SUZUKI JIMNY 2005 3.G Service Service Manual

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REPLACEMENT
Replace air cleaner filter with new one according to steps 1), 2)
and 5), 6) of inspection procedure.
Fuel Lines and Connections
INSPECTION
1) Visually inspect fuel lines and connections for evidence of
fuel leakage, hose cracking and damage. Make sure all
clamps are secure.
Repair leaky joints, if any.
Replace hoses that are suspected of being cracked.
Fuel Filter
REPLACEMENT
Fuel filter (1) is a part of fuel pump assembly (2) which is installed
in fuel tank. Replace fuel filter with new one periodically, referring
to “Fuel Pump Assembly (with Fuel Filter, Fuel Level Gauge and
Fuel Cut Valve)” in Section 6C for proper procedure.
Fuel Tank
INSPECTION
Check fuel tank for damage, cracks, fuel leakage, corrosion and
tank bolts looseness.
If a problem is found, repair or replace.
Emission Control System
Crankcase Ventilation Hoses and Connections
INSPECTION
Refer to “PCV (Positive Crankcase Ventilation) Valve” in this sec-
tion.
WARNING:
This work must be performed in a well ventilated area
and away from any open flames (such as gas hot water
heaters).

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PCV (Positive Crankcase Ventilation) Valve
INSPECTION
Check crankcase ventilation hose and PCV hose for leaks, cracks
or clog, and PCV valve for stick or clog. Refer to “PCV System” of
Section 6E for PCV valve checking procedure.
Fuel Evaporative Emission Control System
INSPECTION
1) Visually inspect hoses for cracks, damage, or excessive
bends. Inspect all clamps for damage and proper position.
2) Check EVAP canister for operation and clog, referring to
“Evaporative Emission (EVAP) Control System” in Section
6E.
If a malfunction is found, repair or replace.
Chassis and Body
Clutch
INSPECTION
Check clutch pedal for height and free travel (1) referring to “Main-
tenance Service” in Section 7C. Adjust or correct if necessary.
Brake Discs and Pads
INSPECTION
1) Remove wheel and caliper but don’t disconnect brake hose
from caliper.
2) Check front disc brake pads and discs for excessive wear,
damage and deflection. Replace parts as necessary. For
details, refer to “Brake Pad” and “Brake Disc” in Section 5.
Be sure to torque caliper pin bolts to specification.

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Brake Drums and Shoes
INSPECTION
1) Remove wheel and brake drum.
2) Check rear brake drums and brake linings for excessive wear
and damage, while wheels and drums are removed. At the
same time, check wheel cylinders for leaks. Replace these
parts as necessary.
For details, refer to “Brake Drum” in Section 5.
Brake Hoses and Pipes
INSPECTION
Check brake hoses and pipes for proper hookup, leaks, cracks,
chafing and other damage.
Replace any of these parts as necessary.
Brake Fluid
CHANGE
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill system with
above recommended fluid and carry out air purge operation.
For air purging procedure, refer to “Air Bleeding of Brake System”
in Section 5.
CAUTION:
After replacing any brake pipe or hose, be sure to carry
out air purge operation.
CAUTION:
Since brake system of this vehicle is factory-filled with
glycol-base brake fluid, do not use or mix different type
of fluid when refilling system; otherwise serious damage
will occur. Do not use old or used brake fluid, or one
taken from unsealed container.

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Parking Brake Lever and Cable
INSPECTION
1) Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition.
2) Check tooth tip of each notch for damage or wear. If any
damage or wear is found, replace parking lever.
3) Check parking brake lever for proper operation and stroke,
and adjust it if necessary.
For checking and adjusting procedures, refer to “Parking
Brake Inspection and Adjustment” in Section 5.
Parking brake lever stroke
“a”: 6 – 8 notches (with 200 N (20 kg, 44 lbs) of pull pres-
sure)
Tires/Wheels
TIRE INSPECTION AND ROTATION
1) Check tires for uneven or excessive wear, or damage.
If defective, replace.
Refer to “Irregular and/or Premature Wear” and “Wear Indi-
cators” in Section 3 for details.
2) Check inflating pressure of each tire and adjust pressure to
specification as necessary.
Refer to “Inflation of Tires” in Section 3F for details.
1. Wear indicator
NOTE:
 Tire inflation pressure should be checked when tires
are cool.
 Specified tire inflation pressure should be found on
tire placard or in owner’s manual which came with the
vehicle.

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3) Rotate tires.
For details, refer to “Tire Rotation” in Section 3F.
WHEEL DISCS INSPECTION
Inspect each wheel disc for dents, distortion and cracks. A disc in
badly damaged condition must be replaced.
WHEEL BEARING INSPECTION
1) Check front wheel bearing for wear, damage, abnormal
noise or rattles. For details, refer to “Wheel Disc, Nut and
Bearing Check” in Section 3D.
2) Check rear wheel bearing for wear, damage, abnormal noise
or rattles. For details, refer to “Wheel Disc, Nut and Bearing
Check” in Section 3E.
Suspension System
INSPECTION
Check suspension bolts and nuts for tightness and retighten them
as necessary.
Repair or replace defective parts, if any.
FRONT
1) Check stabilizer bar (6) for damage or deformation.
2) Check bushing (8) for damage, wear or deterioration.
3) Check coil spring (1), lateral rod (5) and leading arm (3) for
deformation and damage.
4) Check lateral rod (5) and leading arm bushings for wear,
damage and deterioration.
5) Inspect absorbers (2) for evidence of oil leakage, dents or
any other damage on sleeves; and inspect anchor ends for
deterioration.
6) Inspect for cracks or deformation in spring seat.
7) Inspect for deterioration of bump stopper.NOTE:
For details of check points, refer to tables of “Tightening
Torque Specification” in Section 3D and 3E.
4. Front axle housing
7. Ball joint

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REAR
1) Check shock absorber (1) for damage, deformation, oil leak-
age and operation.
2) Check bushings for wear and damage.
3) Check coil spring (4), trailing arm (6) and lateral rod (5) for
deformation and damage.
4) Check trailing arm (6) and lateral rod bushings and bump
stopper (2) for wear, damage and deterioration.
5) Check other suspension parts for damage, loose or missing
parts; also for parts showing signs of wear or lack of lubrica-
tion.
Replace any parts found defective in steps 1) to 5).
Propeller Shafts
INSPECTION
1) Check universal joint and spline of propeller shaft for rattle. If
rattle is found, replace defective part with a new one.
2) Check propeller shaft (front & rear) flange yoke bolts for
tightness, and retighten them as necessary.
Refer to “Components” in Section 4B for tightening torque.
LUBRICATION
Grease splines of propeller shaft No.2 (1) and No.3 (2).
“A”: Chassis Grease
3. Spring seat
3. Nipple

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Manual Transmission Oil
INSPECTION
1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug (2) of transmission.
4) Check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found
up to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified
oil.
5) Tighten level plug to specified torque.
Refer to “Maintenance Service” in Section 7A for installation
and tightening torque.
CHANGE
Change transmission oil with new specified oil referring to “Main-
tenance Service” in Section 7A.
Automatic Transmission Fluid
INSPECTION
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Check fluid level.
For fluid level checking procedure, refer to “Fluid Level
Check” in Section 7B and be sure to perform it under speci-
fied conditions. If fluid level is low, replenish specified fluid.
CHANGE
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to “Changing Fluid” in
Section 7B.
1. Dipstick
2.“FULL HOT” mark
3.“LOW HOT” mark
CAUTION:
Use of specified fluid is absolutely necessary.
1. Drain plug

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FLUID COOLER HOSE CHANGE
Replace inlet and outlet hoses of cooler hose and their clamps.
For replacement procedure, refer to “Oil Cooler Hoses” in Section
7B.
Transfer and Differential Oil
INSPECTION
1) Check transfer case and differential for evidence of oil leak-
age.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug of transfer and differentials (front and
rear) and check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found
up to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified
oil.
4) Tighten level plug to specified torque.
Refer to “Oil Change” in Section 7D, 7E or 7F for tightening
torque.
CHANGE
Change transfer oil and differentials oil with new specified oil
referring to “Oil Change” in Section 7D, 7E or 7F.
[A] : Transfer
[B] : Front differential
[C] : Rear differential
1. Oil filler/level plug (Apply sealant for transfer)
2. Drain plug (Apply sealant)
CAUTION:
Hypoid gear oil must be used for differential.

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Steering System
INSPECTION
1) Check steering wheel for play and rattle, holding vehicle in
straight forward condition on the ground.
Steering wheel play
“a”: 0 – 30 mm (0 – 1.2 in.)
2) Check universal joints of steering lower shaft (1) for rattle
and damage. If rattle or damage is found, replace defective
part with a new one.
3) Check steering linkage (including kingpin) for looseness and
damage. Repair or replace defective part, if any.
4) Check bolts and nuts for tightness and retighten them as
necessary. Repair or replace defective parts, if any.
Refer to table of “Tightening Torque Specifications” in Sec-
tion 3B (or 3B1) and 3C for particular check points.
5) Inspect steering gear box (2) for evidence of oil leakage. If
leakage is found, check oil level in gear box.
6) Check boots of steering linkage for damage (leaks, detach-
ment, tear, dent, etc.). If damage is found, replace defective
boot with new one.
7) Check wheel alignment. Refer to “Preliminary Checks Prior
to Adjusting Front Alignment” in Section 3A.
Steering Knuckle Seal
INSPECTION
1) Remove knuckle seal cover (1).
2) Check knuckle seal (2) for wear, damage and deterioration.
If defective, replace.
3) Apply grease to seal lip and install seal and seal cover.
“a”: Grease 99000-25010

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Power Steering (P/S) System (if equipped)
INSPECTION
1) Visually check power steering system for fluid leakage and
hose for damage and deterioration.
Repair or replace defective parts, if any.
2) With engine stopped, check fluid level indicated on fluid tank
or level gauge of tank cap, which should be between MAX
and MIN marks. If it is lower than MIN, fill fluid up to MAX
mark.
3) Visually check pump drive belt for cracks and wear.
4) Check belt for tension, referring to “Drive Belt” in this section.
If necessary, have belt adjusted or replaced.
All Hinges, Latches and Locks
DOORS INSPECTION
Check that each door of front and back doors opens and closes
smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair
door lock system.
ENGINE HOOD INSPECTION
Check that secondary latch operates properly (check that sec-
ondary latch keeps hood from opening all the way even when pull-
ing hood release handle inside vehicle.) Also check that hood
opens and closes smoothly and properly and hood locks securely
when closed.
If any malfunction is found, lubricate hinge and latch, or repair
hood lock system. Check hood latch bolt for tightness.
Tightening torque
Hood latch bolts
10 N·m (1.0 kg-m, 7.5 lb-ft)
NOTE:
 Be 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.