PEDAL SUZUKI JIMNY 2005 3.G Service Owner's Manual

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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

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4) If rear brake pressure is not within specification, adjust it by
changing stay position as follows.
If rear brake pressure is higher than specification, move stay
“A” to direction “l” and if it is lower, to direction “r”.
Repeat steps 3) and 4) until rear brake pressure is within
specification.
After adjustment, be sure to torque bolt to specification.
Tightening torque
LSPV adjust bolt
(a) : 25 N·m (2.5 kg-m, 18 Ib-ft)
5) Disconnect brake pipe (2) (connecting between master cylin-
der secondary side and 4-way joint) from master cylinder (1).
Tighten plug (special tool) to master cylinder.
Depress brake pedal. If rear brake pressure is 95 – 100
kg/cm
2 when front brake pressure is 100 kg/cm2, it means
that front fail-safe system functions properly.
Special tool
(A) : 09956-02210
1. LSPV lever
2. LSPV spring
3. LSPV stay
Front brake Rear brake
10000 kPa
100 kg/cm
2
1422 psi9500 – 10000 kPa
95 – 100 kg/cm
2
1350 – 1422 psi

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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.

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Brake pad
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper pin bolts (2).
3) Remove caliper (1) from caliper carrier.
4) Remove pads (3).
INSPECTION
Check pad lining for wear. When wear exceeds limit, replace with
new one.
Brake pad thickness (lining + pad rim)
Standard : 15 mm (0.59 in.)
Limit : 7 mm (0.28 in.)
1. Caliper
3. Disc
NOTE:
Hang removed caliper (1) with a wire hook (2) or the like
so as to prevent brake hose from bending and twisting
excessively or being pulled.
Don’t operate brake pedal with pads (3) removed.
CAUTION:
Never polish pad lining with sandpaper. If lining is pol-
ished with sandpaper, hard particles of sandpaper will be
deposited in lining and may damage disc. When pad lin-
ing requires correction, replace it with a new one.
NOTE:
When pads are removed, visually inspect caliper for
brake fluid leak. Correct leaky point, if any.

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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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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

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Brake Shoe
Where lining is worn out beyond service limit, replace shoe.
If one of brake linings is to service limit, all linings must be
replaced at the same time.
Brake shoe thickness (lining + shoe rim) “a”
Standard (lining + rim) : 6.5 mm (0.26 in.)
Service limit : 3.0 mm (0.12 in.)
INSTALLATION
1) Before installing brake drum, check outer diameter of brake
shoes. If it is not within value as specified below, adjust it to
specification by turning adjuster (1).
Outer diameter of brake shoes
“a” : 219.4 - 219.7 mm (8.638 - 8.650 in.)
2) Install brake drum after making sure that inside of brake
drum and brake shoes are free from dirt and oil.
3) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load about 30 times so as to obtain proper
drum-to-shoe clearance.
Adjust parking brake cable.
4) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
5) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake). NOTE:
Never polish lining with sandpaper. If lining is polished
with sandpaper, hard particles of sandpaper will be
deposited in lining and may damage drum. When it is
required to correct lining, replace it with a new one.
NOTE:
See NOTE at the beginning of this section.
2. Spring and rod assembly
3. Brake shoes

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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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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