wheel bolts SUZUKI JIMNY 2005 3.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-33
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.

Downloaded from www.Manualslib.com manuals search engine 5-34 BRAKES
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.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-35
7) Using special tools, draw out rear axle shaft with brake back
plate.
Special tool
(A) : 09943-35511
(B) : 09942-15510
8) Remove wheel bearing retainer and wheel sensor ring (if
equipped with ABS), refer to “Rear Axle Shaft and Wheel
Bearing” in Section 3E.
9) Remove brake back plate from axle shaft.
INSTALLATION
1) Install wheel cylinder, and tighten wheel cylinder bolts to
specified torque. Refer to “Wheel Cylinder” in this section.
2) Install brake back plate (2) to axle shaft (1).
3) For installation procedure here after perform “Rear Axle
Shaft and Wheel Bearing” in Section 3E.
3. Wheel bearing
4. Retainer ring

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-51
Rear Brake Hose/Pipe
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.
Fill and maintain brake fluid level in reservoir. Bleed brake system.
2) Perform brake test and check each installed part for fluid leakage.
CAUTION:
Position clamps to white marks on two brake pipes.
Be sure to obtain more than 3 mm (0.118 in.) clearance between axle housing and brake pipe.
Install clamps properly referring to figure below and tighten bolts.
When installing hose, make sure that it has no twist or kink.
T : Top side 2. Rear axle housing 5. Fuel tank 8. Brake pipe (vehicle with LSPV)
R : Right side 3. Rear wheel cylinder 6. Chassis frame a-b: Clamp
1. Clamp 4. LSPV (if equipped) 7. Fuel pipe Tightening torque

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-53
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

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-33
Reference
When using oscilloscope for this check, check if peak-to-peak
voltage (1) meets specification and waveform is complete.
Peak-to-peak voltage at 1 to 1 1/3 rotation per second
: 340 mV or more at 42 – 54 Hz
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect front wheel speed sensor coupler (3).
3) Hoist vehicle and remove wheel.
4) Remove harness clamp bolts (2) and front wheel speed sen-
sor (1) from knuckle.
SENSOR INSPECTION
Check sensor for damage.
Check sensor for resistance.
If any malfunction is found, replace.
Resistance between terminals of sensor
: 1.2 – 1.6 k
Ω at 20 °C (68 °F)
Resistance between terminal and sensor body
: 1 M
Ω or more
CAUTION:
Do not pull wire harness when removing front wheel
speed sensor.
Do not cause damage to surface of front wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.
1. Right wheel sensor terminals
2. Left wheel sensor terminals

Downloaded from www.Manualslib.com manuals search engine 5E-34 ANTILOCK BRAKE SYSTEM (ABS)
SENSOR RING INSPECTION
Check ring teeth for being missing, damaged or deformed.
Turn drive shaft and check if ring rotation is free from eccen-
tricity and looseness.
Check that no foreign material is attached.
If any faulty is found, repair or replace.
INSTALLATION
1) Check that no foreign material is attached to sensor (1) and
ring.
2) Install it by reversing removal procedure.
Tightening torque
Front wheel speed sensor bolt and front wheel speed sen-
sor harness clamp bolts
(a) : 10 N·m (1.0 kg-m, 7.2 lb-ft)
3) Check that there is no clearance between sensor and
knuckle.
CAUTION:
Do not pull wire harness or twist more than necessary
when installing front wheel speed sensor.
2. Bolt

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-37
5) Remove rear wheel speed sensor (1) from rear axle housing.
SENSOR INSPECTION
Check sensor for damage.
Check sensor for resistance.
Resistance between terminals of sensor
: 1.4 – 1.8 k
Ω at 20 °C (68 °F)
Resistance between sensor terminal and sensor body
: 1 M
Ω or more
If any malcondition is found, replace.
SENSOR RING INSPECTION
Check ring teeth for being missing, damaged or deformed.
Turn wheel and check if ring rotation is free from eccentricity
and looseness.
Check that no foreign material is attached.
If any faulty is found, repair or replace.
INSTALLATION
1) Check that no foreign material is attached to sensor and ring.
2) Install it by reversing removal procedure.
Tightening torque
Rear wheel speed sensor bolt and rear wheel speed sen-
sor harness clamp bolts
(a) : 10 N·m (1.0 kg-m, 7.2 lb-ft)
3) Check that there is no clearance between sensor and rear
axle housing. CAUTION:
Do not pull wire harness when removing rear wheel
speed sensor (1).
Do not cause damage to surface of rear wheel speed
sensor and do not allow dust, etc. to enter its installa-
tion hole.
2. Rear wheel sensor ring
CAUTION:
Do not pull wire harness or twist more than necessary
when installing rear wheel speed sensor.
1. Sensor bolt
2. Clamp bolt

Downloaded from www.Manualslib.com manuals search engine 5E-40 ANTILOCK BRAKE SYSTEM (ABS)
Tightening Torque Specification
Special Tool
Fastening partTightening torque
Nm kg-m lb-ft
Brake pipe flare nuts 16 1.6 11.6
ABS hydraulic unit / control module assembly bracket bolts 11 1.1 8.0
ABS hydraulic unit / control module assembly bolts 9 0.9 6.5
Front wheel speed sensor bolt 10 1.0 7.2
Front wheel speed sensor harness clamp bolts 10 1.0 7.2
Rear wheel speed sensor bolt 10 1.0 7.2
Rear wheel speed sensor harness clamp bolts 10 1.0 7.2
G sensor bolts 23 2.3 17.0
09950-78220 09931-76011 09931-76030
Flare nut wrench (10 mm) Tech 1A kit (SUZUKI scan
tool) See NOTE “A” belowMass storage cartridge for
Tech 1A16/14 pin DLC cable for
Tech 1A
Tech 2 kit (SUZUKI scan
tool) See NOTE “B”
below.
NOTE:
“A” : This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead / probe,
6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
“B” : This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply

Downloaded from www.Manualslib.com manuals search engine 6A1-70 ENGINE MECHANICAL (M13 ENGINE)
INSTALLATION
1) Apply engine oil to pistons, rings, cylinder walls, connecting
rod bearings and crankpins.
2) Install guide hoses (1) over connecting rod bolts.
These guide hoses protect crank pin and threads of rod bolt
from damage during installation of connecting rod and piston
assembly.
3) When installing piston and connecting rod assembly into cyl-
inder bore, point front mark on piston head to crankshaft pul-
ley side.
4) Install piston and connecting rod assembly into cylinder
bore. Use special tool (Piston ring compressor) to compress
rings. Guide connecting rod into place on crankshaft.
Using a hammer handle, tap piston head to install piston into
bore. Hold ring compressor firmly against cylinder block until
all piston rings have entered cylinder bore.
Special tool
(A) : 09916-77310 NOTE:
Do not apply oil between connecting rod and bearing or
between bearing cap and bearing.
A : Crankshaft pulley side
B : Flywheel side