wheel bolts SUZUKI JIMNY 2005 3.G Service User Guide

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4) From the position where contact coil became unable to turn
any further (it stopped), turn it back clockwise about two and
a half rotations and align center mark with alignment mark
(1).
Combination Switch (For Vehicle without Air
Bag System)/Contact Coil and Combination
Switch Assembly (For Vehicle with Air Bag
System)
REMOVAL
1) Remove steering wheel from steering column referring to
“Steering Wheel” in this section.
2) Remove steering column hole cover (1).
3) Remove steering column cover standard screw (1) and tap-
ping screws (2).
4) Loosen steering column mounting bolts and nuts referring to
“Steering Column” in this section.
5) Separate upper cover (3) and lower cover (4), then remove
them.
6) Disconnect all connectors for combination switch/contact coil
and combination switch assembly.
CAUTION:
For vehicle with air bag system
Do not turn contact coil (on combination switch) more
than allowable number of turns (about two and a half
turns from the center position clockwise or counter-
clockwise respectively), or coil will break.

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5) Tighten steering column mounting nuts and bolts by hand
and then tighten mounting nuts (1) first, and then tighten
mounting bolts (2).
Tightening torque
Steering column mounting bolts and nuts
(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
6) Install steering column hole cover (1).
7) Install steering wheel to steering column referring to “Steer-
ing Wheel” in this section.
Steering Column Assembly
CAUTION:
Once the steering column is removed from the vehicle,
the column is extremely susceptible to damage.
Dropping the column assembly on its end could col-
lapse the steering shaft or loosen the plastic shear
pins which maintain column length.
Leaning on the column assembly could cause it to
bend or deform.
Any of the above damage could impair the column’s col-
lapsible design.
NOTE:
When servicing steering column or any column-mounted
component, remove steering wheel. But when removing
steering column simply to gain access to instrument
panel components, leave steering wheel installed on
steering column.

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REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) For vehicle equipped with air bag system, disable air bag
system referring to “Disabling Air Bag System” in Section
10B.
3) If necessary, remove steering wheel and combination switch
assembly referring to “Steering Wheel” and “Combination
switch/Contact Coil and Combination Switch Assembly” in
this section.
If not removing steering wheel and/or combination switch
assembly, perform the following procedure.
a) Turn steering wheel so that vehicle’s front tires are at
straight ahead position.
b) Turn ignition switch to “LOCK” position and remove key.
4) Remove steering column hole cover (1).
5) Disconnect all connectors of the following parts.
Combination switch/contact coil and combination switch
assembly.
Ignition switch.
Immobilizer control system parts (if equipped).
6) Remove joint bolt (steering column side) (3) and loosen joint
bolt (steering gear box side).
7) Remove steering column mounting nuts (2) and bolts (1).WARNING:
For vehicle with air bag system
Never rest a steering column assembly on the steering
wheel with the air bag (inflator) module face down and
column vertical. Otherwise, personal injury may result.

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3) Take measurement “a” as shown.
If it is shorter than specified length, replace column assem-
bly (1) with new one.
Steering column assembly length
“a” : 733.2 – 734.8 mm (28.87 – 28.93 in.)
4) Check steering shaft joints and shaft for any damages such
as crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as lower joint assembly or
column assembly.
5) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
6) Check steering shaft and column for bend, cracks or defor-
mation.
If found defective, replace.
7) Check steering column lower seal (1) for breakage or defor-
mation. If found defective, replace.
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight
forward state.
2) If equipped, install shift (key) interlock cable to ignition
switch.
3) Apply sealant to the steering column lower bracket (shaded
section in the figure) and fit the steering column seal (1) to
the stepped part of the steering column lower bracket
securely.
“A” : Sealant 99000-31090
CAUTION:
After tightening steering column mounting bolts and
nuts shaft joint bolts should be tightened.

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4) Insert steering lower shaft (1) to steering shaft.
5) Put the steering column upper cover (3) on top of the steer-
ing column (2), if necessary and then tighten steering col-
umn mounting nuts (5) and bolts (4) by hand.
6) Tighten mounting nuts (5) first and then mounting bolts (4) to
specified torque.
Tightening torque
Steering column mounting bolts and nuts
(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
7) Tighten steering column side joint bolt (1) first, and then
tighten steering gear box side joint bolt (2).
Tightening torque
Steering shaft joint bolts (b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
8) If combination switch is removed, install combination switch
referring to “Combination Switch/Contact Coil and Combina-
tion Switch Assembly” in this section.
9) Connect all connectors that have been removed in
“removal”.
10) Install steering column hole cover (1).
11) If steering wheel is removed, install steering wheel referring
to “Steering Wheel” in this section.
12) If the vehicle equipped with air bag system, enable air bag
system referring to “Enabling Air Bag System” in Section
10B.
13) Connect negative battery cable.
Steering Lock Assembly (Ignition Switch)
REMOVAL
1) Remove steering column (1) referring to “Steering Column”
in this section.
2. Steering lock

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2) Loosen and remove steering lock mounting bolts (2) using
center punch (1) as shown.
3) Turn ignition key to “ACC” or “ON” position and remove
steering lock assembly from steering column.
INSTALLATION
1) Position oblong hole (1) of steering shaft in the center of hole
(3) in column (4).
2) Turn ignition key to “ACC” or “ON” position and install steer-
ing lock assembly (5) onto column (4).
3) Now turn ignition key to “LOCK” position and pull it out.
4) Align hub on lock with oblong hole (1) of steering shaft and
rotate shaft to assure that steering shaft (2) is locked.
5) Tighten new bolts until head of each bolt is broken off.
6) Turn ignition key to “ACC” or “ON” position and check to be
sure that steering shaft rotates smoothly. Also check for lock
operation.
7) Install steering column referring to “Steering Column” in this
section.
Steering Lower Shaft
REMOVAL
1) Turn steering wheel so that vehicle’s front tires are at
straight-ahead position.
2) Turn ignition switch to “LOCK” position and remove key. NOTE:
Use care not to damage aluminum part of steering lock
body with center punch.
CAUTION:
For vehicle with air bag system
Never turn steering wheel while steering shaft lower joint
is removed.
Should it have been turned and contact coil (on combina-
tion switch) have got out of its centered position, it needs
to be centered again. Also, turning steering wheel more
than about two and a half turns will break contact coil.

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3) Make alignment marks (3) on lower shaft (2) and shaft (col-
umn side) (1) and lower shaft (2) and gear box shaft (gear
box side) (4) for a guide during reinstallation.
4) Remove lower shaft joint bolts.
5) Remove steering lower shaft.
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight
forward state.
2) Insert lower shaft joint into shaft of steering column with
matching marks (3).
3) Align flat part “A” of steering gear box shaft (4) with bolt hole
“B” of lower shaft joint as shown. Then insert lower shaft joint
into steering gear box shaft (4) with matching marks (3).
4) Tighten shaft joint bolt (column side) to specified torque first
and then shaft joint bolt (gear box shaft side) to specified
torque.
Tightening torque
Steering shaft joint bolts (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
1. Steering column assembly
2. Steering lower shaft

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6) Check steering shaft joints and shaft for any damages such
as crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as lower joint assembly or
column assembly.
7) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
8) Check steering shaft and column for bend, cracks or defor-
mation.
If found defective, replace.
Tightening Torque Specifications
Required Service Material
Special Tool
Fastening partTightening torque
Nm kg-m lb-ft
Driver air bag (inflator) module bolts 9 0.9 6.5
Steering shaft nut 33 3.3 23.5
Steering column mounting bolts and nuts 14 1.4 10.5
Steering shaft joint bolts 25 2.5 18.0
Material Recommended SUZUKI product Use
Water tight sealant SEALING COMPOUND 366E
(99000-31090)To apply to steering column seal.
Lithium grease SUZUKI GREASE CE-T
(99000-25290)Contact plate
09944-36011
Steering wheel remover

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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.