Torque SUZUKI JIMNY 2005 3.G Service Owner's Guide

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 3B1-6 POWER STEERING (P/S) SYSTEM (If equipped)
Power Steering Belt Check
INSPECTION
Check that belt is free from any damage and properly fitted
in pulley groove.
Check belt tension by measuring how much it deflects when
pushed at mid-point between pulley with about 10 kg (22 lb)
force.
Deflection of oil pump belt
“a” : 6 – 9 mm (0.25 – 0.35 in.)
Power Steering Belt Tension Adjustment
1) Loosen tension pulley bolts (3) and set hexagon wrench to
hexagon hole (5).
2) Turn tension pulley counterclockwise by hexagon wrench in
order to obtain above specification.
3) Tighten tension pulley bolts to specified torque.
Tightening torque
Tension pulley bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Power Steering Fluid Level Check
With engine stopped check fluid level indicated on P/S fluid reser-
voir (1) or level gauge (3), which should be between MAX and
MIN marks. If it is lower than lower limit (MIN), replenish fluid up
to upper limit (MAX) mark.
1. P/S pump pulley 4. A/C compressor pulley (if equipped)
2. Crank pulley
CAUTION:
Make sure to use an equivalent of DEXRON
®-II,
DEXRON
®-IIE or DEXRON®-III for P/S fluid.
Fluid level should be checked when fluid is cool before
starting engine.
2. Cap

Downloaded from www.Manualslib.com manuals search engine 3B1-16 POWER STEERING (P/S) SYSTEM (If equipped)
7) Apply power steering fluid to sliding surface of cam ring (1).
8) Install cam ring (1) to pump body. The tapered end of cam
ring (1) should face the side plate (2).
9) Apply power steering fluid to each vane (2).
10) Install vanes (10 pipes) (2) to rotor (1).
11) Apply power steering fluid to O-ring (1) and fit it to pump
body.
12) Install O-ring (1) to pump body.
13) Apply power steering fluid to sliding surface of pump cover
(1) and rotor.
14) Match the dowel pins (2) to the holes of the cover plate as
shown and install pump cover to pump body.
15) Tighten pump cover bolts to specified torque.
Tightening torque
Oil pump cover bolts
(a) : 28 N·m (2.8 kg-m, 20.0 lb-ft)
NOTE:
After installing pump cover (1), check to make sure that
shaft can be turned by hand.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-17
16) Apply power steering fluid to relief valve (flow control valve)
(1).
17) Install relief valve (flow control valve) (1) to pump body.
18) Apply power steering fluid to O-ring of plug (3).
19) Install O-ring to plug (3).
20) Tighten plug to specified torque.
Tightening torque
Plug
(a) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
21) Apply power steering fluid to O-rings of pressure switch (1).
22) Install O-rings to pressure switch (1).
23) Install pressure switch (1) to pump body.
Tightening torque
Pressure switch
(a) : 28 N·m (2.8 kg-m, 20.0 lb-ft)
24) Apply power steering fluid to O-ring (2) of suction connector
(1).
25) Install O-ring (2) to suction connector (1).
26) Install suction connector (2) to pump body as shown in fig-
ure. Tighten suction connector bolt (3) to specified torque.
Tightening torque
Suction connector bolt
(a) : 12 N·m (1.2 kg-m, 8.5 lb-ft) NOTE:
Check that relief valve (flow control valve) slides
smoothly.
2. Flow control valve spring
1. P/S pump

Downloaded from www.Manualslib.com manuals search engine 3B1-18 POWER STEERING (P/S) SYSTEM (If equipped)
INSTALLATION
Install components in reverse order of removal procedure noting
the following points.
Tighten each bolt as specified below.
Tightening torque
Oil pump mounting bolts
(a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)
Oil pump high pressure union bolt
(b) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
Adjust P/S belt referring to “Power Steering Belt Check” in
this section.
Connect pressure switch terminal.
Power Steering (P/S) Gear Box
REMOVAL
1) Take out fluid in P/S fluid reservoir with syringe or such.
2) Turn steering wheel fully counterclockwise and loosen sector
shaft nut of P/S gear box.
3) Return steering wheel to straightforward state and remove
pitman arm from P/S gear box by using puller.
4) Remove radiator (for left-steering vehicle) referring to “Radi-
ator” in Section 6B
5) Remove radiator support member.
6) Disconnect suction hose and return hose from P/S fluid res-
ervoir, and remove P/S fluid reservoir assembly (for left-
steering vehicle).
7) Remove steering lower shaft joint bolt (2).CAUTION:
After installation, fill A/T fluid (an equivalent to
DEXRON
®-II, DEXRON®-IIE or DEXRON®-III) and be sure
to bleed air referring to “Air Bleeding Procedure” in this
section.
1. Union bolt
1. Steering lower shaft

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-19
8) Disconnect high pressure hose (2) and return hose (3) from
gear box (1).
9) Remove gear box assy from vehicle.
INSTALLATION
Reverse removal procedure to install P/S gear box noting the fol-
lowing points.
Tightening torque specification.
Tightening torque
Power steering gear box mounting bolt and nuts
(a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)
Gear box high pressure union bolt
(b) : 35 N·m (3.5 kg-m, 25.5 lb-ft)
Before servicing, set steering wheel and wheel / tire at
straight position. NOTE:
Plug up the section where hose disconnection.
CAUTION:
Never turn gear box input shaft. Otherwise, air goes into
gear box, which needs air bleeding for gear box.
NOTE:
Don’t disassemble P/S gear box.
For adjustment of worm shaft starting torque, refer to
item “Adjustment of Worm Shaft Starting Torque” in
Section 3B.
1. Steering gear box 4. High pressure hose
2. Bolt (long) 5. Return hose
3. Bolt (short)

Downloaded from www.Manualslib.com manuals search engine 3B1-20 POWER STEERING (P/S) SYSTEM (If equipped)
Install pitman arm (1) to sector shaft (2) of P/S gear box (3)
with match marks “A” and “B” aligned as shown in figure and
torque to specification.
Tightening torque
Pitman arm mounting nut
(a) : 135 N·m (13.5 kg-m, 98.0 lb-ft)
Install lower shaft by the following steps.
1) Align flat part of steering gear box worm shaft (1) with bolt
hole in lower joint as shown. Then insert lower joint (2) onto
worm shaft.
2) Be sure that front wheels and steering wheel are in straight-
forward state and insert upper joint onto steering shaft.
3) Torque lower shaft joint bolt to specification.
Tightening torque
Steering shaft lower joint bolt
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Fill engine coolant to radiator.
Bleed air in P/S circuit referring to “Air Bleeding Procedure”
in this section.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-21
Tightening Torque Specifications
Required Service Materials
Special Tools
Fastening partTightening torque
Nm kg-m lb-ft
Tension pulley bolt 25 2.5 18.0
Oil pump mounting bolt 25 2.5 18.5
Oil pump high pressure union bolt 60 6.0 43.5
Oil pump cover bolts 28 2.8 20.0
Pressure switch 28 2.8 20.0
Suction connector bolt 12 1.2 8.5
Power steering gear box mounting bolt
and nuts80 8.0 58.0
Gear box high pressure union bolt 35 3.5 25.5
Pitman arm mounting nut 135 13.5 98.0
Steering shaft joint bolt 25 2.5 18.5
Plug 60 6.0 43.5
MaterialRecommended SUZUKI product
(Part Number)Use
Power steering
fluidAn equivalent of DEXRON
®-II,
DEXRON
®-IIE or DEXRON®-III.To fill P/S fluid reservoir
Parts lubrication when installing
Lithium greaseSUPER GREASE (A)
(99000-25010)Oil seal lip of P/S pump pulley shaft
09915-77411 09915-77420 09944-18211 09945-35010
Oil pressure gauge Oil pressure gauge
attachment & hose setTorque check socket Air bleeding hose set