2005 SUZUKI JIMNY body

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-39
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

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-43
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.

Downloaded from www.Manualslib.com manuals search engine 5E-2 ANTILOCK BRAKE SYSTEM (ABS)
General Description
The ABS (Antilock Brake System) is a system to prevent each wheel to lock during hard braking or braking on a
slippery road by controlling the fluid pressure from master cylinder to each brake (either brake caliper or wheel
cylinder).
The ABS of this vehicle monitors all four wheels (four sensors) and controls all four wheels when the system is
active.
The component parts of this ABS includes following parts in addition to those of the conventional brake system.
Wheel speed sensor senses revolution speed of each wheel and sends outputs to ABS control module.
In this ABS, ABS hydraulic unit (actuator assembly), ABS control module, pump motor transistor and fail-
safe transistor are combined as one component.
ABS control module sends operation signal to ABS hydraulic unit to control fluid pressure applied to each
wheel cylinder based on signal from each wheel speed sensor so as to prevent wheel from locking.
ABS hydraulic unit operates according to signal from ABS control module and controls fluid pressure applied
to wheel cylinder of each of 4 wheels.
Fail-safe transistor which supplies power to solenoid valve in ABS hydraulic unit.
Pump motor transistor supplies power to pump motor in ABS hydraulic unit.
“ABS” warning lamp lights to inform abnormality when system fails to operate properly.
G sensor which detects body deceleration speed.
1. Front disc brake 5. Brake master cylinder / booster
2. Proportioning valve [A] : For LH steering vehicle
3. Rear drum brake [B] : For RH steering vehicle
4. ABS hydraulic unit / control module assembly

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-15
Table – B “ABS” Warning Lamp Circuit Check – Lamp Comes “ON” Steady
Refer to TABLE – A for System Circuit Diagram and Circuit Description.
INSPECTION
3 1) Remove combination meter.
Is bulb of ABS warning lamp in good condition?“R/Bl” circuit shorted to ground.
If OK, replace ABS warning cir-
cuit (lamp driver module).Replace bulb.
4 Is IG fuse in good condition? Open in “B/W” wire to combina-
tion meter or poor connection.Repair and replace. Step Action Yes No
Step Action Yes No
1 Perform diagnostic trouble code check. Is there
any DTC (including code No.12, NO CODES on
SUZUKI scan tool) exists?Go to step 2. Go to step 3.
2 Is malfunction DTC (other than code No.12)
exists at step 1?Go to step 7 of ABS diag-
nostic flow table in this
section.Go to step 3.
3 1) Disconnect ABS hydraulic unit / control
module connector.
2) Check for proper connection to ABS hydrau-
lic unit / control module connector at termi-
nals “A14” and “A18”.
3) If OK, turn ignition switch “ON” and mea-
sure voltage at terminal “A18” of connector.
Is it 10 – 14 V?Go to step 4.“B/W” circuit open.
4 1) With ABS control module connector discon-
nected, turn ignition switch ON and light
ABS warning lamp.
2) Connect terminal “A14” of disconnected
connector to ground using service wire.
Does “ABS warning lamp” turn off?Go to step 5.“R/Bl” circuit open.
If wire and connection are
OK, replace ABS lamp
driver module.
5 1) Measure resistance from connector termi-
nal “A24” to body ground.
Is continuity indicated?Substitute a known-good
ABS hydraulic unit / con-
trol module assembly and
recheck.“B” circuit open.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-17
Table – D Code (DTC) is Not Outputted Even With Diag. Switch Terminal Con-
nected to Ground.
CIRCUIT DESCRIPTION
When the diag. switch terminal is connected to the ground with the ignition switch turned ON, the ABS control
module outputs a diagnostic trouble code by flashing “ABS” warning lamp.
INSPECTION
1.“ABS” warning lamp in combination meter 3-1. Diag. switch terminal 4-1. Lock position
2. ABS hydraulic unit / control module assembly 3-2. Diag. ground terminal 4-2. Unlock position
3. Monitor connector 4. ABS hydraulic unit / control module connector of harness
Step Action Yes No
1 Is it shorted diag. switch terminal and ground
terminal by service wire properly?Go to step 2. Connect service wire
securely.
2 1) Disconnect service wire.
2) Disconnect ABS hydraulic unit / control
module connector.
3) Measure resistance between diag. switch
terminal and connector terminal “A12”.
Is it infinite (∞)?“P/B” circuit open. Go to step 3.
3 1) Measure resistance between ground termi-
nal of monitor connector and body ground.
Is continuity indicated?Go to step 4.“B” circuit open or poor
connection.
4 1) Check for proper connection to ABS hydrau-
lic unit / control module at terminal “A12”
and “A24”.
2) If OK, then check “ABS” warning lamp cir-
cuit referring to TABLE A, B and C.
Is it in good condition?Substitute a known-good
ABS hydraulic unit / con-
trol module assembly and
recheck.Repair “ABS” warning
lamp circuit.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-19
INSPECTION
Step Action Yes No
1 Is G sensor installed floor securely? Go to step 2. Tighten sensor or bracket
screw securely. If not, use
new screw.
2 1) Ignition switch OFF.
2) Remove G sensor with bracket.
3) Check for proper connection to G sensor.
4) If OK, then check G sensor referring to “G
Sensor” in this section.
Is it in good condition?Go to step 3. Replace G sensor.
3 1) Disconnect connectors from ABS hydraulic
unit / control module assembly (See [A])
and G sensor.
2) Check for proper connection to ABS control
module at terminals “A11” and “A13”.
3) If OK, then turn ignition switch ON and mea-
sure voltage between “B/W” terminal of sen-
sor connector and body ground.
Is it 10 – 14 V?Go to step 4.“B/W” circuit open.
4 Measure voltage between “R/W” terminal of
sensor connector and body ground.
Is it 0 V?Go to step 5.“R/W” circuit shorted to
power circuit.
5 1) Ignition switch OFF.
2) Check that “R/W” circuit is free from open or
short to ground and “Or/B” circuit. (See [B])
Is it in good condition?“Or/B” circuit open.
If circuit is OK, substitute
a known-good ABS
hydraulic unit / control
module assembly.“R/W” circuit open or
shorted to ground or “Or/
B” circuit.
1. ABS hydraulic unit / control module connector
2. Lock position
3. Unlock position

Downloaded from www.Manualslib.com manuals search engine 5E-20 ANTILOCK BRAKE SYSTEM (ABS)
DTC C1016 (DTC 16) – Stop Lamp Circuit
DESCRIPTION
The ABS control module monitors the voltage at the stop lamp while the ignition switch is ON. When the voltage
is without the specified range at terminal “A2”, a DTC will be set.
INSPECTION
1. Main fuse 4. IG fuse 7. ABS hydraulic unit / control module assembly
2. Ignition switch 5. Stop lamp switch 8. ABS hydraulic unit / control module connector of harness
3. Tail stop fuse 6. Stop lamp
Step Action Yes No
1 1) Turn IG switch OFF.
2) Disconnect connectors from ABS hydraulic
unit / control module assembly.
3) Depress the brake pedal.
4) Measure the voltage between the stop lamp
terminal “A2” and body ground.
Is it 10 – 14 V?Check for proper connection to
ABS control module at terminal
“A2”. If OK, substitute a known-
good ABS control module and
recheck.“G/W” circuit open.

Downloaded from www.Manualslib.com manuals search engine 5E-22 ANTILOCK BRAKE SYSTEM (ABS)
INSPECTION
Step Action Yes No
1 1) Disconnect the applicable sensor connector with ignition
switch OFF.
2) Measure resistance between sensor terminals.
Resistance of wheel speed sensor: 1.4 – 1.8 kΩ (at
20°C, 68°F)
3) Measure resistance between each terminal and body
ground.
Insulation resistance: 1MΩ or higher
Were measured resistance values in step 2) and 3) as spec-
ified? (See [A])Go to step 2. Replace sensor.
2 1) Ignition switch OFF.
2) Disconnect connector from ABS hydraulic unit / control
module assembly. (See [B])
3) Check for proper connection to ABS hydraulic unit / con-
trol module assembly at each sensor terminal.
4) If OK, then turn ignition switch ON and measure voltage
between sensor positive terminal of module connector
and body ground.
Is it 0V?Go to step 3. Sensor positive cir-
cuit shorted to
power.
3 1) Ignition switch OFF.
2) Connect connector to sensor.
3) Measure resistance between sensor terminals at mod-
ule connector.
4) Measure resistance between sensor positive terminal
and negative terminal of module connector, between
positive terminal and body ground.
Are measured resistance values within each specified range
described in above step 1?Go to step 4. Circuit open or
shorted to ground.
4 1) Remove wheel speed sensor.
2) Check sensor for damage or foreign material being
attached.
Is it in good condition? (See [C])Go to step 5. Clean or replace
sensor.
5 Check visually through wheel speed sensor installation hole
for following.
Ring serration (teeth) neither missing or damaged.
No foreign material being attached.
Ring not being eccentric.
Wheel bearing free from excessive play.
Are they in good condition? (See [D])Go to step 6. Clean, repair or
replace.
6 1) Install sensor to knuckle or axle housing.
2) Tighten sensor bolt to specified torque and check that
there is not any clearance between sensor and knuckle
or axle housing. (See [E])
Replace sensor if any.
Referring to “Front Wheel Speed Sensor” in this section,
check output voltage or waveform of sensor. Is proper out-
put voltage or waveform obtained?Substitute a known-
good ABS hydraulic
unit / control module
assembly and
recheck.Replace sensor and
recheck.