2005 SUZUKI JIMNY AIR CON

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-7
Brake warning light
turns on when brake
is appliedBrake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Insufficient amount of brake fluid Add brake fluid.
Faulty P & Differential valve (Differential switch) Replace.
Brake warning light
fails to turn on even
when parking brake is
appliedBulb burnt out Replace bulb.
Brake warning light circuit open Repair circuit.
ABS warning light
does not turn on for 2
sec. after ignition
switch has turned ON.Bulb burnt out Replace bulb.
ABS warning light circuit open, if equipped with
ABS (including check relay)Check system referring to “TABLE-
A” in Section 5E.
ABS warning light
remains on after igni-
tion switch has turned
on for 2 sec.Malfunctioning ABS, if equipped with ABS Check system referring to “TABLE-
B” in Section 5E. Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine 5-12 BRAKES
If number of notches is out of specification, adjust cable by refer-
ring to adjustment procedure described on the following so as to
obtain specified parking brake stroke.
ADJUSTMENT
After confirming that above 5 conditions are all satisfied, adjust
parking brake lever stroke by loosening or tightening adjusting nut
(3) indicated in figure.
Parking brake stroke (when lever is pulled up at 200 N (20
kg, 44 Ibs) : 6 – 8 notches
Booster Operation Check
There are two ways to perform this inspection, with and without a
tester. Ordinarily, it is possible to roughly determine its condition
without using a tester.NOTE:
Check tooth tip of each notch for damage or wear. If any
damage or wear is found, replace parking brake lever.
NOTE:
Make sure for following conditions before cable adjust-
ment.
No air is trapped in brake system.
Brake pedal travel is proper.
Brake pedal has been depressed a few times with
about 30 kg (66 Ibs) load.
Parking brake lever (1) has been pulled up a few times
with about 20 kg force.
Rear brake shoes are not worn beyond limit, and self
adjusting mechanism operates properly.
NOTE:
Check brake drum for dragging after adjustment.
2. Brake cable
NOTE:
For this check, make sure that no air is in hydraulic line.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-13
CHECK AIR TIGHTNESS
1) Start engine.
2) Stop engine after running for 1 to 2 minutes.
3) Depress brake pedal several times with the same load as in
ordinary braking and observe pedal travel. If pedal goes
down deep the first time but its travel decreases as it is
depressed the second and more times, air tightness is
obtained.
4) If pedal travel doesn’t change, air tightness isn’t obtained.
CHECK OPERATION
1) With engine stopped, depress brake pedal several times with
the same load and make sure that pedal travel doesn’t
change.
2) Start engine while depressing brake pedal. If pedal travel
increases a little, operation is satisfactory. But no change in
pedal travel indicates malfunction.
1. 1st
2. 2nd
3. 3rd
NOTE:
If defective, inspect vacuum lines and sealing parts, and
replace any faulty part. When this has been done, repeat
the entire test.
1. 1st, 2nd, 3rd

Downloaded from www.Manualslib.com manuals search engine 5-14 BRAKES
CHECK AIR TIGHTNESS UNDER LOAD
1) With engine running, depress brake pedal. Then stop engine
while holding brake pedal depressed.
2) Hold brake pedal depressed for 30 seconds. If pedal height
does not change, condition is good. But it isn’t if pedal rises.
H : Hold
H : Hold
T : 30 seconds

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-15
Fluid Pressure Test (If Equipped with LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
1) Stop vehicle on level floor and place approximately about
140 kg (309 Ibs) weight on rear housing so that rear axle
weights 600 kg (1323 Ib).
Rear axle weight
“L” : 600 kg (1323 lb)
2) Install special tool to front and rear brake.
Special tool
Front brake
(A) : 09956-02310
(B) : 55473-82030 (Use the air bleeder plug supplied as a
spare part)
Rear brake
(A) : 09956-02310
(B) : 55473-82030 (Use the air bleeder plug supplied as a
spare part)
3) Depress brake pedal gradually till fluid pressure of front
brake becomes as specified below and check corresponding
pressure of rear brake. It should be within specification given
below.
As done above, apply 100 kg/cm
2 pressure to front brake and
check that rear brake pressure is within specification as given
below.NOTE:
Special tool should be connected to bleeder plug hole of
front (driver’s side brake) and rear brakes.
1. Air bleeder plug
2. Weight
3. Attachment
Front brake Rear brake
5000 kPa
50 kg/cm
2
711 psi3800 – 5100 kPa
38 – 51 kg/cm
2
540 – 725 psi
Front brake Rear brake
10000 kPa
100 kg/cm
2
1422 psi5100 – 6500 kPa
51 – 65 kg/cm
2
725 – 924 psi

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 5-18 BRAKES
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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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.