body SUZUKI JIMNY 2005 3.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine 3D-40 FRONT SUSPENSION
19) Lower floor jack until tension of suspension coil spring
becomes a little loose and remove right and left sides lower
mounting bolt of shock absorber (1).
20) Remove front mounting bolts of leading arm.
21) Lower front axle housing gradually.
22) Remove axle housing.
INSTALLATION
1) Place rear axle housing on floor jack. Then install leading
arm front mounting bolts (right & left) in proper direction as
shown. At this time, mount nuts but don’t tighten them.
2) Install lower part of shock absorber (1) to right and left sides
of axle housing and install bolts (2) in proper direction as
shown in figure. At this time, mount nuts (3) but don’t tighten
them.
A : Body outside

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-41
3) Install air locking hub vacuum pipe and tighten clamp bolts to
specified torque (for 4WD).
Tightening torque
Vacuum pipe clamp bolts
(a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
4) Install stabilizer bar, refer to “Stabilizer Bar / Bushings” in
this section.
5) Install lateral rod (1) to vehicle body and axle housing.
Install bolts in proper direction as shown in figure.
At this time, mount bolt and nut but don't tighten them.
6) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side (for 4WD).
“A” : Sealant 99000-31110
7) Install differential carrier assembly (2) to axle housing and
tighten carrier bolts to specified torque (for 4WD).
Tightening torque
Front differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Install front propeller shaft (1) to joint flange aligning match
marks (3) and torque flange bolts to specification (for 4WD).
Tightening torque
Front propeller shaft flange bolts
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
NOTE:
For left hand steering vehicle, install lateral rod with its
bending point (2) placed to right side of vehicle.
[A] : Right hand steering vehicle
[B] : Left hand steering vehicle

Downloaded from www.Manualslib.com manuals search engine 3E-10 REAR SUSPENSION
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).

Downloaded from www.Manualslib.com manuals search engine 3E-12 REAR SUSPENSION
Install bushings so that either face of bushing are aligned
with housing edge of leading arm, also the length between
the aligned side end of bushing and trailing arm (1) are
within specification below.
Specification for trailing arm bushing protrusion
“a” : 8.5 – 10.5 mm (0.33 – 0.41 in.)
“b” : 6.0 – 9.0 mm (0.24 – 0.35 in.)
2) Install trailing arm (1) to vehicle body and rear axle housing,
referring to figure for proper installing direction of bolts.
3) Remove floor jack.
4) Connect wheel speed sensor harness clamps to trailing arm
(if equipped with ABS).
5) Connect parking brake cable clamp to trailing arm.
6) Lower hoist and with vehicle in non-loaded condition, tighten
trailing arm nuts to specified torque.
Tightening torque
Trailing arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Rear Axle Shaft and Wheel Bearing
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove rear brake drum and disconnect parking brake
cable from brake back plate. For details, refer to “Brake back
plate” in Section 5.
3) Drain gear oil from rear axle housing by loosening drain plug.

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-19
10) Loosen rear mounting nuts of trailing arm (2) but don’t
remove bolt.
11) Remove shock absorber (1) lower mounting bolt.
12) Lower floor jack until tension of suspension coil spring
becomes a little loose and remove rear mount bolts of trailing
arm.
13) Lower rear axle housing gradually.
14) Remove axle housing.
INSTALLATION
Install removed parts in reverse order of removal, noting the fol-
lowing.
1) Place rear axle housing (1) on floor jack. Then install trailing
arm (2) rear mounting bolts (right & left) in proper direction
as shown. At this time, mount nuts but don’t tighten them.
2) Install coil spring (2) (right & left) on spring seat (1) of axle
housing and raise axle housing.
3. Out side
4. Body center
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.)

Downloaded from www.Manualslib.com manuals search engine 3F-2 WHEELS AND TIRES
General Description
Tires
This vehicle is equipped with following tire.
Tire size
: 205/70 R15 or 175/80 R15
The tires are of tubeless type. The tires are designed to operate satisfactorily with loads up to the full rated load
capacity when inflated to the recommended inflation pressure.
Correct tire pressures and driving habits have an important influence on tire life Heavy cornering, excessively
rapid acceleration, and unnecessary sharp braking increase tire wear.
Wheels
Standard equipment wheels are following steel wheels.
15 x 5 1/2 JJ
Replacement Tires
When replacement is necessary, the original equipment type tire should be used. Refer to the Tire Placard.
Replacement tires should be of the same size, load range and construction as those originally on the vehicle.
Use of any other size or type tire may affect ride, handling, speedometer / odometer calibration, vehicle ground
clearance and tire or snow chain clearance to the body and chassis.
It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it
should be paired with the tire having the most tread, to equalize braking traction.
The metric term for tire inflation pressure is the kilopascal (kPa).
Tire pressures will usually be printed in both kPa and psi on the
Tire Placard. Metric tire gauges are available from tool suppliers.
The following chart, converts commonly used inflation pressures
from kPa to psi. WARNING:
Do not mix different types of tires on the same vehicle such as radial, bias and bias-belted tires except
in emergencies, because vehicle handling may be seriously affected and may result in loss of control.
kPa
kgf/cm2psi
160
180
200
220
240
260
280
300
320
3401.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.423
26
29
32
35
38
41
44
47
50

Downloaded from www.Manualslib.com manuals search engine WHEELS AND TIRES 3F-3
Replacement Wheels
Wheels must be replaced if they are bent, dented, have excessive
lateral or radial runout, leak air through welds, have elongated
bolt holes, if lug nuts won’t stay tight, or if they are heavily rusted.
Wheels with greater runout than shown in “How to Measure
Wheel Runout” may cause objectional vibrations.
Wheels for replacement must be equivalent to the originally
equipped wheels in load capacity, diameter, rim width, off-set and
mounting configuration. A wheel of improper size or type may
affect wheel and bearing life, brake cooling, speedometer / odom-
eter calibration, ground clearance to the body and chassis.
How To Measure Wheel Runout
To measure the wheel runout, it is necessary to use accurate dial
indicator. The tire may be on or off the wheel. The wheel should
be installed to the wheel balancer of the like for proper measure-
ment.Take measurements of both lateral runout (1) and radial
runout (2) at both inside and outside of the rim flange. With dial
indicator set in place securely, turn the wheel one full revolution
slowly and record every reading of the indicator.
When the measured runout exceeds the specification and correc-
tion by the balancer adjustment is impossible, replace the wheel.
If the reading is affected by welding, paint or scratch, it should be
ignored.
Lateral runout limit
“a” : 1.20 mm (0.047 in.)
Radial runout limit
“b” : 1.20 mm (0.047 in.)
Metric Lug Nuts and Wheel Studs
All models use metric lug nuts and wheel studs.
Metric lug nuts and wheel studs size
: M12 x 1.25

Downloaded from www.Manualslib.com manuals search engine 5-38 BRAKES
INSTALLATION
1) Install master cylinder as shown and torque attaching nuts to
specification.
Tightening torque
Master cylinder nuts
(a) : 13 N·m (1.3 kg-m, 9.5 Ib-ft)
2) Attach hydraulic lines and torque flare nuts to specification.
Tightening torque
Brake pipe flare nuts
(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
3) Connect reservoir lead wire.
4) Fill reservoir with specified brake fluid.
5) After installing, bleed air from system (refer to “Air Bleeding
of Brake System” in this section) and check brake pedal
height and play.
6) Perform brake test and check each installed part for fluid
leakage.
Master Cylinder
NOTE:
See NOTE at the beginning of this section.
Check clearance between booster piston rod and pri-
mary.
[A] : For vehicle without ABS 7. Piston cup
: Apply brake fluid confirm installing direction.
[B] : For vehicle with ABS 8. Secondary piston
1. Piston stopper circlip 9. Sealing
: Apply brake fluid confirm installing direction.
2. Piston stopper 10. Secondary piston return spring
3. Cylinder cup and plate
: Apply brake fluid confirm installing direction.11. Secondary piston stopper bolt
4. Primary piston 12. Master cylinder body
5. Piston cup
: Apply brake fluid confirm installing direction.Tightening Torque
6. Secondary piston pressure cup
: Apply brake fluid confirm installing direction.Do not reuse

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-39
DISASSEMBLY
1) Remove circlip (1).
2) Remove primary piston.
3) [For vehicle with ABS]
Pull out primary piston assembly straight so as not to cause
any damage to inside o cylinder wall.
Pull out secondary piston assembly straight so as not to
cause any damage to inside of cylinder wall and by tapping
flange with a piece of wood or something soft.
4) [For vehicle without ABS]
Remove piston stopper bolt (1). Then remove secondary pis-
ton by blowing compressed air (2) into hole from which pis-
ton stopper bolt was removed.
Be cautions during removal as secondary piston jumps out.
INSPECTION
Inspect all disassembled parts for wear or damage, and
replace parts if necessary.
Inspect master cylinder bore for scoring or corrosion. It is
best to replace corroded cylinder.
Corrosion can be identified as pits or excessive roughness.
2. Master cylinder
NOTE:
Wash disassembled parts with brake fluid.
Do not reuse piston cups.
NOTE:
Polishing bore of master cylinder with cast aluminum
body with anything abrasive is prohibited, as damage to
cylinder bore may occur.
[A]: Vehicle equipped with ABS
[B]: Vehicle not equipped with ABS

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-43
LSPV Assembly
INSPECTION AND ADJUSTMENT
1) Confirm the following before inspection and adjustment.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
Vehicle is free from any other load.
Place it on level floor.
2) Push up LSPV lever with finger till it stops and measure
length of coil spring (“a” in figure).
3) Spring length “a” should be as specified.
Spring length “a”
147 mm (5.79 in.)
4) If it isn’t, adjust it to specification by changing stay position
as shown in figure. After adjustment, tighten bolt to specified
torque.
Tightening torque
LSPV adjust bolt
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
NOTE:
Check to make sure that LSPV body and brake pipe joints
are free from fluid leakage. Replace defective parts, if
any.