed air from system.CAUTION:
Do not allow brake fluid to get on painted surfaces.
WARNING:
Never disassemble P valve assembly. If it is found faulty,
replace it with new assembly.
1. Flare nuts