2005 SUZUKI JIMNY ect

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LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped)
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Hoist vehicle.
3) Disconnect brake pipes from LSPV.
4) Remove LSPV assembly from vehicle.
5) Remove spring and stay from LSPV.
INSTALLATION
Install by reversing removal procedure, noting the following.
1) Torque each bolt and nut to specification as indicated
respectively.
Tightening torque
LSPV bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Brake pipe flare nuts
(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
2) Upon completion of installation, fill reservoir tank with speci-
fied fluid and bleed air from brake system.
Tightening torque
LSPV bleeder plug
(a) : 8 N·m (8.0 kg-m, 6.0 lb-ft)
3) After bleeding air, check that LSPV is installed properly,
referring to following INSPECTION & ADJUSTMENT. CAUTION:
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted surface.
LSPV assembly must not be disassembled.
Replace with new one if defective.
NOTE:
As shown in figure, LSPV assembly should be removed
together with its spring and stay installed as they are.
NOTE:
Make sure to bleed air from LSPV bleeder without fail.

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LSPV Assembly
INSPECTION AND ADJUSTMENT
1) Confirm the following before inspection and adjustment.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
Vehicle is free from any other load.
Place it on level floor.
2) Push up LSPV lever with finger till it stops and measure
length of coil spring (“a” in figure).
3) Spring length “a” should be as specified.
Spring length “a”
147 mm (5.79 in.)
4) If it isn’t, adjust it to specification by changing stay position
as shown in figure. After adjustment, tighten bolt to specified
torque.
Tightening torque
LSPV adjust bolt
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
NOTE:
Check to make sure that LSPV body and brake pipe joints
are free from fluid leakage. Replace defective parts, if
any.

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P (Proportioning) Valve
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Disconnect brake pipes from P valve.
3) Remove P valve.
INSTALLATION
1) Install P valve (2).
Tightening torque
P valve bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
2) Tighten flare nuts to specified torque.
Tightening torque
Brake pipe flare nuts
(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
3) Fill reservoir with specified brake fluid.
4) Bleed air from system.CAUTION:
Do not allow brake fluid to get on painted surfaces.
WARNING:
Never disassemble P valve assembly. If it is found faulty,
replace it with new assembly.
1. Flare nuts

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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

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REMOVAL
1) Raise, suitably support vehicle. Remove wheel if necessary.
2) Clean dirt and foreign material from both hose end or pipe end fittings. Remove brake hose and pipe.
INSTALLATION
1) Install brake hose and pipe by reversing removal procedure, noting the following points.
For installation, make sure that steering wheel is in straightforward position and hose has no twist or kink.
Check to make sure that hose doesn’t contact any part of suspension, both in extreme right and extreme left
turn conditions. If it does at any point, remove and correct. Fill and maintain brake fluid level in reservoir.
Bleed brake system.
2) Perform brake test and check installed part for fluid leakage.

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Parking Brake Lever/Cable
Parking brake lever
REMOVAL
1) Hoist vehicle and release parking brake lever.
2) Disconnect negative cable at battery.
3) Remove parking brake lever cover.
4) Disconnect lead wire of parking brake switch at coupler.
5) Remove adjusting nut.
6) Loosen bracket nut (3) and disconnect parking brake cables
(2) from equalizer (4).
7) Remove parking brake lever bolts and then remove parking
brake lever assembly (1).
INSTALLATION
1) Install in reverse order of REMOVAL procedure.
Equalizer angle “a” : within 15 degrees
Tightening torque
Parking brake lever bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
2) After all parts are installed, parking brake lever needs to be
adjusted. Refer to “Parking Brake Inspection and Adjust-
ment” in this section.
3) Check brake drum for dragging and brake system for proper
performance. NOTE:
Don’t disassemble parking brake lever switch. It must be
removed and installed as a complete switch assembly.
1. Parking brake lever
2. Parking brake cable
3. Adjusting nut
4. Equalizer

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Parking Brake Cable
REMOVAL
1) Raise, suitably support vehicle and remove wheel if necessary.
2) Remove parking brake cable.
INSTALLATION
1) Install it by reversing removal procedure, noting the following points.
Install clamps properly referring to figure below.
Tighten bolts and nuts to specified torque.
2) Upon completion of installation, adjust cable. (Refer to “Parking Brake Inspection and Adjustment” in this
section.) Then check brake drum for dragging and brake system for proper performance. After removing
vehicle from hoist, brake test should be performed.
E : View E J : View J 2. Floor Tightening torque
G : View G K : View K 3. Cross member
H : View H 1. Bracket 4. Clamp