2005 SUZUKI JIMNY check engine

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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.

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Excessive pedal travel
(Pedal stroke too
large)Partial brake system failure Check brake systems and repair as
necessary.
Insufficient fluid in master cylinder reservoirs Fill reservoirs with approved brake
fluid.
Check for leaks and air in brake
systems.
Check warning light. Bleed system
if required.
Air in system (pedal soft/spongy) Bleed system.
Rear brake system not adjusted (malfunctioning
auto adjusting mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoes Replace brake shoes.
Worn rear brake shoes Replace brake shoes.
Dragging brakes (A
very light drag is
present in all disc
brakes immediately
after pedal is released)Master cylinder pistons not returning correctly Repair master cylinder.
Restricted brake tubes or hoses Check for soft hoses or damaged
tubes and replace with new hoses
and/or new brake tubes.
Incorrect parking brake adjustment on rear
brakesCheck and adjust to correct specifi-
cations.
Weakened or broken return springs in the brake Replace.
Sluggish parking-brake cables or linkage Repair or replace.
Wheel cylinder or caliper piston sticking Repair as necessary.
Malfunctioning ABS, if equipped with ABS Check system and replace as nec-
essary.
Pedal pulsation (Pedal
pulsates when
depressed for brak-
ing.) Damaged or loose wheel bearings Replace wheel bearings.
Distorted steering knuckle or rear axle shafts Replace knuckle or rear axle shaft.
Excessive disc lateral runout Check per instructions. If not within
specifications, replace or machine
the disc.
Parallelism not within specifications Check per instructions. If not with
specifications, replace or machine
the disc.
Rear drums out of round. Check runout.
Repair or replace drum as neces-
sary.
Braking noise
Glazed shoe linings, or foreign matters stuck to
liningsRepair or replace brake shoe.
Worn or distorted shoe linings Replace brake shoe (or pad).
Loose front wheel bearings Replace wheel bearing.
Distorted backing plates or loose mounting
boltsReplace or retighten securing bolts.
Brake warning light
turns on after engine
startParking brake applied Release parking brake and check
that brake warning light turns off.
Insufficient amount of brake fluid Add brake fluid.
Brake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Brake warning light circuit faulty Repair circuit. Condition Possible Cause Correction

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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

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Brake Pedal Free Height Adjustment
1) Check brake pedal free height.
If it is not within specification, check and adjust following item
2) and 3).
Brake pedal free height “a” from wall
LH steering vehicle : 221 – 227 mm (8.70 – 8.94 in.)
RH steering vehicle : 217 – 223 mm (8.54 – 8.78 in.)
2) Check measurement between booster mounting surface and
center of clevis pin hole. When booster push rod clevis has
been reinstalled, it is important that the measurement is
adjusted. (Refer to “Brake Booster Inspection and Adjust-
ment” in this section.)
3) Check stop light switch position. Adjust it if it is out of specifi-
cation.
Brake Pedal Play Check
Pedal play should be within specification below.
If out of specification, check stop light switch for proper installation
position and adjust if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Brake pedal play “a” : 1 – 8 mm (0.04 – 0.31 in.)
Stop Light Switch Adjustment
Adjustment should be made as follows when installing switch. Pull
up brake pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread and
brake pedal is specified. Then tighten lock nut to specified torque.
Clearance between brake pedal and stop light switch
“c” : 1.5 – 2.0 mm (0.06 – 0.08 in.)
Tightening torque
Stop light switch lock nut
(a) : 6.5 N·m (0.65 kg-m, 4.7 lb-ft)

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Excessive Pedal Travel Check
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 30 kg (66
Ibs) load, measure brake pedal to wall clearance “d” or “e”.
Clearance “d” or “e” between brake pedal and wall
LH steering vehicle clearance “d” : Over 55 mm (2.17 in.)
RH steering vehicle clearance “e” : Over 76 mm (2.99 in.)
4) If clearance “d” or “e” is less than specification, the most pos-
sible cause is either rear brake shoes are worn out beyond
limit or air is in lines.
Should clearance “d” or “e” remain less than specification
even after replacement of brake shoes and bleeding of sys-
tem, other possible but infrequent cause is malfunction of
rear brake shoe adjusters or booster push rod length out of
adjustment.
–Bleed brake system. Refer to “Air Bleeding of Brake Sys-
tem” in this section.
–Remove brake drums for adjuster inspection. Refer to
“Rear Brake” in this section. If defective, correct or replace.
Front Brake Disc Check
Refer to item “Front Disc Brake” in this section for inspection point
and procedure.
Front Brake Pad Check
Inspect pad linings (3) periodically according to maintenance
schedule whenever wheels are removed (for tire rotation or other
reason). Take a look through each end (or hole) of caliper and
check lining thickness of outside and inside pads. If lining is worn
and its thickness (“a” in figure) is less than limit, all pads must be
replaced at the same time.
Front brake pad thickness “a” (lining thickness)
Limit : 2.0 mm (0.08 in.)
[A]: LH steering vehicle
[B]: RH steering vehicle
1. Pad rim
2. Disc

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Rear Brake Shoe Check
Inspection should be carried out on following points after brake
pedal travel (pedal to wall clearance) check, even when pedal
travel is normal. Amount of brake shoe wear can be checked as
follows.
1) Hoist vehicle.
2) Remove rubber plug (1) from brake back plate.
3) Through hole of back plate, visually check for thickness of
brake shoe lining (2). If lining thickness “a” is found less than
limit, replace all shoes with new ones at the same time.
Rear brake shoe thickness “a” (lining thickness)
Limit : 1.0 mm (0.04 in.)
Master Cylinder and Brake Fluid Level Check
1) Check master cylinder and reservoir for crack, damage and
brake fluid leakage. If any faulty condition exists, correct or
replace.
2) Check that brake fluid level is between MAX and MIN marks
on reservoir.
3. Brake shoe rim

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 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.