2005 SUZUKI JIMNY oil

Downloaded from www.Manualslib.com manuals search engine 4B-4 PROPELLER SHAFTS
INSTALLATION
Install propeller shaft(s) reversing removal procedure noting fol-
lowing points :
When installing propeller shaft, align the match marks.
Otherwise, vibration may occur during driving.
Use following specification to torque universal joint flange.
Tightening torque
Propeller shaft bolt (propeller shaft No.1, No.2 and No.3
rear differential side)
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Propeller shaft bolt (propeller shaft No.3 transfer case
side)
(b) : 33 N·m (3.3 kg-m, 24 lb-ft)
Grease splines of propeller shaft No. 2 and No. 3.
“A” : Chassis Grease 99000-25030
Match marks (1) are provided on slip-on spline connections
of propeller shaft No. 2 and No. 3. Inserting splined end into
spIined bore without regard to match marks can be a possi-
ble cause of noise or vibration of propeller shaft. Be sure to
index marks. NOTE:
If transmission oil was drained for front propeller shaft
removal, pour specified gear oil into transmission case
to specified level.

Downloaded from www.Manualslib.com manuals search engine 5-4 BRAKES
Diagnosis
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road test
brakes by making brake applications with both light and heavy pedal forces at various speeds to determine if the
vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the other without brake application. If it does, check the tire
pressure, front end alignment and front suspension attachments for looseness. See diagnosis table for other
causes.
Brake Fluid Leaks
Check the master cylinder fluid levels. While a slight drop in reservoir level does result from normal lining wear,
an abnormally low level indicates a leak in the system. In such a case, check the entire brake system for leak-
age. If even a slight evidence of leakage is noted, the cause should be corrected or defective parts should be
replaced.
If fluid level is lower than the minimum level of reservoir, refilling is necessary. Fill reservoir with specified brake
fluid.
Brake fluid: Refer to reservoir tank cap.
Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components
in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the drum brake wheels.
If deterioration of rubber is evident, disassemble all hydraulic parts and wash with alcohol. Dry these parts with
compressed air before assembly to keep alcohol out of the system. Replace all rubber parts in the system,
including hoses. Also, when working on the brake mechanisms, check for fluid on the linings. If excessive fluid is
found, replace the linings.
If master cylinder piston seals are satisfactory, check for leakage or excessive heat conditions. If condition is not
found, drain fluid, flush with brake fluid, refill and bleed the system.
The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to contaminated fluid.CAUTION:
Since brake system of this vehicle is factory-filled with brake fluid indicated on reservoir tank cap, do
not use or mix different type of fluid when refilling; otherwise serious damage will occur.
Do not use old or used brake fluid, or any fluid from a unsealed container.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-5
Diagnosis Table
Condition Possible Cause Correction
Not enough braking
forceBrake oil leakage from brake lines Locate leaking point and repair.
Brake disc or pads stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Poor contact of shoes on brake drum Repair for proper contact.
Brake shoes linings stained with oil or wet with
waterReplace.
Badly worn brake shoe linings Replace.
Defective wheel cylinders Repair or replace.
Malfunctioning caliper assembly Repair or replace.
Air in system Bleed system.
Maladjusted sensor spring length of LSPV Check or adjust.
Broken sensor spring of LSPV Replace.
Defective collar of LSPV Replace.
Malfunctioning ABS (Antilock brake system), if
equippedCheck system and replace as nec-
essary.
Brake pull (Brakes not
working in unison)Pad or shoe linings are wet with water or
stained with oil in some brakesReplace.
Drum-to-shoe clearance out of adjustment in
some brakes (Malfunctioning auto adjusting
mechanism)Check for inoperative auto adjusting
mechanism.
Drum is out of round in some brakes Replace.
Wheel tires are inflated unequally Inflate equally.
Malfunctioning wheel cylinders Repair or replace.
Disturbed front wheel alignment Adjust as prescribed.
Unmatched tires on same axle Tires with approximately the same
amount of tread should be used on
the same axle.
Restricted brake tubes or hoses Check for soft hoses and damaged
lines.
Replace with new hoses and new
double-walled steel brake tubing.
Malfunctioning caliper assembly Check for stuck or sluggish pistons
and proper lubrication of caliper
slide bush.
Loose suspension parts Caliper should slide.
Check all suspension mountings.
Loose calipers Check and torque bolts to specifica-
tions.
Noise (high pitched
squeak without brake
applied)Front lining worn out Replace brake pads.
Rear brake locked pre-
maturelyMaladjusted sensor spring length of LSPV Check or adjust.
Malfunctioning LSPV assembly Replace assembly.
Brake locked
(For vehicles
equipped with ABS)Malfunctioning ABS, if equipped Check system and replace as nec-
essary.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-11
Rear Drum Brake Shoe Adjustment
Rear brake has self-adjusting mechanism but it does require
adjustment for proper drum to shoe clearance when brake shoe
has been replaced or brake drum has been removed for some
other service.
Adjustment is automatically accomplished by depressing brake
pedal about 30 times with approximately 30 kg (66 Ibs) load after
all parts are installed.
Then check brake drum for dragging and brake system for proper
performance. After lowering vehicle from hoist, brake test should
be performed.
Parking Brake Inspection and Adjustment
INSPECTION
Hold center of parking brake lever grip and pull it up with 20 kg
(44 Ibs) force.
With parking brake lever pulled up as above, count ratchet
notches.
There should be 6 to 8 notches.
Also, check if both right and left rear wheels are locked firmly. To
count number of notches easily, listen to click sounds that ratchet
makes while pulling parking brake lever without pressing its but-
ton.
One click sound corresponds to one notch.NOTE:
Be sure to use particular brake fluid either as indicated
on reservoir cap of that vehicle or recommended in
owner’s manual which comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked
on reservoir.
When brake warning lamp lights sometimes during driv-
ing, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake system for
leakage.
Correct leaky points and then refill to specified level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has
been used for mineral oil or a container which is wet from
water. Mineral oil will cause swelling and distortion of
rubber parts in hydraulic brake system and water mixed
into brake fluid will lower fluid boiling point. Keep all fluid
containers capped to prevent contamination.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-17
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.

Downloaded from www.Manualslib.com manuals search engine 5-26 BRAKES
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.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-31
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

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.