AIR CON SUZUKI JIMNY 2005 3.G Service Workshop Manual

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1. Air locking hub assembly 4. VSV2 7. 4WD controller 10. 4WD indicator light 13. ABS controller
2. VSV1 5. Vacuum accumulation tank 8. Intake manifold 11. 4WD switch 14. Transfer
3. Check valve 6. Vacuum switch 9. Wheel spindle 12. Combination meter

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Components and Functions
Component Function
4WD switch When the transfer shift lever is shifted to 4L or 4H position from 2H, this switch
turns ON and cause the 4WD control system to turn ON.
4WD controller When the 4WD switch turns on, the 4WD controller activates VSV2 to lock the
air locking hubs and when it receives an “ON” signal from the vacuum switch, it
makes VSV2 to complete operation within 5 seconds and causes the 4WD indi-
cator light to light up.
If vacuum in the vacuum circuit fails to reach the specified level due to a leakage
in the vacuum circuit (when no “ON” signal is inputted from the vacuum switch),
the 4WD controller stops operation of VSV2 in 15 seconds and makes the 4WD
indicator light to flash to warn occurrence of a trouble.
When the 4WD switch turns off, the 4WD controller activates VSV1 for 10 sec-
onds to unlock the hubs and at the same time makes the 4WD indicator light
turn off.
VSV1 VSV1 operates according to the signal from the 4WD controller. When it is acti-
vated, the port opens and vacuum in the intake manifold is applied through the
vacuum circuit to unlock to the slide gear in the air locking hub. As a result, the
air locking hubs are unlocked.
VSV2 VSV2 operates according to the signal from the 4WD controller. When it is acti-
vated, the port opens and vacuum in the intake manifold is applied through the
vacuum circuit to lock to the slide gear in the air locking hub. As a result, the air
locking hubs are locked.
Vacuum switch When VSV2 receives the “ON” signal from 4WD switch, vacuum is applied
through its circuit to the vacuum switch. The vacuum switch turns on when it
detects vacuum exceeding 260 mmHg.
“4WD” indicator lamp It lights up when 4WD control system is in the 4WD mode.
It flashes to warn that locking hub operation has not completed (4WD control
system fails to shift 4WD).

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Diagnosis
Diagnosis Table
For description not found in the table below, refer to “Diagnosis Table” in Section 3.
4WD CONTROL SYSTEM
4WD CONTROL SYSTEM DIAGNOSTIC FLOW TABLE
Before performing the trouble diagnosis, check that the air locking hub assemblies are in good condition and
there is no air leakage from vacuum hoses and vacuum pipe. Refer to “4WD Control System Check” in this sec-
tion for air leakage.
[NOTES ON SYSTEM CIRCUIT INSPECTION]
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before circuit inspection and
observe what is written there.
For system circuit, refer to the figure of “System Circuit” in this section. Condition Possible Cause Correction
4WD Indicator light
flashingHub locking procedure error
Defective VSV2
Defective vacuum switch
Defective check valve or vacuum tank
Air leak from vacuum circuit
Clogged vacuum hose or pipe
Faulty 4WD controllerShift transfer shift control lever
2WD → 4WD once again
Replace
Replace
Replace
Check and repair
Replace
Check and replace
2WD/4WD switching
errorDefective air locking hub assembly
Abnormality in 4WD control system
Air leakage from vacuum circuit
Clogged vacuum hose or pipe
Defective check valve or vacuum tankReplace
Inspect referring to “4WD Control
System Diagnostic Flow Table”
Check and replace
Replace
Replace
Step Action Yes No
1 Check ground circuit.
1) Disconnect coupler from 4WD controller
with ignition switch OFF.
2) Check for proper connection to 4WD con-
troller at all terminals.
3) If OK, check continuity between A5 terminal
and body ground.
Is there continuity between A5 terminal and
body ground?Go to Step 2.“B” wire is open.
2 Check power circuit.
1) Disconnect coupler from 4WD controller.
2) Turn ignition switch ON.
3) Check voltage between A10 terminal and
ground.
Is it 10 – 14 V?Go to Step 3.“Y/R” circuit is open or
short.

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4WD Controller and ITS Circuit Check
VOLTAGE CHECK
Check for input or output voltage of 4WD controller (1) (voltage
between each circuit and body ground) with 4WD controller con-
nector connected and ignition switch turned START (engine run).
* : With engine runningCAUTION:
Disable air bag system (if equipped with Air Bag), refer
to “Disabling Air Bag System” in Section 10B.
This check must be carried out in a well-ventilated
place.
Terminal Circuit Wire Color Normal Voltage Condition
A1 VSV1 Gr/Babout 0 V10 seconds after transfer shift con-
trol lever : 4WD → 2WD
10 – 14 V Transfer shift control lever: 4WD
A2 VSV2 Gr/R*about 0 V5 seconds after transfer shift control
lever : 2WD → 4WD
10 – 14 V Transfer shift control lever: 2WD
A34WD indicator
lampBl*about 0 V Transfer shift control lever: 4WD
10 – 14 V Transfer shift control lever: 2WD
A4 A/C controller G/W*10 – 12 V5 – 10 seconds after engine starts or
transfer shift control lever switches.
about 0 VA/C switch and blower fan switch
ON.
A5 Ground B about 0 V any time
A6 Vacuum switch Gr*about 0 V5 seconds after transfer shift control
lever : 2WD → 4WD
10 – 14 V Other than above
A7 4WD switch Bl/Babout 0 V Transfer shift control lever: 4WD
10 – 14 V Transfer shift control lever: 2WD
A8 A/C switch G/Babout 0 VA/C switch ON and blower fan switch
ON
10 – 14 V Other than above
A9 Ignition coil Br0 – 1 V IG: ON
Voltage varies according to engine speed.
A10 Ignition switch Y/R 10 – 14 V IG: ON

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4WD Control System Check
AIR LOCKING HUB
1) Start engine and shift transfer shift control lever to 2H posi-
tion.
2) Connect vacuum pump gauge (special tool) to the spindle
hose (2) which is disconnected from upper side pipe as
shown. Apply vacuum and check operating sound from air
locking hub (1).
If there is not operating sound, replace air locking hub
assembly.
Vacuum specification
More than 40 kPa (0.40 kg/cm
2, 5.70 Psi)
Special tool
(A) : 09917-47910
3) Connect hose, then start engine and shift transfer shift con-
trol lever to 4H or 4L position.
4) Connect vacuum pump gauge to the spindle hose (2) dis-
connected from lower side pipe.
Apply vacuum and check operating sound from air locking
hub (1).
If there is no operating sound, replace air locking hub
assembly.
Vacuum specification
More than 40 kPa (0.40 kg/cm
2, 5.70 Psi)
Special tool
(A) : 09917-47910
VSV1 AND VSV2
1) Disconnect coupler from VSV1 (1) (VSV2) (2) and check
resistance between two terminals of VSV1 (1) (VSV2) (2).
If resistance is out of specification, replace.
Resistance of VSV1 and VSV2
: 33 – 39
Ω

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2) Blow air from B and check that air comes out of C.
If found faulty, replace.
3) Connect 12 V-battery to VSV1 (VSV2) terminals and check
continuity between A and B.
Blow air from B and check that air comes out of A.
If found faulty, replace.
VACUUM SWITCH
1) Disconnect coupler from vacuum switch and check resis-
tance between two terminals of vacuum switch.
If resistance is out of specification, replace.
Resistance of vacuum switch
: More than 1 M
Ω
2) Connect vacuum pump gauge and apply vacuum more than
40 kPa (0.40 kg/cm
2, 5.70 Psi), then check resistance
between terminals of vacuum switch.
If resistance is out of specification, replace.
Vacuum switch resistance
: Less than 0.8
Ω
Special tool
(A) : 09917-47910
4WD SWITCH
Refer to “4WD Switch” in Section 7D.
VACUUM HOSE / PIPE
Inspect vacuum hoses for leaks or cracks, vacuum pipes for
cracks, dents or corrosion. If defective, replace.

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5) Apply lithium grease to lip portion and hollow of oil seal (1).
“A” : Grease 99000-25010
6) Install sensor rotor (3) as shown (if equipped with ABS).
7) Apply lithium grease inside wheel bearing thin.
“A” : Grease 99000-25010
8) Install wheel hub complete with bearings and oil seal onto
front wheel spindle.
9) Install bearing washer.
10) Tighten wheel bearing lock nut to specified torque while turn-
ing wheel hub by hand.
Special tool
(A) : 09944-77020 (For 4WD)
(A) : 09951-16050 (For 2WD)
Tightening torque
Wheel bearing lock nut
(a) : 220 N·m (22.0 kg-m, 160 lb-ft)
11) Install hub cap (for 2WD model) or air locking hub assembly
(for 4WD model) as follows. NOTE:
Amount of grease applied to hollow in oil seal (1) should
be more than 60% of its vacant space.
2. Wheel hub
NOTE:
Pipe (2) used here should have inner diameter of
90 mm (3.55 in.) – 96 mm (3.77 in.) and its outside
should not contact teeth of sensor rotor (3).
Use care not to insert wheel hub (4) diagonally.
1. Steel plate
5. Hydraulic press

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14) Blow air into pipes at the top and the front of wheel spindle
and check that it comes out of the hole as shown in figure
(for 4WD).
15) Connect spindle vacuum hoses to wheel spindle (for 4WD).
16) Connect tie rod and drag rod to steering knuckle, refer to
“Tie rod and Drag Rod” in Section 3B.
17) Install wheel hub assembly, refer to “Wheel Hub / Bearing /
Oil Seal” in this section.
18) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
: 95 N·m (9.5 kg-m, 69.0 lb-ft)
19) Lower hoist.
Front Axle Shaft / Oil Seal / Kingpin Bearing
Outer Race
REMOVAL
1) Hoist vehicle.
2) Drain differential gear oil from front axle housing by loosing
drain plug (for 4WD).
3) Remove steering knuckle. For details, refer to “Steering
Knuckle / Wheel Spindle” in this section.
4) Draw out axle shaft (2).CAUTION:
As this hole is a part of the passage of the vacuum that
activates the air locking hub, if it is clogged with grease,
the air locking hub cannot be locked or unlocked.
Therefore, be careful not to apply too much grease to
avoid clogging the vacuum passage.
1. Front axle housing

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INSTALLATION
1) Install bushings (1) by using hydraulic press and special
tools, noting the following point.
Install bushings (1) so that either face of bushing are aligned
with housing edge of leading arm (2), also the length
between the aligned side end of bushing and leading arm (2)
are within specification below.
Special tool
(A) : 09913-85210
(B) : 09951-26010
Specification for leading 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 leading arm (1) to vehicle body and axle housing,
referring to figure for proper installing direction of bolts.
Nuts should not be tightened.
3) Install shock absorber lower mounting bolt, refer to “Front
Shock Absorber” in this section.
4) Install air locking hub vacuum pipe clamp bolts and tighten
them to specified torque (for 4WD).
Tightening torque
Vacuum pipe clamp bolts
(b) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
5) Lower hoist and with vehicle in non-loaded condition, tighten
nuts of leading arm to specified torque.
Tightening torque
Leading arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
2. Vacuum hose
3. Body outside
[A] : Front
[B] : Rear

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6F1
6F2
6G
1A
6K
7A
7A1
7B1
3E
8A
8B
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3E
REAR SUSPENSION
CONTENTS
General Description ....................................... 3E-2
Diagnosis ........................................................ 3E-3
Diagnosis Table ........................................... 3E-3
Rear Shock Absorber Check ........................ 3E-3
Trailing Arm, Lateral Rod, Axle Housing
and Coil Spring Check ................................. 3E-3
Trailing Arm and Lateral Rod Bush Check ... 3E-3
Rear Suspension Fasteners ......................... 3E-4
Bearing Retainer and Axle Shaft Oil Seal
Check ........................................................... 3E-4
Bump Stopper and Spring Rubber Seat
Check ........................................................... 3E-4
Wheel Disc, Nut and Bearing Check ............ 3E-4On-Vehicle Service ........................................ 3E-5
Rear Shock Absorber................................... 3E-5
Coil Spring ................................................... 3E-6
Bump Stopper .............................................. 3E-9
Lateral Rod .................................................. 3E-9
Trailing Arm / Bushing................................ 3E-10
Rear Axle Shaft and Wheel Bearing .......... 3E-12
Rear Axle Shaft Inner Oil Seal ................... 3E-17
Rear Axle Housing ..................................... 3E-18
Tightening Torque Specifications .............. 3E-22
Required Service Materials ......................... 3E-22
Special Tools ................................................ 3E-23

WARNING:
When hoisting vehicle, be sure to select the lifting point suitable for the service work referring to Sec-
tion 0A.
NOTE:
All suspension fasteners are an important attaching part in that it could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any suspension part. Replace it with a new part, or
damage to the part may result.