ect SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 3B1-12 POWER STEERING (P/S) SYSTEM (If equipped)
On-Vehicle Service
Power Steering Belt
REMOVAL
1) Disconnect negative cable at battery.
2) Loosen tension pulley bolts (2).
3) Remove power steering belt (1).
INSPECTION
Check power steering belt for wear and cracks, and replace
as required.
INSTLLATION
1) Install belt to power steering pump pulley (1), crankshaft pul-
ley (2), A/C pulley (if equipped) (3) and tension pulley (4).
2) Adjust belt tension referring to “Power Steering Belt Check”
in this section.
Power Steering (P/S) Pump
REMOVAL
1) Take out fluid in P/S fluid reservoir with syringe or such.
2) Remove P/S belt.
3) Disconnect high pressure hose and low pressure hose.
4) Disconnect pressure switch lead harness.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-13
5) Remove P/S pump (1) removing 3 mounting bolts (3).
DISASSEMBLY
1) Clean its exterior thoroughly.
2) With aluminum plates placed on vise first, grip pump case
with it.
3) Remove suction connector (10) and O-ring from pump body
(1).
4) Remove power steering pressure switch (3) from pump body
(1).
5) Remove relief valve (flow control valve) (2) and spring from
pump body (1).
6) Remove pump cover (11), O-ring and cam ring (6) from
pump body (1).
7) Remove vanes (9) from rotor (5).
8) Remove snap ring (8) from pump shaft (4) and pull out rotor
(5) and pulley (shaft) (4).
9) Remove side plate (7) and O-ring from pump body (1).
10) Remove oil seal from pump body (1).
INSPECTION
Pump body, cover and shaft
Check sliding surfaces of each part for wear and damage.
If any defect is found, replace pump assembly.CAUTION:
Clean couplers at intake and discharge ports com-
pletely before disconnection.
Plug ports of removed pump to prevent dust and any
foreign object from entering.
2. P/S pump bracket
1. Pulley 3. Pump cover
2. Pump body

Downloaded from www.Manualslib.com manuals search engine 3B1-14 POWER STEERING (P/S) SYSTEM (If equipped)
CAM RING AND SIDE PLATE
Check vane sliding surface of cam ring (2) for wear and damage.
If any defect is found, replace pump assembly.
ROTOR AND VANE
Check sliding surfaces of rotor and vane for wear and dam-
age.
Check clearance between rotor and vane.
Replace pump assembly if any defect is found.
Clearance between rotor and vane
Standard : 0.01 mm (0.0004 in.)
Limit : 0.06 mm (0.0023 in.)
RELIEF VALVE (FLOW CONTROL VALVE) AND ITS SPRING
Check fluid passage of relief valve and orifice of connector
for obstruction (clogged).
Check sliding surface of relief valve for wear and damage.
2. Side plate
1. Thickness gauge

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-15
Check free length of relief valve spring (1).
Replace pump assembly if any defective is found.
Relief valve spring free length
Standard : 36.5 mm (1.44 in.)
Limit : 33.5 mm (1.32 in.)
ASSEMBLY
Reverse disassembly procedure for assembly, noting the follow-
ing.
1) Apply power steering fluid to shaft (2) outer surface and
grease to oil seal lip (1) and insert it from oil seal side.
“A” : Grease 99000-25010
2) Apply power steering fluid to O-rings and fit them to pump
body.
3) Install side plate (2) to pump body.
4) Apply power steering fluid to sliding surface of rotor (1).
5) Install rotor (1) to shaft, directing “dot” (2) marked side of
rotor toward pump cover (facing up).
6) Install new snap ring to shaft, then make sure to fit snap ring
into shaft groove securely.
NOTE:
Carefully align the dowel pins (3) on the side plate (2) at
bolt hole (1) as shown in figure.
NOTE:
Never reuse the removed snap ring.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-17
16) Apply power steering fluid to relief valve (flow control valve)
(1).
17) Install relief valve (flow control valve) (1) to pump body.
18) Apply power steering fluid to O-ring of plug (3).
19) Install O-ring to plug (3).
20) Tighten plug to specified torque.
Tightening torque
Plug
(a) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
21) Apply power steering fluid to O-rings of pressure switch (1).
22) Install O-rings to pressure switch (1).
23) Install pressure switch (1) to pump body.
Tightening torque
Pressure switch
(a) : 28 N·m (2.8 kg-m, 20.0 lb-ft)
24) Apply power steering fluid to O-ring (2) of suction connector
(1).
25) Install O-ring (2) to suction connector (1).
26) Install suction connector (2) to pump body as shown in fig-
ure. Tighten suction connector bolt (3) to specified torque.
Tightening torque
Suction connector bolt
(a) : 12 N·m (1.2 kg-m, 8.5 lb-ft) NOTE:
Check that relief valve (flow control valve) slides
smoothly.
2. Flow control valve spring
1. P/S pump

Downloaded from www.Manualslib.com manuals search engine 3B1-18 POWER STEERING (P/S) SYSTEM (If equipped)
INSTALLATION
Install components in reverse order of removal procedure noting
the following points.
Tighten each bolt as specified below.
Tightening torque
Oil pump mounting bolts
(a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)
Oil pump high pressure union bolt
(b) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
Adjust P/S belt referring to “Power Steering Belt Check” in
this section.
Connect pressure switch terminal.
Power Steering (P/S) Gear Box
REMOVAL
1) Take out fluid in P/S fluid reservoir with syringe or such.
2) Turn steering wheel fully counterclockwise and loosen sector
shaft nut of P/S gear box.
3) Return steering wheel to straightforward state and remove
pitman arm from P/S gear box by using puller.
4) Remove radiator (for left-steering vehicle) referring to “Radi-
ator” in Section 6B
5) Remove radiator support member.
6) Disconnect suction hose and return hose from P/S fluid res-
ervoir, and remove P/S fluid reservoir assembly (for left-
steering vehicle).
7) Remove steering lower shaft joint bolt (2).CAUTION:
After installation, fill A/T fluid (an equivalent to
DEXRON
®-II, DEXRON®-IIE or DEXRON®-III) and be sure
to bleed air referring to “Air Bleeding Procedure” in this
section.
1. Union bolt
1. Steering lower shaft

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-19
8) Disconnect high pressure hose (2) and return hose (3) from
gear box (1).
9) Remove gear box assy from vehicle.
INSTALLATION
Reverse removal procedure to install P/S gear box noting the fol-
lowing points.
Tightening torque specification.
Tightening torque
Power steering gear box mounting bolt and nuts
(a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)
Gear box high pressure union bolt
(b) : 35 N·m (3.5 kg-m, 25.5 lb-ft)
Before servicing, set steering wheel and wheel / tire at
straight position. NOTE:
Plug up the section where hose disconnection.
CAUTION:
Never turn gear box input shaft. Otherwise, air goes into
gear box, which needs air bleeding for gear box.
NOTE:
Don’t disassemble P/S gear box.
For adjustment of worm shaft starting torque, refer to
item “Adjustment of Worm Shaft Starting Torque” in
Section 3B.
1. Steering gear box 4. High pressure hose
2. Bolt (long) 5. Return hose
3. Bolt (short)

Downloaded from www.Manualslib.com manuals search engine 3B1-20 POWER STEERING (P/S) SYSTEM (If equipped)
Install pitman arm (1) to sector shaft (2) of P/S gear box (3)
with match marks “A” and “B” aligned as shown in figure and
torque to specification.
Tightening torque
Pitman arm mounting nut
(a) : 135 N·m (13.5 kg-m, 98.0 lb-ft)
Install lower shaft by the following steps.
1) Align flat part of steering gear box worm shaft (1) with bolt
hole in lower joint as shown. Then insert lower joint (2) onto
worm shaft.
2) Be sure that front wheels and steering wheel are in straight-
forward state and insert upper joint onto steering shaft.
3) Torque lower shaft joint bolt to specification.
Tightening torque
Steering shaft lower joint bolt
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Fill engine coolant to radiator.
Bleed air in P/S circuit referring to “Air Bleeding Procedure”
in this section.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-21
Tightening Torque Specifications
Required Service Materials
Special Tools
Fastening partTightening torque
Nm kg-m lb-ft
Tension pulley bolt 25 2.5 18.0
Oil pump mounting bolt 25 2.5 18.5
Oil pump high pressure union bolt 60 6.0 43.5
Oil pump cover bolts 28 2.8 20.0
Pressure switch 28 2.8 20.0
Suction connector bolt 12 1.2 8.5
Power steering gear box mounting bolt
and nuts80 8.0 58.0
Gear box high pressure union bolt 35 3.5 25.5
Pitman arm mounting nut 135 13.5 98.0
Steering shaft joint bolt 25 2.5 18.5
Plug 60 6.0 43.5
MaterialRecommended SUZUKI product
(Part Number)Use
Power steering
fluidAn equivalent of DEXRON
®-II,
DEXRON
®-IIE or DEXRON®-III.To fill P/S fluid reservoir
Parts lubrication when installing
Lithium greaseSUPER GREASE (A)
(99000-25010)Oil seal lip of P/S pump pulley shaft
09915-77411 09915-77420 09944-18211 09945-35010
Oil pressure gauge Oil pressure gauge
attachment & hose setTorque check socket Air bleeding hose set

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-1
6F1
6F2
6G
6H
6K
7A
3C
7E
7F
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3C
STEERING WHEEL AND COLUMN
CONTENTS
General Description ....................................... 3C-2
Diagnosis ........................................................ 3C-3
Inspection and Repair Required
After Accident ............................................... 3C-3
On-Vehicle Service......................................... 3C-3
Service Precautions (For Vehicle with
Air Bag System) ........................................... 3C-3
Diagnosis and servicing ........................... 3C-3
Disabling air bag system .......................... 3C-3
Enabling air bag system ........................... 3C-3
Handling and storage ............................... 3C-3
Disposal.................................................... 3C-3
Drive Air Bag (Inflator) Module (For Vehicle
with Air Bag System) .................................... 3C-4
Steering Wheel ............................................. 3C-5Centering contact coil (for vehicle with
air bag system)......................................... 3C-8
Combination Switch (For Vehicle without
Air Bag System)/Contact Coil and
Combination Switch Assembly (For Vehicle
with Air Bag System).................................... 3C-9
Steering Column Assembly........................ 3C-11
Steering Lock Assembly
(Ignition Switch) ......................................... 3C-15
Steering Lower Shaft ................................. 3C-16
Checking Steering Column for Accident
Damage ......................................................... 3C-18
Tightening Torque Specifications .............. 3C-19
Required Service Material ........................... 3C-19
Special Tool .................................................. 3C-19

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem components or wiring. Failure to follow WARNINGS could result in unintentional activation of
the system or could render the system inoperative. Either of these two conditions may result in
severe injury.
The procedures in this section must be followed in the order listed to temporarily disable the air
bag system and prevent false diagnostic codes from setting. Failure to follow procedures could
result in possible air bag system activation, personal injury or otherwise unneeded air bag system
repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.