2005 SUZUKI JIMNY ATE

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.

Downloaded from www.Manualslib.com manuals search engine 5-20 BRAKES
Brake pad
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper pin bolts (2).
3) Remove caliper (1) from caliper carrier.
4) Remove pads (3).
INSPECTION
Check pad lining for wear. When wear exceeds limit, replace with
new one.
Brake pad thickness (lining + pad rim)
Standard : 15 mm (0.59 in.)
Limit : 7 mm (0.28 in.)
1. Caliper
3. Disc
NOTE:
Hang removed caliper (1) with a wire hook (2) or the like
so as to prevent brake hose from bending and twisting
excessively or being pulled.
Don’t operate brake pedal with pads (3) removed.
CAUTION:
Never polish pad lining with sandpaper. If lining is pol-
ished with sandpaper, hard particles of sandpaper will be
deposited in lining and may damage disc. When pad lin-
ing requires correction, replace it with a new one.
NOTE:
When pads are removed, visually inspect caliper for
brake fluid leak. Correct leaky point, if any.

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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.

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INSPECTION
Cylinder Slide Bush
Check slide bush for smooth movement as shown.
If it is found faulty, correct or replace. Apply rubber grease to bush
outer surface. Rubber grease should be the one whose viscosity
is less affected by such low temperature as – 40 °C (– 40 °F).
Bush Dust Boot and Cylinder Boot
Check boots for breakage, crack and damage. If defective,
replace.
Piston Seal
Excessive or uneven wear of pad lining may indicate unsmooth
return of the piston. In such a case, replace rubber seal.
1. Apply rubber grease

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CHECK FOR FRONT BRAKE AFTER INSTALLATION
Mount tires and make certain that they rotate smoothly, with a
force of less than 3.0 kg (6.6 Ib).
If tire rotation is heavy, check the following:
Piston, piston seal and cylinder slide bush of caliper for
installation.
Wheel bearings for breakage.
Disc for flatness (Improper flatness brings disc into contact
with lining during rotation and makes rotation heavy).
To check this, measure disc deflection.NOTE:
For above check the following must be observed.
Jack up front wheels, both right and left, off the
ground.
Shift transfer shift lever to 2H (rear wheel) position (if
equipped) and start engine for a few seconds then
stop.
Side figure shows outer periphery of tire.
Be careful not to depress brake pedal when checking
tire for rotation.
1. String
2. Spring measure

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-29
Rear Brake
Brake drum
REMOVAL
1) Hoist vehicle and pull up parking brake lever.
2) Remove wheel.
3) Release parking brake lever.
4) Loosen parking brake cable adjusting nut (1).
1. Brake back plate 5. Shoe return spring lower 9. Shoe hold down pin
2. Brake shoe 6. Adjuster lever 10. Wheel cylinder
: Apply brake fluid to piston cap
3. Spring and rod assembly 7. Adjuster spring Tightening torque
4. Parking brake shoe lever 8. Shoe hold down spring

Downloaded from www.Manualslib.com manuals search engine 5-30 BRAKES
5) To increase clearance between brake shoe and brake drum,
remove rubber plug from brake back plate and turn adjuster
downward with flat-head screw driver.
6) Remove brake drum (1) off by using 8 mm bolts (2).
INSPECTION
Brake Drum
Inspect drum for cleanliness. Check wear of its braking surface by
measuring its inside diameter.
Drum inner diameter “a”
Standard : 220 mm (8.66 in.)
Service Limit : 222 mm (8.74 in.)
Whenever brake drums are removed, they should be thoroughly
cleaned and inspected for cracks, scores, deep grooves.
Cracked, scored, or grooved drum
A cracked, drum is unsafe for further service and must be
replaced.
Do not attempt to weld a cracked drum.
Smooth up any slight scores. Heavy or extensive scoring will
cause excessive brake lining wear and it will probably be neces-
sary to resurface drum braking surface.
If brake linings are slightly worn and drum is grooved, drum
should be polished with fine emery cloth but should not be turned.
NOTE:
When drum is removed, visually inspect wheel cylinder
for brake fluid leakage. Correct leaky point, if any.

Downloaded from www.Manualslib.com manuals search engine 5-32 BRAKES
Brake shoe
REMOVAL
1) Remove brake drum referring to “Brake Drum” in this sec-
tion.
2) Remove shoe return spring lower (3), spring and rod assem-
bly (4) and shoe hold down springs (2) by turning shoe hold
down pins (1).
3) Remove parking brake shoe lever (5) from brake back plate.
INSPECT
Inspect lever for free movement against brake shoe web. If
defective, correct or replace.
Inspect ratchet or thread rod part for wear, sticking and cor-
rosion.
Inspect for damage or weakening.
Inspect each part with arrow for rust. If found defective,
replace.
INSTALLATION
Assemble parts as shown in reverse order of removal.
1) Apply rubber grease to brake back plate and parking brake
shoe lever as shown in the figure. WARNING:
Use special care when installing brake shoe return
spring. Failure in its proper installation may allow it to
spring back and cause personal injury.
1. Apply rubber grease