2005 SUZUKI JIMNY front

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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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Caliper assembly
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove brake flexible hose mounting bolt from caliper. As
this will allow fluid to flow out of hose, have a container ready
beforehand.
3) Remove caliper pin bolts.
4) Remove caliper from carrier.
DISASSEMBLY
1) Before disassembly, clean all around caliper with brake fluid.
2) Remove piston set ring (1) and boot from caliper, pry off with
a flat-bladed tool. Be careful not to damage boot.
3) Blow compressed air into cylinder through bolt hole where
flexible hose was fitted. With this air pressure, piston can be
pushed out of cylinder.
4) Remove piston seal using a thin blade like a thickness
gauge, etc.
5) Remove bleeder plug and cap from caliper.
WARNING:
Do not apply too highly compressed air which will cause
piston to jump out of cylinder. Place a cloth (1) to prevent
piston from damage. It should be taken out gradually
with moderately compressed air. Do not place your fin-
gers in front of piston when using compressed air.
NOTE:
Be careful not to damage inside (bore side) of cylinder.

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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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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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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 Hose/Pipe
Front brake hose/pipe
For left-hand steering vehicle
[A] : For vehicle without ABS X : View X 5. Brake caliper 12. To front left brake caliper
[B] : For vehicle with ABS Y : View Y 6. 4 way joint 13. To rear brake
F : Front side Z : View Z 7. 5 way joint a-d: Clamp
R : Right side 1. E-ring 8. ABS hydraulic unit/control mod-
ule assemblyTightening torque
T : Top side 2. Flexible hose 9. P valve
V : View V 3. Hose washer 10. Hose bracket
W : View W 4. Hose bolt 11. To front right brake caliper