2005 SUZUKI JIMNY master cylinder

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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.

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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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Master Cylinder
Master Cylinder Reservoir
REMOVAL
1) Disconnect reservoir lead wire at coupler.
2) Clean outside of reservoir (1).
3) Take out fluid with syringe or such.
4) Remove reservoir connector pin (2) by using special tool.
Special tool
(A) : 09922-85811
Remove reservoir (1).
CAUTION:
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted surfaces.
2. Connector pin
3. Grommets

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INSTALLATION
1) When using new grommets, lubricate them with the same
fluid as the one to fill reservoir with. Then press-fit grommets
to master cylinder. Grommets must be seated in place.
2) Install reservoir (1) and drive in reservoir pin (2).
3) Connect reservoir lead wire.
4) Fill reservoir (1) with specified fluid.
5) Upon completion of installation, check for fluid leakage.
Master Cylinder Assembly
REMOVAL
1) Disconnect reservoir lead wire at coupler.
2) Clean around reservoir cap (1) and take out fluid with
syringe or such.
3) Disconnect brake pipes (4) from master cylinder (3).
4) Remove master cylinder attaching nuts (5).
5) Remove master cylinder (3).
For vehicle equipped with P & B valve (6), remove master
cylinder (3) with P & B valve (6) and its bracket, then sepa-
rate P & B valve (6) from master cylinder (3). NOTE:
See NOTE at the beginning of this section.
NOTE:
Drive in reservoir pin (2) till both of its ends at the right
and left of reservoir (1) become the same length.
2. Cap
CAUTION:
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted surfaces.
2. Reservoir

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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

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DISASSEMBLY
1) Remove circlip (1).
2) Remove primary piston.
3) [For vehicle with ABS]
Pull out primary piston assembly straight so as not to cause
any damage to inside o cylinder wall.
Pull out secondary piston assembly straight so as not to
cause any damage to inside of cylinder wall and by tapping
flange with a piece of wood or something soft.
4) [For vehicle without ABS]
Remove piston stopper bolt (1). Then remove secondary pis-
ton by blowing compressed air (2) into hole from which pis-
ton stopper bolt was removed.
Be cautions during removal as secondary piston jumps out.
INSPECTION
Inspect all disassembled parts for wear or damage, and
replace parts if necessary.
Inspect master cylinder bore for scoring or corrosion. It is
best to replace corroded cylinder.
Corrosion can be identified as pits or excessive roughness.
2. Master cylinder
NOTE:
Wash disassembled parts with brake fluid.
Do not reuse piston cups.
NOTE:
Polishing bore of master cylinder with cast aluminum
body with anything abrasive is prohibited, as damage to
cylinder bore may occur.
[A]: Vehicle equipped with ABS
[B]: Vehicle not equipped with ABS

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Brake Booster
REMOVAL
1) Remove master cylinder assembly, referring to “Maser Cylin-
der” in the section.
2) Disconnect brake vacuum hose (2) from booster (1).
3) Remove brake pipes (3).
1. Brake master cylinder assembly 5. Nut 9. Brake vacuum hose
2. Brake booster assembly 6. Clevis pin Tightening torque
3. Gasket 7. Clip
4. Push rod clevis 8. Nut
CAUTION:
Never disassemble brake booster. Disassembly will spoil
its original function. If faulty condition is found, replace it
with new one.

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4) Disconnect push rod clevis pin (4) from brake pedal arm (3).
5) Remove attaching nuts (6) and then booster as shown.
INSTALLATION
1) Install booster to dash panel as shown, Then connect
booster push rod clevis (2) to pedal arm (3) with clevis pin
(4) and clip (5).
2) Tighter booster attaching nuts to the specified torque.
Tightening torque
Booster nuts
(a) : 13 N·m (1.3 kg-m, 9.5 Ib-ft)
3) Connect brake vacuum hose to brake booster.
4) Install master cylinder, referring to “Master Cylinder” in this
section.
Inspection and adjustment
INSTALLATION POSITION OF PUSH ROD
Install push rod clevis (1) so that measurement “a” is obtained
and torque nut (2) to specification.
Tightening torque
Booster clevis nut
(a) : 25 N·m (2.5 kg-m, 18.0 Ib-ft)
Distance “a” between center of booster clevis pin hole
and booster surface
Standard : 126.1 – 127.1 mm (4.96 - 5.00 in.)
1. Steering column
2. Push rod clevis
5. Clip
NOTE:
See NOTE at the beginning of this section.
Check length of push rod clevis and adjust clearance
between booster piston rod and master cylinder pis-
ton. Refer to “Brake Booster Inspection and Adjust-
ment” in this section
Apply silicone grease to master cylinder piston.
1. Steering column