sensor SUZUKI JIMNY 2005 3.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-37
A/C Evaporator Thermistor (A/C Evaporator
Temperature Sensor)
INSPECTION
Check resistance between terminals for A/C evaporator ther-
mistor (1).
If check results are as not specified, replace thermistor.
A/C evaporator temperature sensor resistance
Expansion Valve
INSPECTION
Refer to “Performance Diagnosis” in this section.
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to
“Recover” in this section.
3) Remove attaching bolt (1).
4) Remove suction hose (2) and receiver dryer outlet pipe (3)
from expansion valve (4).
5) Remove expansion valve (4).Sensor Temperature (°C (°F)) Resistance (k
Ω)
0 (32) 6.4 – 7.0
25 (77) 1.8 – 2.2
NOTE:
When A/C evaporator thermistor (1) removed, its should
be reinstalled in original position.
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-19
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.

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-23
6) Remove front wheel bearing lock nut by using special tool.
Special tool
(A) : 09944-77020 (For 4WD)
(A) : 09951-16050 (For 2WD)
7) Remove front wheel bearing washer.
8) Remove wheel hub complete (1) with bearings (2) and oil
seal (4).
Special tool
(A) : 09943-35511 or 09943-35512
(B) : 09942-15510
9) Remove sensor rotor from wheel hub as shown (if equipped
with ABS).
10) Remove wheel bearing oil seal and circlip.
3. Circlip
NOTE:
If wheel hub can not be removed by hand, use special
tools as shown.
CAUTION:
Pull out sensor rotor from wheel hub gradually and
evenly.
Attempt to pull it out partially may cause it to be
deformed.
1. Sensor rotor
2. Wheel hub
3. Vise
4. Flat end rod

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-25
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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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.

Downloaded from www.Manualslib.com manuals search engine 3D-38 FRONT SUSPENSION
Front Axle Housing
REMOVAL
1) Hoist vehicle.
2) Remove front wheels.
3) Drain front differential gear oil (for 4WD).
4) Remove caliper carrier bolts (R&L) and suspend caliper.
5) Remove right and left brake disc.
6) Remove wheel speed sensor (if equipped with ABS).
7) Disconnect spindle vacuum hoses from wheel spindle (for
4WD).
8) Remove tie rod (and drag rod) end nuts and disconnect tie
rod (and drag rod) ends (2) from knuckle arm (1) (R&L) with
special tool.
Special tool
(A) : 09913-65210 CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.
NOTE:
If brake disc can not be removed by hand, use 8mm bolts
(1).
CAUTION:
Give match mark to spindle vacuum hose and wheel
spindle before removal.
1. Vacuum hose to lock
2. Vacuum hose to unlock

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 3E-10 REAR SUSPENSION
INSTALLATION
1) Install lateral rod to vehicle body and rear axle housing.
Tighten bolt and nut temporarily by hand.
2) Lower hoist and with vehicle in non-loaded condition, tighten
lateral rod 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)
Trailing Arm / Bushing
REMOVAL
1) Hoist vehicle.
2) Support rear axle housing (1) by using floor jack (2).
3) Disconnect parking brake cable clamp (1) from trailing arm.
4) Disconnect wheel speed sensor harness clamps (2) from
trailing arm (if equipped with ABS).
5) Remove trailing arm mounting bolts.
6) Remove trailing arm (1).

Downloaded from www.Manualslib.com manuals search engine 3E-12 REAR SUSPENSION
Install bushings so that either face of bushing are aligned
with housing edge of leading arm, also the length between
the aligned side end of bushing and trailing arm (1) are
within specification below.
Specification for trailing 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 trailing arm (1) to vehicle body and rear axle housing,
referring to figure for proper installing direction of bolts.
3) Remove floor jack.
4) Connect wheel speed sensor harness clamps to trailing arm
(if equipped with ABS).
5) Connect parking brake cable clamp to trailing arm.
6) Lower hoist and with vehicle in non-loaded condition, tighten
trailing arm nuts to specified torque.
Tightening torque
Trailing arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Rear Axle Shaft and Wheel Bearing
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove rear brake drum and disconnect parking brake
cable from brake back plate. For details, refer to “Brake back
plate” in Section 5.
3) Drain gear oil from rear axle housing by loosening drain plug.