engine SUZUKI JIMNY 2005 3.G Service Workshop Manual

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General Description
1. Rear axle housing 4. Bearing oil seal 7. Brake drum 10. Bump stopper
2. Rear wheel bearing 5. Oil seal protector 8. Rear axle shaft 11. Coil spring
3. Bearing retainer ring 6. Lateral rod 9. Shock absorber 12. Trailing arm

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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)

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Check wheel bearings for wear. When measuring thrust
play, apply a dial gauge to axle shaft center after removing
wheel center cap from wheel disc.
When measurement exceeds limit, replace bearing.
Rear wheel bearing thrust play limit
: 0.8 mm (0.03 in.)
By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If it is defective, replace bearing.
On-Vehicle Service
Rear Shock Absorber
The shock absorber is non-adjustable, non-refillable, and cannot be disassembled. The only service the shock
absorber requires is replacement when it has lost its resistance, is damaged, or leaking fluid.
REMOVAL
1) Hoist vehicle.
2) Support rear axle housing (1) by using floor jack (2) to pre-
vent it from lowering.
WARNING:
When discarding shock absorber, be sure to refer to instructions in “Rear Shock Absorber Check” in
this section for proper procedure as it is gas sealed type.

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3) Remove upper mounting bolt (2).
4) Remove lower mounting bolt (3).
5) Remove shock absorber (1).
INSTALLATION
1) Install shock absorber (1), refer to figure for proper installing
direction of bush and washer (2).
Tighten bolts (3) temporarily by hand.
2) Remove floor jack.
3) Lower hoist.
4) Tighten shock absorber bolts (3) to specified torque.
Tightening torque
Shock absorber upper and lower bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
Coil Spring
REMOVAL
1) Hoist vehicle and remove wheel.
2) Support rear axle housing (1) by using floor jack (2).
3) Remove brake flexible hose E-ring (2).
NOTE:
Tighten lower bolt with vehicle off hoist and in non-
loaded condition.
1. Brake flexible hose

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4) Remove shock absorber lower mounting bolt (2).
5) Lower rear axle housing (2) gradually as far down as where
coil spring (1) can be removed.
6) Remove coil spring (1).
7) Remove spring rubber seat (1).
1. Shock absorber

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INSTALLATION
1) Install spring rubber seat (1).
2) Install coil spring (2) on spring seat (1) of axle housing and
then raise axle housing.
3) Install shock absorber lower mounting bolt.
Tighten bolt temporarily by hand.
4) Install brake flexible hose E-ring.
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 and tighten absorber lower bolt (2) to specified
torque.
Tightening torque
Shock absorber lower bolt
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft) NOTE:
Before installing spring rubber seat (1), apply soap water
on it.
NOTE:
Upper and lower diameters of coil spring (2) are differ-
ent.
Bring larger diameter end at bottom and set its open
end in place on spring seat (1).
When seating coil spring (2), mate spring end with
stepped part (3) of rear axle spring seat (1) as shown.
A : Upper side (small dia.)
B : Lower side (large dia.)
NOTE:
For tightening of lower bolt (2), refer to NOTE given under
“Shock Absorber” in this section.

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Bump Stopper
REMOVAL
1) Hoist vehicle.
2) Remove wheel.
3) Remove bump stopper (1) by using special tool.
Special tool
(A) : 09941-66010
INSTALLATION
1) Tighten bump stopper (1) to specified torque by using spe-
cial tool.
Special tool
(A) : 09941-66010
Tightening torque
Bump stopper
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
2) 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)
3) Lower hoist.
Lateral Rod
REMOVAL
1) Hoist vehicle.
2) Remove lateral rod mounting bolt (2) and nut (3).
3) Remove lateral rod (1).

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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).

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7) Remove bushings (1) by using hydraulic press and special
tools.
Special tool
(A) : 09924-74510
(B) : 09951-16030
(C) : 09951-26010
INSTALLATION
1) Install bushings (1) by using hydraulic press and special
tools, noting the following points.
Special tool
(A) : 09913-85210
(B) : 09951-26010
For axle side bushings (1), install them so that center line
and slit lines of them are parallel as shown figure.
2. Slit
3. Center line of bushings
4. Slit line of bushings