battery SUZUKI JIMNY 2005 3.G Service Owner's Manual

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A/C Switch
REMOVAL AND INSTALLATION
Refer to “Heater Control Lever Assembly” in Section 1A.
INSPECTION
Press A/C switch button and check if there is continuity
between terminals “A” and “B”.
With battery voltage (+) connected to terminal “C” and (–) to
terminal “A”, press A/C Switch button and blower fan switch
to “Hi” (3rd position).
Check if indicator lamp lights.
Condenser Cooling Fan Motor Relay
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove condenser cooling fan motor relay (1) from vehicle.
3) Check that there is no continuity between terminal “a” and
“b”. If there is continuity, replace relay.
4) Check that there is continuity between terminals “a” and “b”
when battery is connected to terminal “c” and “d”.
If there is no continuity, replace relay.
Compressor
REMOVAL
1) Run engine at idle speed with air conditioning ON for 10 min-
utes. After that stop the engine.
2) Disconnect negative (–) cable at battery.
3) Recover refrigerant from refrigeration system by referring to
“Recovery” in this section.
1. Blower fan and A/C switch
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-1
6F1
6F2
6G
6H
3B
7C1
7D
7E
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B
STEERING GEAR BOX (MANUAL TYPE)
AND LINKAGE
CONTENTS
General Description ....................................... 3B-2
Diagnosis ........................................................ 3B-3
Diagnosis Table ........................................... 3B-3
Steering Wheel Play Check ......................... 3B-3
Tie Rod And Drag Rod Check ...................... 3B-3
Steering Gear Box Oil Level Check ............. 3B-4
Adjustment of Worm Shaft Starting Torque . 3B-4On-Vehicle Service ........................................ 3B-6
Steering Gear Box ....................................... 3B-6
Tie Rod And Drag Rod................................. 3B-8
Tightening Torque Specifications .............. 3B-10
Required Service Material ........................... 3B-10
Special Tools ................................................ 3B-10 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. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system 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.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM)
NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified dur-
ing reassembly to assure proper retention of these parts.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-1
6F1
6F2
6G
6H
6K
3B1
7D
7E
7F
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B1
POWER STEERING (P/S) SYSTEM
(If equipped)
CONTENTS
General Description ......................................3B1-2
Diagnosis .......................................................3B1-3
Diagnosis Table .......................................... 3B1-3
Steering Wheel Play Check ........................ 3B1-5
Steering Force Check ................................. 3B1-5
Power Steering Belt Check ......................... 3B1-6
Power Steering Belt Tension Adjustment .... 3B1-6
Power Steering Fluid Level Check .............. 3B1-6
Idle-Up System Check ................................ 3B1-7
Power Steering Fluid Leakage Check ......... 3B1-7Air Bleeding Procedure ............................... 3B1-8
Hydraulic Pressure In P/S Circuit Check .. 3B1-10
On-Vehicle Service ..................................... 3B1-12
Power Steering Belt .................................. 3B1-12
Power Steering (P/S) Pump ...................... 3B1-12
Power Steering (P/S) Gear Box ................ 3B1-18
Tightening Torque Specifications ............. 3B1-21
Required Service Materials ........................ 3B1-21
Special Tools ............................................... 3B1-21 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. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system 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.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified dur-
ing reassembly to assure proper retention of these parts.

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 3C-4 STEERING WHEEL AND COLUMN
Drive Air Bag (Inflator) Module (For Vehicle
with Air Bag System)
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to “Disabling Air Bag System”
in Section 10B.
3) Remove steering wheel side cap (1) of left side.
4) Loosen 2 bolts (2) mounting driver air bag (inflator) module
till it turns freely, pull them out and fix them to bolt clamps (3).
5) Remove driver air bag (inflator) module (1) from steering
wheel.
6) Disconnect yellow connector (2) in order a) – b) as shown.
INSPECTION
WARNING:
When handling an air bag (inflator) module, be sure to
read “Service Precautions” given earlier in this section
and observe each instruction. Failure to follow them
could cause a damage to the air bag (inflator) module or
result in personal injury.
WARNING:
Never disassemble driver air bag (inflator) module or
measure its resistance. Otherwise, personal injury may
result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-5
Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.
Air bag being deployed
Trim cover (1) (pad surface) being cracked
Wire harness (3) or connector being damaged
Air bag (inflator) module being damaged or having been
exposed to strong impact (dropped)
INSTALLATION
1) Check that horn wire is connected to horn terminal securely.
2) Connect yellow connector (1) of driver air bag (inflator) mod-
ule (3) pushing connector till it is locked.
3) Install driver air bag (inflator) module to steering wheel, tak-
ing care so that no part of wire harness is caught between
them.
4) Make sure that clearance between module and steering
wheel is uniform all the way.
5) Tighten driver air bag (inflator) module mounting bolts (1) to
specified torque.
Tightening torque
Driver air bag (inflator) module mounting bolts
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
6) Install steering wheel side cap (2).
7) Connect negative battery cable.
8) Enable air bag system. Refer to “Enabling Air Bag System”
under “Service Precautions” in Section 10B.
Steering Wheel
2. Inflator case
CAUTION:
For vehicle with air bag system
Removal of the steering wheel allows the contact coil to
turn freely but do not turn the contact coil (on the combi-
nation switch) more than allowable number of turns
(about two and a half turns from the center position
clockwise or counterclockwise respectively), or coil will
break.

Downloaded from www.Manualslib.com manuals search engine 3C-6 STEERING WHEEL AND COLUMN
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Remove steering wheel pad (for vehicle without air bag sys-
tem) or driver air bag (inflator) module (for vehicle with air
bag system) as follows.
Vehicle without air bag system for TYPE A
a) Remove steering wheel pad.
b) Disconnect horn connector.
Vehicle without air bag system for TYPE B
a) As shown in the figure, while pushing the set spring (1) with
a screwdriver or the like inserted in the hole of the steering
wheel, pull the lower part of the pad forward and remove
the steering wheel pad.
Vehicle with air bag system
a) Remove driver air bag (inflator) module from steering wheel
referring to “Driver Air Bag (Inflator) Module” in this section.
3) Remove steering shaft nut.
4) Make alignment marks (1) on steering wheel and shaft for a
guide during reinstallation.
[A] : For TYPE A
[B] : For TYPE B

Downloaded from www.Manualslib.com manuals search engine 3C-12 STEERING WHEEL AND COLUMN
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.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-15
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

Downloaded from www.Manualslib.com manuals search engine 3D-12 FRONT SUSPENSION
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.