2005 SUZUKI JIMNY All

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 4B-6 PROPELLER SHAFTS
6) Push out bearing race (2) on flange yoke (1) in the same
way as Step 2).
7) Holding bearing race (2) by a vise (3), tap flange yoke (1)
and take out race.
8) Take out bearing race (2) on the opposite side of flange yoke
(1) in the same way as Step 5) to Step 6).
REASSEMBLY
1) Apply grease to rollers (1) in bearing races (2).
“A” : Grease 99000-25030
2) With spider (4) inserted into bearing race (2) to prevent roll-
ers in race from coming out, insert bearing race (2) into shaft
yoke (3) until it is flush with side face of shaft yoke (3), tap-
ping it by a copper hammer (1).
CAUTION:
Do not reuse spider (1), bearings (2) and circlips. Other-
wise it may damage propeller shaft or cause abnormal
vibration or noise.
NOTE:
Make sure that rollers (1) in bearing race (2) are all in
place.

Downloaded from www.Manualslib.com manuals search engine PROPELLER SHAFTS 4B-7
3) Insert bearing race into opposite side of shaft yoke until it is
flush with side face of shaft yoke, tapping it by a copper
hammer.
4) In the same way as Step 2) to Step 3), insert bearing races
into flange yoke.
5) Using round bar of 22 – 24 mm (0.87 in. – 0.94 in.) in diame-
ter and hammer, tap bearing races into shaft or flange yoke
until circlips can be installed in its groove on yoke bores.
6) Install 4 circlips in each groove on shaft and flange yoke
bores.
Tightening Torque Specification
Required Service Material
NOTE:
After reassembly, ensure that both shaft yoke and
flange yoke move smoothly.
Make sure that each circlip is fitted in groove securely.
Fastening portionTightening torque
Nm kg-m lb-ft
Propeller shaft bolt (propeller shaft No.1 No.2 and No.3 rear dif-
ferential side)50 5.0 36.5
Propeller shaft bolt (propeller shaft No.3 transfer case side) 33 3.3 24
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium greaseSUPER GREASE C
(99000-25030)To apply to spider bearing race and propel-
ler shaft No.2 and No.3 splines.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
5
9
10
10A
10B
9
10
10A
10B
SECTION 5
BRAKES
CONTENTS
General Description ......................................... 5-3
Diagnosis .......................................................... 5-4
Road Testing Brakes ...................................... 5-4
Brake Fluid Leaks .......................................... 5-4
Substandard or Contaminated Brake Fluid .... 5-4
Diagnosis Table ............................................. 5-5
Brake Pedal Free Height Adjustment ............. 5-8
Brake Pedal Play Check ................................ 5-8
Stop Light Switch Adjustment ........................ 5-8
Excessive Pedal Travel Check ....................... 5-9
Front Brake Disc Check ................................. 5-9
Front Brake Pad Check .................................. 5-9
Rear Brake Shoe Check .............................. 5-10
Master Cylinder and Brake Fluid Level
Check ........................................................... 5-10
Rear Drum Brake Shoe Adjustment ............. 5-11
Parking Brake Inspection and Adjustment ... 5-11
Booster Operation Check ............................. 5-12Fluid Pressure Test
(If Equipped with LSPV) ............................... 5-15
On-Vehicle Service ........................................ 5-17
Air Bleeding of Brake System ...................... 5-17
Brake Hose and Pipe Inspection.................. 5-18
Front Disc Brake .......................................... 5-19
Brake pad ................................................. 5-20
Caliper assembly...................................... 5-22
Brake Disc.................................................... 5-26
Rear Brake ................................................... 5-29
Brake drum............................................... 5-29
Brake shoe ............................................... 5-32
Wheel Cylinder............................................. 5-33
Brake back plate ...................................... 5-34
Master Cylinder .............................................. 5-36
Master Cylinder Reservoir ........................... 5-36
Master Cylinder Assembly ........................... 5-37 WARNING:
For lifting point of vehicle, refer to Section 0A.
WARNING:
For vehicles equipped with Supplement Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E first.
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.

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 5-6 BRAKES
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

Downloaded from www.Manualslib.com manuals search engine 5-8 BRAKES
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)