2005 SUZUKI JIMNY bolts

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-21
11) Connect brake flexible hose (2) to bracket on axle housing
and secure it with E-ring (1).
12) Connect brake pipe to brake flexible hose and tighten brake
pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut
(a) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
13) Clean mating surface of axle housing (2) (right & left) with
brake back plate and apply sealant as shown.
“B” : Sealant 99000-31090
14) Apply grease to axle shaft oil seals lip (1) (right & left) as
shown.
“A” : Grease 99000-25010
15) Install rear axle shafts, brake shoes, brake drums and
wheels. For details, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
16) Lower hoist.
17) Tighten right and left trailing arm nuts and shock absorber
lower bolts to specified torque.
Tighten lateral rod bolt and nut to specified torque.
Tightening torque
Trailing arm nuts and lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Shock absorber lower bolts
(b) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
18) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
19) Perform brake test (foot brake and parking brake). (For
brake test, see Section 5.)
20) Check each installed part for oil leakage.
NOTE:
When tightening these bolts and nuts, be sure that vehi-
cle is off hoist and in non loaded condition.
1. Shock absorber
2. Trailing arm
3. Lateral rod

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 5-20 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.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-21
INSTALLATION
1) Install pad shim (1) (to outside pad) and pads (2) to caliper
carrier (3).
2) Install caliper and torque caliper pin bolts (1) to specification.
Tightening torque
Brake caliper pin bolts
(a) : 22 N·m (2.2 kg-m, 16.0 Ib-ft)
3) Install wheel and torque front wheel nuts to specification.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
4) Upon completion of installation, perform brake test.NOTE:
See NOTE at the beginning of this section.
NOTE:
Make sure that boots are fit into groove securely.

Downloaded from www.Manualslib.com manuals search engine 5-22 BRAKES
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.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-25
5) Fit boot as it is in figure into boot groove in cylinder with fin-
gers.
6) Insert piston into cylinder by hand and fit boot in boot groove
in piston.
7) To confirm that boot is fitted in its groove in cylinder properly,
pull piston out of cylinder a little but do not take it all out.
8) Insert piston into cylinder by hand.
9) Install piston set ring.
INSTALLATION
1) Install caliper to caliper carrier.
2) Torque caliper pin bolts (1) to specification.
Tightening torque
Brake caliper pin bolts
(a) : 22 N·m (2.2 kg-m, 16.0 lb-ft)
NOTE:
Boot’s face “B” should be at the same level from cylin-
der’s face “A” all around.
NOTE:
Make sure that boots are fit into groove securely.

Downloaded from www.Manualslib.com manuals search engine 5-26 BRAKES
3) Install brake flexible hose (4) as shown and torque hose
mounting bolt (3) to specification.
Tightening torque
Front brake flexible hose bolt
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
4) Install wheel and torque wheel nuts to specification.
5) After completing installation, fill reservoir with brake fluid and
bleed brake system. Perform brake test and check each
installed part for oil leakage.
Brake Disc
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by loosening carrier bolts (2 pcs).
3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
1. Brake caliper
2. Washer
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.