SUZUKI JIMNY 2005 3.G Service Workshop Manual

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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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3 Check 4WD switch circuit.
1) Connect coupler to 4WD controller.
2) Turn ignition switch ON and check voltage
between A7 terminal and ground.
Transfer lever is in 2H : about 10 – 14 V
Transfer lever is in 4L or 4H : about 0 V
Is check result satisfactory?Go to Step 4. Check 4WD switch (refer
to “4WD Switch” in Sec-
tion 7D), “Bl/B” and “B”
circuits of 4WD switch.
If OK, substitute a known-
good 4WD controller and
recheck.
4 Check VSV1 circuit.
1) Turn ignition switch ON.
2) Check voltage between A1 terminal and
ground.
Is it 10 – 14 V when transfer lever is in 4H or 4L
range and about 0 V for 10 seconds after it is
shifted to 2H range?Go to Step 5. Check VSV1 (refer to
“4WD Control System
Check” in this section),
“Y/R” and “Gr/B” circuits
of VSV1.
If OK, substitute a known-
good 4WD controller and
recheck.
5 Check VSV2 circuit.
1) Turn ignition switch ON.
2) Check voltage between A2 terminal and
ground.
Is it 10 – 14 V when transfer lever is in 2H range
and about 0 V for 5 seconds after it is shifted to
4H or 4L range?Go to Step 6. Check VSV2 (refer to
“4WD Control System
Check” in this section),
“Y/R” and “Gr/R” circuits
of VSV2.
If OK, substitute a known-
good 4WD controller and
recheck.
6 Check vacuum switch circuit.
1) Turn ignition switch ON (stating engine).
2) Check voltage between A6 terminal and
ground.
Is it 10 – 14 V when transfer lever is in 2H range
and about 0 V for 5 seconds after it is shifted to
4H or 4L range?Go to Step 7. Check vacuum switch
(refer to “4WD Control
System Check” in this
section), “Gr” and “B” cir-
cuits of vacuum switch.
If OK, substitute a known-
good 4WD controller and
recheck.
7 Check 4WD indicator light circuit.
1) Turn ignition switch ON.
2) Check voltage between A3 terminal and
ground.
Is it 10 – 14 V when transfer lever is in 2H range
and about 0 V within 15 seconds after it is
shifted to 4H or 4L range?Substitute a known-good
4WD controller and
recheck.Check “Bl” circuit (includ-
ing indicator light and
combination meter refer to
“Combination Meter” in
Section 8).
If OK, substitute a known-
good 4WD controller and
recheck. Step Action Yes No

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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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CHECK VALVE
1) Remove check valve (1).
2) Close B side of check valve with finger as shown and apply
–50 cmHg vacuum by means of vacuum pump. Then check
that vacuum is applied. Apply vacuum to another side of
check valve and check that vacuum is not applied.
Replace if defective.
Special tool
(A) : 09917-47910
Stabilizer bar / bushing check
BAR
Inspect for damage or deformation. If defective, replace.
BUSHING
Inspect for damage, wear or deterioration. If defective, replace.
A : Intake manifold side
B : Vacuum switching valve side

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Shock Absorber and/or Coil Spring Check
1) Inspect shock absorber for oil leakage. If shock absorber is
found faulty, replace it as an assembly unit, because it can
not be disassembled.
2) Shock absorber function check
Check and adjust tire pressures as specified.
Bounce body three or four times continuously by pushing
front end on the side with shock absorber to be checked.
Apply the same amount of force at each push and note
shock absorber resistance both when pushed and rebound-
ing.
Also, note how many times vehicle body rebounds before
coming to stop after hands are off. Do the same for shock
absorber on the other side.
Compare shock absorber resistance and number of rebound
on the right with those on the left.
And they must be equal in both. With proper shock absorber,
body should come to stop the moment hands are off or after
only one or two small rebounds. If shock absorbers are sus-
pected, compare them with known good vehicle or shock
absorber.
3) Inspect for damage or deformation.
4) Inspect for cracks or deformation in spring seat.
5) Inspect for deterioration of bump stopper.
6) Inspect shock absorber mount for wear, cracks or deforma-
tion.Replace any parts found defective in steps 2) – 6).
Leading Arm / Lateral Rod / Steering Knuckle
Check
Inspect for cracks, deformation or damage.

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Leading Arm Bushing / Lateral Rod Bushing
Check
Inspect for damage, wear or deterioration.
If defective, replace.
Kingpin / Kingpin Bearing Check
1) Inspect for wear or deterioration.
2) Inspect for crack, damage or deformation of kingpin.
If defective, replace.
Barfield Joint Check
To be checked on this joint is its axial play, which shows up when
a push-and-pull motion is given to live axle shaft and wheel spin-
dle held in both hands, as shown in figure. There should be no
play at all but a play of up to 1.5 mm (0.06 in.) is permissible. If
play exceeds service limit, replace it.
Axial play in barfield joint
Steering Knuckle Seal Check
The knuckle seal used at the spherical sliding joint between the
knuckle and the inner case accomplishes the additional purposes
of keeping out road dust and of acting as the damper for the
steering handwheel. As the wear of this seal advances, its damp-
ing effect decreases and thus make the front wheel develop a ten-
dency to “shimmy” not only that road dust begins to creep into the
sliding clearance to promote the wear of the spherical sliding sur-
faces.
Check the knuckle seal for wear or damage. If defective, replace
with new one.
Standard Service Limit
0 mm (no play) 1.5 mm (0.06 in.)

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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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On-Vehicle Service
Stabilizer Bar / Bushings
REMOVAL
1) Hoist vehicle.
2) Remove front bumper.
3) Disconnect stabilizer ball joints (right & left) (1) from front
axle housing (2).
4) Remove stabilizer bar mount bush bracket bolts (1).
5) Remove stabilizer bar with its ball joint.
6) Disconnect stabilizer ball joints (right & left) from its bar.
INSTALLATION
1) Connect stabilizer ball joints (right & left) to its bar.