ect SUZUKI JIMNY 2005 3.G Service Workshop Manual

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.

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LSPV Assembly
INSPECTION AND ADJUSTMENT
1) Confirm the following before inspection and adjustment.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
Vehicle is free from any other load.
Place it on level floor.
2) Push up LSPV lever with finger till it stops and measure
length of coil spring (“a” in figure).
3) Spring length “a” should be as specified.
Spring length “a”
147 mm (5.79 in.)
4) If it isn’t, adjust it to specification by changing stay position
as shown in figure. After adjustment, tighten bolt to specified
torque.
Tightening torque
LSPV adjust bolt
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
NOTE:
Check to make sure that LSPV body and brake pipe joints
are free from fluid leakage. Replace defective parts, if
any.

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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

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Brake Booster
REMOVAL
1) Remove master cylinder assembly, referring to “Maser Cylin-
der” in the section.
2) Disconnect brake vacuum hose (2) from booster (1).
3) Remove brake pipes (3).
1. Brake master cylinder assembly 5. Nut 9. Brake vacuum hose
2. Brake booster assembly 6. Clevis pin Tightening torque
3. Gasket 7. Clip
4. Push rod clevis 8. Nut
CAUTION:
Never disassemble brake booster. Disassembly will spoil
its original function. If faulty condition is found, replace it
with new one.

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4) Disconnect push rod clevis pin (4) from brake pedal arm (3).
5) Remove attaching nuts (6) and then booster as shown.
INSTALLATION
1) Install booster to dash panel as shown, Then connect
booster push rod clevis (2) to pedal arm (3) with clevis pin
(4) and clip (5).
2) Tighter booster attaching nuts to the specified torque.
Tightening torque
Booster nuts
(a) : 13 N·m (1.3 kg-m, 9.5 Ib-ft)
3) Connect brake vacuum hose to brake booster.
4) Install master cylinder, referring to “Master Cylinder” in this
section.
Inspection and adjustment
INSTALLATION POSITION OF PUSH ROD
Install push rod clevis (1) so that measurement “a” is obtained
and torque nut (2) to specification.
Tightening torque
Booster clevis nut
(a) : 25 N·m (2.5 kg-m, 18.0 Ib-ft)
Distance “a” between center of booster clevis pin hole
and booster surface
Standard : 126.1 – 127.1 mm (4.96 - 5.00 in.)
1. Steering column
2. Push rod clevis
5. Clip
NOTE:
See NOTE at the beginning of this section.
Check length of push rod clevis and adjust clearance
between booster piston rod and master cylinder pis-
ton. Refer to “Brake Booster Inspection and Adjust-
ment” in this section
Apply silicone grease to master cylinder piston.
1. Steering column

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REMOVAL
1) Raise, suitably support vehicle. Remove wheel if necessary.
2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose and pipe.
INSTALLATION
1) Install brake hose and pipe by reversing removal procedure, noting the following points.
For installation, make sure that steering wheel is in straightforward position and hose has no twist or kink.
Check to make sure that hose doesn’t contact any part of suspension, both in extreme right and extreme left
turn conditions. If it does at any point, remove and correct. Fill and maintain brake fluid level in reservoir.
Bleed brake system.
2) Perform brake test and check installed part for fluid leakage.

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

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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

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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.