Brake fluid SUZUKI JIMNY 2005 3.G Service Owner's Manual

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ASSEMBLY
1) Check that slide bushes and boots for wear, corrosion, dam-
age, movement or deterioration. If it is found faulty, correct or
replace.
Apply rubber grease to bush outer surface. And then make
sure that each bush slides easily through each caliper bolt
hole.
2) Tighten bleeder plug to specified torque and install cap.
Tightening torque
Front caliper bleeder plug
(a) : 11 N·m (1.1 g-m, 8.0 lb-ft)
3) Piston seal is used to seal piston and cylinder and to adjust
clearance between pad and disc. Replace with a new one at
every overhaul. Fit piston seal into groove in cylinder taking
care not to twist it.
4) Before inserting piston (2) into cylinder, install new boot (1)
onto piston (2) as shown.
“A” : 2-grooved side directed inside
“B” : 3-grooved side directed outside 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 and piston seal to cylinder,
apply fluid to them.
After reassembling brake lines, bleed air from them.
NOTE:
Where temperature gets as low as – 30 °C (– 22 °F) in cold
weather, use rubber grease whose viscosity varies very
little even at – 40 °C (– 40 °F).
1. Apply rubber grease

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3) Install brake flexible hose (4) as shown and torque hose
mounting bolt (3) to specification.
Tightening torque
Front brake flexible hose bolt
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
4) Install wheel and torque wheel nuts to specification.
5) After completing installation, fill reservoir with brake fluid and
bleed brake system. Perform brake test and check each
installed part for oil leakage.
Brake Disc
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by loosening carrier bolts (2 pcs).
3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
1. Brake caliper
2. Washer
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.

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Rear Brake
Brake drum
REMOVAL
1) Hoist vehicle and pull up parking brake lever.
2) Remove wheel.
3) Release parking brake lever.
4) Loosen parking brake cable adjusting nut (1).
1. Brake back plate 5. Shoe return spring lower 9. Shoe hold down pin
2. Brake shoe 6. Adjuster lever 10. Wheel cylinder
: Apply brake fluid to piston cap
3. Spring and rod assembly 7. Adjuster spring Tightening torque
4. Parking brake shoe lever 8. Shoe hold down spring

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5) To increase clearance between brake shoe and brake drum,
remove rubber plug from brake back plate and turn adjuster
downward with flat-head screw driver.
6) Remove brake drum (1) off by using 8 mm bolts (2).
INSPECTION
Brake Drum
Inspect drum for cleanliness. Check wear of its braking surface by
measuring its inside diameter.
Drum inner diameter “a”
Standard : 220 mm (8.66 in.)
Service Limit : 222 mm (8.74 in.)
Whenever brake drums are removed, they should be thoroughly
cleaned and inspected for cracks, scores, deep grooves.
Cracked, scored, or grooved drum
A cracked, drum is unsafe for further service and must be
replaced.
Do not attempt to weld a cracked drum.
Smooth up any slight scores. Heavy or extensive scoring will
cause excessive brake lining wear and it will probably be neces-
sary to resurface drum braking surface.
If brake linings are slightly worn and drum is grooved, drum
should be polished with fine emery cloth but should not be turned.
NOTE:
When drum is removed, visually inspect wheel cylinder
for brake fluid leakage. Correct leaky point, if any.

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2) Install shoe hold down springs (2) by pushing them down in
place and turning hold down pins (1).
3) Install shoe return spring and parking brake shoe lever
spring.
4) For procedure hereafter, refer to “Brake Drum” in this sec-
tion.
Wheel Cylinder
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) Loosen brake pipe flare nut (or nuts) but only within the
extent that fluid does not leak.
4) Remove wheel cylinder mounting bolts. Disconnect brake
pipe (or pipes) from wheel cylinder and put wheel cylinder
breather plug cap (1) onto pipe to prevent fluid from spilling.
INSPECTION
Inspect wheel cylinder disassembled parts for wear, cracks, cor-
rosion or damage.
3. Shoe return spring lower
4. Spring and rod assembly
5. Adjuster lever
6. Adjuster spring
NOTE:
Clean wheel cylinder components with brake fluid.

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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.

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Master Cylinder
Master Cylinder Reservoir
REMOVAL
1) Disconnect reservoir lead wire at coupler.
2) Clean outside of reservoir (1).
3) Take out fluid with syringe or such.
4) Remove reservoir connector pin (2) by using special tool.
Special tool
(A) : 09922-85811
Remove reservoir (1).
CAUTION:
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted surfaces.
2. Connector pin
3. Grommets

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INSTALLATION
1) When using new grommets, lubricate them with the same
fluid as the one to fill reservoir with. Then press-fit grommets
to master cylinder. Grommets must be seated in place.
2) Install reservoir (1) and drive in reservoir pin (2).
3) Connect reservoir lead wire.
4) Fill reservoir (1) with specified fluid.
5) Upon completion of installation, check for fluid leakage.
Master Cylinder Assembly
REMOVAL
1) Disconnect reservoir lead wire at coupler.
2) Clean around reservoir cap (1) and take out fluid with
syringe or such.
3) Disconnect brake pipes (4) from master cylinder (3).
4) Remove master cylinder attaching nuts (5).
5) Remove master cylinder (3).
For vehicle equipped with P & B valve (6), remove master
cylinder (3) with P & B valve (6) and its bracket, then sepa-
rate P & B valve (6) from master cylinder (3). NOTE:
See NOTE at the beginning of this section.
NOTE:
Drive in reservoir pin (2) till both of its ends at the right
and left of reservoir (1) become the same length.
2. Cap
CAUTION:
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted surfaces.
2. Reservoir

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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

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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