2005 SUZUKI JIMNY Torque

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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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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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PIPE
Inspect the tube for damage, cracks, dents and corrosion. If any
defect is found, replace it.
Front Disc Brake
1. Caliper pin bolt 10. Carrier bolt
2. Boot11. Brake caliper carrier
3. Cylinder slide bush
: Apply rubber grease to mating surface of caliper12. Pad clip
4. Bleeder plug cap 13. Disc brake caliper
5. Bleeder plug 14. Disc brake pad
6. Anti noise shim 15. Piston seal
: Apply brake fluid to all around part of piston seal
7. Disc brake piston
: Apply brake fluid to contact surface of cylinderTightening torque
8. Cylinder bootDo not reuse.
9. Seat ring (boot ring)

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INSTALLATION
1) Install pad shim (1) (to outside pad) and pads (2) to caliper
carrier (3).
2) Install caliper and torque caliper pin bolts (1) to specification.
Tightening torque
Brake caliper pin bolts
(a) : 22 N·m (2.2 kg-m, 16.0 Ib-ft)
3) Install wheel and torque front wheel nuts to specification.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
4) Upon completion of installation, perform brake test.NOTE:
See NOTE at the beginning of this section.
NOTE:
Make sure that boots are fit into groove securely.

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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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5) Fit boot as it is in figure into boot groove in cylinder with fin-
gers.
6) Insert piston into cylinder by hand and fit boot in boot groove
in piston.
7) To confirm that boot is fitted in its groove in cylinder properly,
pull piston out of cylinder a little but do not take it all out.
8) Insert piston into cylinder by hand.
9) Install piston set ring.
INSTALLATION
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts (1) to specification.
Tightening torque
Brake caliper pin bolts
(a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
NOTE:
Boot’s face “B” should be at the same level from cylin-
der’s face “A” all around.
NOTE:
Make sure that boots are fit into groove securely.

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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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INSPECTION
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and disc is not defective unless they are serious.
But when there are deep scratches or scratches all over disc sur-
face, replace it. When only one side is scratched, polish and cor-
rect that side.
Brake disc thickness “a”
Standard : 10 mm (0.394 in.)
Limit : 8.0 mm (0.315 in.)
Use wheel nuts (1) and suitable plain washers (2) to hold the disc
securely against the hub, then mount a dial indicator as shown
and measure the runout at 10 mm (0.39 in.) from the outer edge
of the disc.
Disk deflection
Limit : 0.15 mm (0.006 in.)
INSTALLATION
1) Install disc to wheel hub.
2) Install caliper assembly to steering knuckle.
3) Torque caliper carrier bolts to specification.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
4) Install wheel and torque front wheel nuts to specification.
5) Upon completion of installation, perform brake test.
NOTE:
Check front wheel bearing for looseness before measure-
ment.
NOTE:
See NOTE at the beginning of this section.