2005 SUZUKI JIMNY Service Workshop Manual

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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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Rinse cylinder in clean brake fluid. Shake excess rinsing
fluid from cylinder. Do not use a cloth to dry cylinder, as lint
from cloth cannot be kept from cylinder bore surfaces.
ASSEMBLY
1) Install secondary piston assembly into cylinder.
2) Install primary piston in cylinder.
3) Depress, and install circlip (2).
4) Install piston stopper bolt with pistons pushed in all the way
and tighten it to specified torque (For vehicle without ABS).
Tightening torque
Piston stopper bolt
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Fill Reservoir
NOTE:
See NOTE at the beginning of this section.
Before assembling, wash each part in fluid recom-
mended to use for that vehicle.
1. Rod
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use container which has
been used for mineral oil or which is wet from water. Min-
eral oil will cause swelling and distortion of rubber parts
in hydraulic brake system and water will mix with brake
fluid, lowering fluid boiling point. Keep all fluid contain-
ers capped to prevent contamination.

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Fluid to fill reservoir with is indicated on reservoir cap of that vehi-
cle with embossed letters or in owner’s manual supplied with it.
Add fluid up to MAX line.

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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.