steering SUZUKI JIMNY 2005 3.G Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-39
9) Remove knuckle seal cover bolts, take off knuckle seal cover
(1), knuckle seal and knuckle seal retainer.
10) Remove upper and lower kingpins (2) from steering knuckle.
11) Remove knuckle with hub assembly from axle housing (for
2WD model) or draw out right and left axle shafts with
knuckle and hub assembly (for 4WD model).
12) Before removing front propeller shaft (1), give match marks
(3) on joint flange (2) and front propeller shaft as shown (for
4WD).
13) Remove front differential from front axle housing (for 4WD).
14) Remove air locking hub vacuum pipe from axle housing (1)
(for 4WD).
15) Support front axle housing by using floor jack.
16) Remove lateral rod, refer to “Lateral Rod” in this section.
17) Remove stabilizer bar, refer to “Stabilizer Bar / Bushings” in
this section.
18) Loosen mounting nuts of leading arm (1) but don’t remove
bolts. NOTE:
The removed upper and lower kingpins (2) must be kept
separated so as to prevent an error when putting them
back in their place in reassembly.
NOTE:
At this time, lower kingpin bearing sometimes falls off.
So remove bearing while pulling off knuckle gradually.

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-41
3) Install air locking hub vacuum pipe and tighten clamp bolts to
specified torque (for 4WD).
Tightening torque
Vacuum pipe clamp bolts
(a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
4) Install stabilizer bar, refer to “Stabilizer Bar / Bushings” in
this section.
5) Install lateral rod (1) to vehicle body and axle housing.
Install bolts in proper direction as shown in figure.
At this time, mount bolt and nut but don't tighten them.
6) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side (for 4WD).
“A” : Sealant 99000-31110
7) Install differential carrier assembly (2) to axle housing and
tighten carrier bolts to specified torque (for 4WD).
Tightening torque
Front differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Install front propeller shaft (1) to joint flange aligning match
marks (3) and torque flange bolts to specification (for 4WD).
Tightening torque
Front propeller shaft flange bolts
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
NOTE:
For left hand steering vehicle, install lateral rod with its
bending point (2) placed to right side of vehicle.
[A] : Right hand steering vehicle
[B] : Left hand steering vehicle

Downloaded from www.Manualslib.com manuals search engine 3D-42 FRONT SUSPENSION
9) Install right and left axle shafts to axle housing (for 4WD).
Install knuckle to axle housing (for 2WD).
10) Install kingpins (2) and knuckle seal cover (1) to steering
knuckle (R&L), refer to “Steering Knuckle / Wheel Spindle” in
this section.
11) Install right and left brake disc and caliper assembly.
Tighten carrier bolts to specified torque.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
12) Connect spindle vacuum hoses to wheel spindle (for 4WD),
while aligning the match mark.
13) Install ABS wheel sensor to steering knuckle (if equipped
with ABS).
14) Install tie rod ends and drag rod end to knuckle arm (1)
(R&L). Tighten new nuts to specified torque.
Tightening torque
Tie rod end nuts and drag rod end nut (Knuckle side)
(a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)
15) Install wheels and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
: 95 N·m (9.5 kg-m, 69.0 lb-ft)
16) Lower hoist.NOTE:
Place knuckle seal and retainer in axle housing before
installing axle shaft (knuckle), using care for installation
direction of knuckle seal.
NOTE:
To prevent ball stud from being rotated while tightening
tie rod end nut, tighten Nut (M12 x 1.25) to about 20 N·m
(2.0 kg-m, 14.5 Ib-ft) and remove it. Then tighten new nut
to specified torque.

Downloaded from www.Manualslib.com manuals search engine 3F-6 WHEELS AND TIRES
Maintenance and Minor Adjustments
Wheel and Tire
Wheel repairs that use welding, heating, or peening are not approved. All damaged wheels should be replaced.
Studs
If a broken stud is found, see Section 3E (rear) or Section 3D (front) for Note and Replacement procedure.
Matched tires and wheels
(For vehicle equipped with steel wheels)
Tires and wheels are matchmounted at the assembly plant.
This means that the radially stiffest part of the tire, or “high spot”,
is matched to the smallest radius or “low spot” of the wheel.
This is done to provide the smoothest possible ride.
The “high spot” of the tire is originally marked by paint dot (1) on
the outboard sidewall. This paint dot will eventually wash off the
tire.
The “low spot” of the wheel is originally marked by paint dot (2) on
the wheel rim-flange. Properly assembled, the wheel rim’s paint
dot should be aligned with the tire’s paint dot as shown in left fig-
ure.
Whenever a tire is dismounted from its wheel, it should be
remounted so that the tire and wheel are matched. If the tire’s
paint dot cannot be located, a line should be scribed on the tire
and wheel before dismounting to assure that it is remounted in
the same position.
Inflation of Tires
The pressure recommended for any model is carefully calculated to give a satisfactory ride, stability, steering,
tread wear, tire life and resistance to bruises.
Tire pressure, with tires cold, (after vehicle has set for three hours or more, or driven less than one mile) should
be checked monthly or before any extended trip. Set to the specifications on the tire placard located on the
driver’s side door lock pillar.
It is normal for tire pressure increase when the tires become hot during driving. Do not bleed or reduce tire pres-
sure after driving. Bleeding reduces the “Cold Inflation Pressure.”
Higher than Recommended Pressure Can Cause:
1) Hard ride
2) Tire bruising or carcass damage
3) Rapid tread wear at center of tire
Unequal Pressure on Same Axle Can Cause:
1) Uneven braking
2) Steering lead
3) Reduced handling
4) Swerve on acceleration
Valve caps should be kept on valves to keep dust and water out.

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Lower than Recommended Pressure Can Cause:
1) Tire squeal on turns
2) Hard steering
3) Rapid and uneven wear on the edges of the tread
4) Tire rim bruises and rupture
5) Tire cord breakage
6) High tire temperatures
7) Reduced handling
8) High fuel consumption
Tire placard
The tire placard is located on the driver’s side door lock pillar and should be referred to for tire information. The
placard lists the maximum load, tire size and cold tire pressure where applicable.
Tire rotation
To equalize wear, rotate tires according to left figure. Radial tires
should be rotated periodically. Set tire pressure. NOTE:
Whether rim size and/or maximum load are listed or not depends on regulations of each country.
NOTE:
Due to their design, radial tires tend to wear faster in the
shoulder area, particularly in front positions. This makes
regular rotation especially necessary.
[A] : RH steering vehicle
[B] : LH steering vehicle
F : Front

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-3
General Description
When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pis-
tons (two in front and four in rear).
The master cylinder is a tandem master cylinder. Three (or two) brake pipes are connected to the master cylin-
der and they make two independent circuits. One connects front brakes (right and left) and the other connects
rear brakes (right and left).
The load sensing proportioning valve (LSPV), the proportioning and bypass (P & B) valve or proportioning (P)
valve is included in these circuits between the master cylinder and the rear brake.
In this brake system, the disc brake type is used for the front wheel brake and a drum brake type (leading/trailing
shoes) for the rear wheel brake.
The parking brake system is mechanical. It applies brake force to only rear wheels by means of the cable and
mechanical linkage system. The same brake shoes are used for both parking and foot brakes.
NOTE:
The figures shows left-hand steering vehicle.
WARNING:
If any hydraulic component is removed or brake line disconnected, bleed the brake system. The
torque values specified are for dry, unlubricated fasteners.
[A] : Vehicle without ABS, LSPV 1. Master cylinder 4. P & B valve F: Forward
[B] : Vehicle with LSPV 2. 5-way joint (4-way joint) 5. P (Proportioning) valve
[C] : Vehicle with ABS 3. LSPV (Load Sensing Proportion-
ing valve)6. Hydraulic Unit

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 5-8 BRAKES
Brake Pedal Free Height Adjustment
1) Check brake pedal free height.
If it is not within specification, check and adjust following item
2) and 3).
Brake pedal free height “a” from wall
LH steering vehicle : 221 – 227 mm (8.70 – 8.94 in.)
RH steering vehicle : 217 – 223 mm (8.54 – 8.78 in.)
2) Check measurement between booster mounting surface and
center of clevis pin hole. When booster push rod clevis has
been reinstalled, it is important that the measurement is
adjusted. (Refer to “Brake Booster Inspection and Adjust-
ment” in this section.)
3) Check stop light switch position. Adjust it if it is out of specifi-
cation.
Brake Pedal Play Check
Pedal play should be within specification below.
If out of specification, check stop light switch for proper installation
position and adjust if necessary.
Also check pedal shaft bolt and master cylinder pin installation for
looseness and replace if defective.
Brake pedal play “a” : 1 – 8 mm (0.04 – 0.31 in.)
Stop Light Switch Adjustment
Adjustment should be made as follows when installing switch. Pull
up brake pedal toward you and while holding it there, adjust
switch position so that clearance between end of thread and
brake pedal is specified. Then tighten lock nut to specified torque.
Clearance between brake pedal and stop light switch
“c” : 1.5 – 2.0 mm (0.06 – 0.08 in.)
Tightening torque
Stop light switch lock nut
(a) : 6.5 N·m (0.65 kg-m, 4.7 lb-ft)

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-9
Excessive Pedal Travel Check
1) Start engine.
2) Depress brake pedal a few times.
3) With brake pedal depressed with approximately 30 kg (66
Ibs) load, measure brake pedal to wall clearance “d” or “e”.
Clearance “d” or “e” between brake pedal and wall
LH steering vehicle clearance “d” : Over 55 mm (2.17 in.)
RH steering vehicle clearance “e” : Over 76 mm (2.99 in.)
4) If clearance “d” or “e” is less than specification, the most pos-
sible cause is either rear brake shoes are worn out beyond
limit or air is in lines.
Should clearance “d” or “e” remain less than specification
even after replacement of brake shoes and bleeding of sys-
tem, other possible but infrequent cause is malfunction of
rear brake shoe adjusters or booster push rod length out of
adjustment.
–Bleed brake system. Refer to “Air Bleeding of Brake Sys-
tem” in this section.
–Remove brake drums for adjuster inspection. Refer to
“Rear Brake” in this section. If defective, correct or replace.
Front Brake Disc Check
Refer to item “Front Disc Brake” in this section for inspection point
and procedure.
Front Brake Pad Check
Inspect pad linings (3) periodically according to maintenance
schedule whenever wheels are removed (for tire rotation or other
reason). Take a look through each end (or hole) of caliper and
check lining thickness of outside and inside pads. If lining is worn
and its thickness (“a” in figure) is less than limit, all pads must be
replaced at the same time.
Front brake pad thickness “a” (lining thickness)
Limit : 2.0 mm (0.08 in.)
[A]: LH steering vehicle
[B]: RH steering vehicle
1. Pad rim
2. Disc

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-27
INSPECTION
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and disc is not defective unless they are serious.
But when there are deep scratches or scratches all over disc sur-
face, replace it. When only one side is scratched, polish and cor-
rect that side.
Brake disc thickness “a”
Standard : 10 mm (0.394 in.)
Limit : 8.0 mm (0.315 in.)
Use wheel nuts (1) and suitable plain washers (2) to hold the disc
securely against the hub, then mount a dial indicator as shown
and measure the runout at 10 mm (0.39 in.) from the outer edge
of the disc.
Disk deflection
Limit : 0.15 mm (0.006 in.)
INSTALLATION
1) Install disc to wheel hub.
2) Install caliper assembly to steering knuckle.
3) Torque caliper carrier bolts to specification.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
4) Install wheel and torque front wheel nuts to specification.
5) Upon completion of installation, perform brake test.
NOTE:
Check front wheel bearing for looseness before measure-
ment.
NOTE:
See NOTE at the beginning of this section.