steering wheel SUZUKI JIMNY 2005 3.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 3A-4 FRONT WHEEL ALIGNMENT
Camber And Caster Check And Adjustment
Should camber or caster be found out of specifications upon
inspection, locate its cause first. If it is in damaged, loose, bent,
dented or worn suspension parts and axle housing, they should
be replaced. If it is in vehicle body, repair it so as to attain specifi-
cations.
Steering Angle Check And Adjustment
When tie rod (2) or tie rod end (3) was replaced, check toe and
then also steering angle with turning radius gauge (1).
If steering angle is not correct, check if right and left tie rods are
equal in length “A”.
Steering angle
Inside : 35° ± 3°
Outside : 32° ± 3°
Side Slip(Reference)
For inspecting front wheel side slip with side slip tester:
If side slip exceeds limit, toe or front wheel alignment may out not
be correct.
Side slip limit
: Less than 3 mm/m (Less than 0.118 in/3 ft) NOTE:
To prevent possible incorrect reading of camber or
caster, vehicle front end must be moved up and down a
few times before inspection.
NOTE:
If tie rod lengths were changed to adjust steering angle,
reinspect toe-in.

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 3B-2 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
General Description
1. Steering gear box 5. Tie rod 9. Worm shaft 13. Sector shaft
2. Pitman arm 6. Steering lower shaft 10. Ball 14. Rack gear
3. Drag rod 7. Steering wheel 11. Ball nut
4. Knuckle arm 8. Steering upper shaft 12. Gear case

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-3
Diagnosis
Diagnosis Table
Refer to “Diagnosis Table” in Section 3.
Steering Wheel Play Check
Check steering wheel for play and rattle, holding vehicle in
straight forward condition on ground.
Steering wheel play
“a” : 10 – 30 mm (0.4 – 1.2 in.)
If play is not within specification, inspect for the following. If found
defective, replace.
Wear of tie rod end ball stud.
Wear of king pin bearing
Wear of steering shaft joint.
Loosely install or joined parts.
Wear of steering rack / sector gear.
Tie Rod And Drag Rod Check
Inspect deformation or damage. Replace any defective part.
INSPECTION
1) Inspect for play in tie rod end ball joint (1). If found defective,
replace.
2) Inspect boot (2) for tear. If even a small tear is noted, replace
with new one.

Downloaded from www.Manualslib.com manuals search engine 3B-4 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
Steering Gear Box Oil Level Check
Oil surface should be up to the level as shown in figure. If not, add
prescribed gear oil, SAE 90.
Steering gear box oil level
“a” : 23 mm (0.91 in.)
Apply sealant to thread parts of breathing plug and tighten breath-
ing plug to specified torque.
(A) : Sealant 99000-31110
Tightening torque
Breathing plug
(a) : 4 N·m (0.4 kg-m, 3.0 lb-ft)
Adjustment of Worm Shaft Starting Torque
Steering gear box has adjusting bolt (1) which gives preload to
sector shaft.
Special tool
(A) : 09944-18211
MAKE ADJUSTMENT ACCORDING TO FOLLOWING PRO-
CEDURE.
1) Check worm shaft (1) to ensure that it is free from thrust
play.
2) Position pitman arm (2) in nearly parallel with worm shaft (1)
as shown. (With pitman arm (2) in this position, front wheels
are in straightforward state.)

Downloaded from www.Manualslib.com manuals search engine 3B-8 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
Tie Rod And Drag Rod
REMOVAL
1) Hoist vehicle and remove wheel (s).
2) Remove tie rod end nut from steering knuckle.
3) Mark (3) one end of tie rod before removing the rod as
shown in figure to distinguish the correct installing direction
easy.
4) Disconnect tie rod end (2) from knuckle (1), using special
tool.
Special tool
(A) : 09913-65210
5) For ease of adjustment after installation, make marking (3) of
tie rod end lock nut position on tie rod thread. Then loosen
lock nut (2) and remove tie rod end (1) from tie rod.
INSTALLATION
1) Install tie rod end lock nut (2) and tie rod end (1) to tie rod
and/or drag rod. Align lock nut with mark (3) on tie rod
thread.

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-9
2) Adjust tie rod (and/or drag rod) length to the measurement
shown in figure; then tighten tie rod end lock nuts temporarily
by finger.
Tie rod and drag rod length
Tie rod length “a” : 1132 mm (44.6 in.)
Drag rod length “a” : 864.5 mm (34.0 in.)
3) Align lock nut (3) with mark on tie rod thread and connect tie
rod end to knuckle and/or pitman arm. Tighten new nut (1) to
specified torque.
Tightening torque
Tie rod end nut
(a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)
4) Inspect for proper toe and steering angle (inside & outside).
(Refer to “Preliminary Checks Prior To Adjusting Front Align-
ment” in Section 3A).
Adjust tie rod (2) and drag rod length as required, if neces-
sary.
5) After confirming proper toe, tighten tie rod end lock nut (3) to
specified torque.
Tightening torque
Tie rod end lock nut
(b) : 65 N·m (6.5 kg-m, 47.0 lb-ft)
6) Tighten wheel nuts to specified torque and lower hoist.NOTE:
Make the length “b” of right and left tie rod end the same.
NOTE:
To prevent ball stud from being rotated while tightening
tie rod end nut (1), tighten Nut (M12 × 1.25) to about 20
N·m (2.0 kg-m, 14.5 Ib-ft) and remove it.
Then tighten new nut (1) to specified torque.

Downloaded from www.Manualslib.com manuals search engine 3B-10 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
Tightening Torque Specifications
Required Service Material
Special Tools
Fastening partTightening torque
Nm kg-m lb-ft
Steering gear box oil plug 4 0.4 3.0
Steering gear box adjusting bolt lock nut 30 3.0 22.0
Pitman arm mounting nut 135 13.5 98.0
Steering shaft joint bolt 25 2.5 18.0
Steering gear box nuts and bolt 80 8.0 58.0
Tie rod end nut and drag rod end nut
(knuckle side)43 4.3 31.5
Wheel nut 95 9.5 69.0
Tie rod end lock nut 65 6.5 47.0
Drag rod end nut (pitman arm side) 50 5.0 36.5
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant SUZUKI BOND NO. 1215
(99000-31110)Thread of oil breathing plug
09913-65210 09944-18211
Tie-rod end remover Pinion torque checking socket

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 3B1-2 POWER STEERING (P/S) SYSTEM (If equipped)
General Description
The power steering system in this vehicle reduces the driver’s effort needed in turning the steering wheel by uti-
lizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an
integral type with the mechanical gear unit, hydraulic pressure cylinder unit and control valve unit all housed in
the gear box.
1. Steering gear box 2. Power steering (P/S) pump 3. P/S fluid reservoir
1. Power steering gear box 3. Spool valve 5. P/S fluid reservoir
2. Control valve section 4. Power steering (P/S) pump