2005 SUZUKI JIMNY bolt

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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.

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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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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

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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