check engine SUZUKI JIMNY 2005 3.G Service Workshop Manual

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Wheel Disc, Nut and Bearing Check
1) Inspect each wheel disc for dents, distortion and cracks.
Disc in badly damaged condition must be replaced.
2) Check wheel nuts for tightness and as necessary, retighten
them to specification.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
3) Check wheel bearing for wear. After retightening lock nut to
specified torque, apply dial gauge to wheel hub center and
measure thrust play.
Wheel bearing thrust play limit
: 0.05 mm (0.002 in)
When measurement exceeds limit, replace bearing.
4) By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If defective, replace bearing.

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Front Shock Absorber
REMOVAL
1) Hoist vehicle.
2) Support front axle housing by using floor jack to prevent it
from lowering, refer to “When Using Floor Jack” under “Vehi-
cle Lifting Points” in Section 0A.
3) Remove shock absorber lower mounting bolt (6).
4) Remove shock absorber upper mounting lock nut (2) and
absorber nut (3). Then remove shock absorber (1).
INSTALLATION
Install removed parts in reverse order of removal proceeded, not-
ing the followings.
As shown in figure, install washer (4) and bush (5) first and
after tightening absorber nut (3) tighten lock nut (2) to speci-
fied torque.
Tightening torque
Shock absorber lock nut
(a) : 29 N·m (2.9 kg-m, 21.0 lb-ft)
Install absorber lower mounting bolt (6) in proper direction as
shown in the figure and tighten it with no load applied to axle
housing.
Tightening torque
Shock absorber lower nut
(b) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Confirm front end (wheel) alignment referring to “Preliminary
Checks Prior to Adjusting Front Alignment” in Section 3A.
Coil Spring
REMOVAL
1) Hoist vehicle and remove wheel.
2) Disconnect stabilizer ball joint from axle housing.
3) Remove brake caliper carrier bolts and suspend caliper.
W: Wheel side
7. Lower mounting nut
CAUTION:
During removal, be careful not to damage brake flexible
hose and wheel speed sensor harness (vehicle with ABS)
and not to depress brake pedal.

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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.
7) Confirm front end (wheel) alignment, referring to “Prelimi-
nary Checks Prior to Adjusting Front Alignment” in Section
3A.
Bump Stopper and Spring Upper Seat
REMOVAL
1) Remove coil spring, refer to “Coil Spring” in this section.
2) Remove bump stopper and spring upper seat.
INSTALLATION
1) Install bump stopper (1) and spring upper seat (2).
2) Install coil spring, refer to “Coil Spring” in this section.
Wheel Hub / Bearing / Oil Seal
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove brake caliper carrier bolts and suspend caliper (1).
3) Remove ABS wheel sensor (if equipped with ABS).
NOTE:
Before installing bump stopper (1), apply soap water on
it.
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.

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c) Install front axle shaft circlip (1) and apply thin coat of
grease to spline part of axle shaft.
“A” : Grease 99000-25010
d) Clean mating surface of air locking hub and wheel hub.
Install air locking hub assembly to wheel hub and tighten
bolts to specified torque.
Tightening torque
Air locking hub bolts
(a) : 48 N·m (4.8 kg-m, 35.0 lb-ft)
12) Install ABS wheel sensor (if equipped with ABS).
13) Install 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)
14) Install wheel and tighten wheel nuts specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
15) Lower hoist.
16) For 4WD model:
Check air locking hub for air leakage, refer to “4WD System
Check” in this section. NOTE:
When installing circlip (1) to front axle shaft, utilize screw
hole in axle shaft to pull it out and bring large diameter
(2) of circlip at right as shown.

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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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4) Install axle shaft (2) to front axle housing (1) (for 4WD).
5) Install knuckle to front axle housing. For details, refer to
“Steering Knuckle / Wheel Spindle” in this section.
6) Refill front axle (differential) housing with new specified gear
oil (for 4WD). Refer to “Maintenance Service” in Section 7E
for refill.
7) After servicing, check that no oil leakage exists.
Steering Knuckle Seal
REMOVAL
1) Hoist vehicle.
2) Remove knuckle seal cover bolts and seal cover (1).
3) Cut oil seal in place with scissors or knife, and take it off.
INSTALLATION
1) Cut replacement oil seal at one place with scissors or a
knife.

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17) Tighten lateral rod (1) mounting bolt and nut to specified
torque.
Tightening torque
Lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
18) Tighten right and left shock absorber lower mounting nuts
and leading arm mounting nuts to specified torque.
Tightening torque
Shock absorber lower nuts and leading arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
19) Refill front axle (differential) housing with new specified gear
oil. Refer to “Maintenance Service” in Section 7E for refill.
20) Confirm front end (wheel) alignment referring to “Preliminary
Checks Prior to Adjusting Front Alignment” in Section 3A. NOTE:
When tightening bolt and nut, be sure that vehicle is off
hoist and in non loaded condition.
NOTE:
When tightening these nuts, be sure that vehicle is off
hoist and in non loaded condition.
1. Shock absorber
2. Leading arm

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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.

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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)