engine oil SUZUKI JIMNY 2005 3.G Service Owners Manual

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Diagnosis
Diagnosis Table
Refer to “Diagnosis Table” in Section 3.
Rear Shock Absorber Check
Inspect for deformation or damage.
Inspect bushings for wear or damage.
Inspect for evidence of oil leakage.
Replace any defective part.
Trailing Arm, Lateral Rod, Axle Housing and
Coil Spring Check
Inspect for cracks, deformation or damage.
Replace any defective part.
Trailing Arm and Lateral Rod Bush Check
Inspect for wear and breakage. If found defective, replace.WARNING:
When handling rear shock absorber in which high-pres-
sure gas is sealed, make sure to observe the following
precautions.
Don’t disassemble it.
Don’t put it into the fire.
Don’t store it where it gets hot.
Before disposing it, be sure to drill a hole in it where
shown by an arrow in the figure and let gas and oil out.
Lay it down sideways for this work.
The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill. There-
fore, be sure to wear goggle.
A : Drill hole with approximately 3 mm (0.12 in.) diameter.

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Rear Suspension Fasteners
Check each bolt and nut fastening suspension parts for tightness.
Tighten loose one, if any, to specified torque, referring to “Tighten-
ing Torque Specifications” of this section.
Bearing Retainer and Axle Shaft Oil Seal
Check
When brake drum has been removed, check inside of brake
drum for gear oil leakage.
Also, check backside of brake back plate for oil leakage.If oil
leakage is found, replace defective oil seal.
Whenever it is possible to check oil seal during disassembly,
check its lip for wear.
If oil leakage or worn lip is found, replace defective oil seal.
Bump Stopper and Spring Rubber Seat Check
Inspect for wear and breakage. If found defective, replace.
Wheel Disc, Nut and Bearing Check
Inspect each wheel disc for dents, distortion and cracks. A
disc in badly damaged condition must be replaced.
Check wheel hub nuts for tightness and, as necessary,
retighten to specification.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)

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3) Remove upper mounting bolt (2).
4) Remove lower mounting bolt (3).
5) Remove shock absorber (1).
INSTALLATION
1) Install shock absorber (1), refer to figure for proper installing
direction of bush and washer (2).
Tighten bolts (3) temporarily by hand.
2) Remove floor jack.
3) Lower hoist.
4) Tighten shock absorber bolts (3) to specified torque.
Tightening torque
Shock absorber upper and lower bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
Coil Spring
REMOVAL
1) Hoist vehicle and remove wheel.
2) Support rear axle housing (1) by using floor jack (2).
3) Remove brake flexible hose E-ring (2).
NOTE:
Tighten lower bolt with vehicle off hoist and in non-
loaded condition.
1. Brake flexible hose

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4) Remove shock absorber lower mounting bolt (2).
5) Lower rear axle housing (2) gradually as far down as where
coil spring (1) can be removed.
6) Remove coil spring (1).
7) Remove spring rubber seat (1).
1. Shock absorber

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INSTALLATION
1) Install spring rubber seat (1).
2) Install coil spring (2) on spring seat (1) of axle housing and
then raise axle housing.
3) Install shock absorber lower mounting bolt.
Tighten bolt temporarily by hand.
4) Install brake flexible hose E-ring.
5) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
6) Lower hoist and tighten absorber lower bolt (2) to specified
torque.
Tightening torque
Shock absorber lower bolt
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft) NOTE:
Before installing spring rubber seat (1), apply soap water
on it.
NOTE:
Upper and lower diameters of coil spring (2) are differ-
ent.
Bring larger diameter end at bottom and set its open
end in place on spring seat (1).
When seating coil spring (2), mate spring end with
stepped part (3) of rear axle spring seat (1) as shown.
A : Upper side (small dia.)
B : Lower side (large dia.)
NOTE:
For tightening of lower bolt (2), refer to NOTE given under
“Shock Absorber” in this section.

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Install bushings so that either face of bushing are aligned
with housing edge of leading arm, also the length between
the aligned side end of bushing and trailing arm (1) are
within specification below.
Specification for trailing arm bushing protrusion
“a” : 8.5 – 10.5 mm (0.33 – 0.41 in.)
“b” : 6.0 – 9.0 mm (0.24 – 0.35 in.)
2) Install trailing arm (1) to vehicle body and rear axle housing,
referring to figure for proper installing direction of bolts.
3) Remove floor jack.
4) Connect wheel speed sensor harness clamps to trailing arm
(if equipped with ABS).
5) Connect parking brake cable clamp to trailing arm.
6) Lower hoist and with vehicle in non-loaded condition, tighten
trailing arm nuts to specified torque.
Tightening torque
Trailing arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Rear Axle Shaft and Wheel Bearing
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove rear brake drum and disconnect parking brake
cable from brake back plate. For details, refer to “Brake back
plate” in Section 5.
3) Drain gear oil from rear axle housing by loosening drain plug.

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INSTALLATION
Install removed parts in reverse order of removal procedure, not-
ing the following.
1) Aligning serrations between new stud bolt(s) (1) and flange,
install new stud bolt(s) (1) by tightening nut (2) as shown.
2) Press-fit wheel bearing (1) and retainer ring (2) as shown.
3) For vehicle with ABS, press-fit new sensor rotor as shown.
4) Inspect axle shaft length.
Rear axle shaft length
“a” : 775.5 mm (30.5 in.) (left side),
559.5 mm (22.0 in.) (right side)
5) Apply grease to axle shaft oil seal lip (1) as shown.
“A” : Grease 99000-25010
6) Apply sealant to mating surface of axle housing (2) with
brake back plate.
“B” : Sealant 99000-31110
3. Washer
4. Flange of axle shaft
NOTE:
Use care not to cause any damage to outside of
retainer ring (2).
Refer to figure so that wheel bearing (1) is installed in
proper direction.
NOTE:
Use care not to cause any damage to outside of retainer
ring (2).
[A]: Vehicle without ABS
[B]: Vehicle with ABS
NOTE:
Make sure to remove old sealant before applying it anew.

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7) Install rear axle shaft to rear axle housing (2) and tighten
brake back plate nuts (4) to specified torque.
Tightening torque
Brake back plate nuts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Connect brake pipe (3) to wheel cylinder and tighten brake
pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut
(b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
9) Tighten wheel speed sensor bolt to specified torque (if
equipped with ABS).
Tightening torque
Wheel speed sensor bolt
(c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
10) Install parking brake cable (3) to brake back plate (1).
11) Install brake shoes, referring to “Brake Shoe” in Section 5.
12) Install brake drum. Refer to “Rear Brake Drum” in Section 5.
13) Refill differential housing with new specified gear oil. Refer to
“Maintenance Service” in Section 7E for refill.
14) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “Bleeding Brakes” in Section 5.)
15) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.5 lb-ft) NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing (2).
1. Wheel speed sensor
2. Cable stopper ring

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16) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load over ten times so as to obtain proper
drum-to shoe clearance.
Adjust parking brake cable. (For adjustment, refer to “Parking
Brake Check and Adjustment” in Section 5.)
17) Tighten parking brake lever cover screws.
18) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
19) Check each installed part for oil leakage.
Rear Axle Shaft Inner Oil Seal
REMOVAL
1) Remove rear axle shaft. For details, refer to “Rear Axle Shaft
and Wheel Bearing” in this section.
2) Remove rear axle shaft inner oil seal by using special tools.
Special tool
(A) : 09942-15510
(B) : 09944-96010 (remover)
(C) : 09921-26010 (collar)
INSTALLATION
1) Using special tools drive in oil seal (1) until it contacts oil seal
protector (2) in axle housing.
Special tool
(A) : 09913-75520
“A” : Grease 99000-25010
2) For procedure hereafter, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
NOTE:
Make sure that oil seal (1) is free from inclination as it
is installed.
Refer to figure so that oil seal (1) is installed in proper
direction.
3. Differential side

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10) Loosen rear mounting nuts of trailing arm (2) but don’t
remove bolt.
11) Remove shock absorber (1) lower mounting bolt.
12) Lower floor jack until tension of suspension coil spring
becomes a little loose and remove rear mount bolts of trailing
arm.
13) Lower rear axle housing gradually.
14) Remove axle housing.
INSTALLATION
Install removed parts in reverse order of removal, noting the fol-
lowing.
1) Place rear axle housing (1) on floor jack. Then install trailing
arm (2) rear mounting bolts (right & left) in proper direction
as shown. At this time, mount nuts but don’t tighten them.
2) Install coil spring (2) (right & left) on spring seat (1) of axle
housing and raise axle housing.
3. Out side
4. Body center
NOTE:
Upper and lower diameters of coil spring (2) are differ-
ent. Bring larger diameter end at bottom and set its
open end in place on spring seat (1).
When seating coil spring (2), mate spring end with
stepped part (3) of rear axle spring seat (1) as shown.
A: Upper side (small dia.)
B: Lower side (large dia.)