front SUZUKI JIMNY 2005 3.G Service Service Manual

Downloaded from www.Manualslib.com manuals search engine 3C-14 STEERING WHEEL AND COLUMN
3) Take measurement “a” as shown.
If it is shorter than specified length, replace column assem-
bly (1) with new one.
Steering column assembly length
“a” : 733.2 – 734.8 mm (28.87 – 28.93 in.)
4) Check steering shaft joints and shaft for any damages such
as crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as lower joint assembly or
column assembly.
5) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
6) Check steering shaft and column for bend, cracks or defor-
mation.
If found defective, replace.
7) Check steering column lower seal (1) for breakage or defor-
mation. If found defective, replace.
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight
forward state.
2) If equipped, install shift (key) interlock cable to ignition
switch.
3) Apply sealant to the steering column lower bracket (shaded
section in the figure) and fit the steering column seal (1) to
the stepped part of the steering column lower bracket
securely.
“A” : Sealant 99000-31090
CAUTION:
After tightening steering column mounting bolts and
nuts shaft joint bolts should be tightened.

Downloaded from www.Manualslib.com manuals search engine 3C-16 STEERING WHEEL AND COLUMN
2) Loosen and remove steering lock mounting bolts (2) using
center punch (1) as shown.
3) Turn ignition key to “ACC” or “ON” position and remove
steering lock assembly from steering column.
INSTALLATION
1) Position oblong hole (1) of steering shaft in the center of hole
(3) in column (4).
2) Turn ignition key to “ACC” or “ON” position and install steer-
ing lock assembly (5) onto column (4).
3) Now turn ignition key to “LOCK” position and pull it out.
4) Align hub on lock with oblong hole (1) of steering shaft and
rotate shaft to assure that steering shaft (2) is locked.
5) Tighten new bolts until head of each bolt is broken off.
6) Turn ignition key to “ACC” or “ON” position and check to be
sure that steering shaft rotates smoothly. Also check for lock
operation.
7) Install steering column referring to “Steering Column” in this
section.
Steering Lower Shaft
REMOVAL
1) Turn steering wheel so that vehicle’s front tires are at
straight-ahead position.
2) Turn ignition switch to “LOCK” position and remove key. NOTE:
Use care not to damage aluminum part of steering lock
body with center punch.
CAUTION:
For vehicle with air bag system
Never turn steering wheel while steering shaft lower joint
is removed.
Should it have been turned and contact coil (on combina-
tion switch) have got out of its centered position, it needs
to be centered again. Also, turning steering wheel more
than about two and a half turns will break contact coil.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-17
3) Make alignment marks (3) on lower shaft (2) and shaft (col-
umn side) (1) and lower shaft (2) and gear box shaft (gear
box side) (4) for a guide during reinstallation.
4) Remove lower shaft joint bolts.
5) Remove steering lower shaft.
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight
forward state.
2) Insert lower shaft joint into shaft of steering column with
matching marks (3).
3) Align flat part “A” of steering gear box shaft (4) with bolt hole
“B” of lower shaft joint as shown. Then insert lower shaft joint
into steering gear box shaft (4) with matching marks (3).
4) Tighten shaft joint bolt (column side) to specified torque first
and then shaft joint bolt (gear box shaft side) to specified
torque.
Tightening torque
Steering shaft joint bolts (a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
1. Steering column assembly
2. Steering lower shaft

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-1
6F1
6F2
6G
1A
6K
7A
7A1
3D
7F
8A
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3D
FRONT SUSPENSION
CONTENTS
General Description ....................................... 3D-2
4WD Control System .................................... 3D-2
Diagnosis ........................................................ 3D-8
Diagnosis Table ........................................... 3D-8
4WD Controller and ITS Circuit Check ....... 3D-10
4WD Control System Check ...................... 3D-11
Stabilizer bar / bushing check ................ 3D-13
Shock Absorber and/or Coil Spring
Check ......................................................... 3D-14
Leading Arm / Lateral Rod / Steering
Knuckle Check ........................................... 3D-14
Leading Arm Bushing / Lateral Rod
Bushing Check ........................................... 3D-15
Kingpin / Kingpin Bearing Check ................ 3D-15
Barfield Joint Check ................................... 3D-15
Steering Knuckle Seal Check ..................... 3D-15
Wheel Disc, Nut and Bearing Check .......... 3D-16On-Vehicle Service ...................................... 3D-17
Stabilizer Bar / Bushings ............................ 3D-17
Front Shock Absorber ................................ 3D-19
Coil Spring ................................................. 3D-19
Bump Stopper and Spring Upper Seat ...... 3D-21
Wheel Hub / Bearing / Oil Seal .................. 3D-21
Steering Knuckle / Wheel Spindle.............. 3D-28
Front Axle Shaft / Oil Seal / Kingpin
Bearing Outer Race ................................... 3D-32
Steering Knuckle Seal................................ 3D-34
Lateral Rod ................................................ 3D-35
Leading Arm / Bushing............................... 3D-36
Front Axle Housing .................................... 3D-38
Tightening Torque Specifications .............. 3D-44
Required Service Material ........................... 3D-44
Special Tool .................................................. 3D-45

WARNING:
When hoisting vehicle, be sure to select the lifting point suitable for the service work referring to Sec-
tion 0A.
NOTE:
All front suspension fasteners are an important attaching part in that it 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 speci-
fied during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or
damage to the part may result.

Downloaded from www.Manualslib.com manuals search engine 3D-2 FRONT SUSPENSION
General Description
4WD Control System
The 4WD control system consists of a 4WD switch, a vacuum switch, a vacuum tank, two vacuum switching
valves (VSV1 and VSV2) and air locking hub assemblies.
The 4WD controller controls locking or unlocking of the air locking hub according to operation of the transfer shift
control lever.
Vacuum generated in the intake manifold passes through the check valve and stored in the vacuum tank.
According to signals from the 4WD switch, the 4WD controller activates VSV1 (for unlocking) or VSV2 (for lock-
ing) to apply vacuum from the vacuum tank so that the front axle and the wheel hub are disengaged or engaged.
1. Front axle housing 3. Steering knuckle 5. Wheel spindle 7. Wheel bearing
2. Shock absorber 4. Kingpin 6. Wheel hub 8. Front axle shaft (4WD)

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-3
1. Air locking hub assembly 4. VSV2 7. 4WD controller 10. 4WD indicator light 13. ABS controller
2. VSV1 5. Vacuum accumulation tank 8. Intake manifold 11. 4WD switch 14. Transfer
3. Check valve 6. Vacuum switch 9. Wheel spindle 12. Combination meter

Downloaded from www.Manualslib.com manuals search engine 3D-4 FRONT SUSPENSION
SYSTEM CIRCUIT
1. 4WD controller 4. 4WD indicator lamp 7. Blower fan switch 10. Vacuum switch 13. IG fuse
2. VSV1 5. ECM 8. A/C switch (if equipped) 11. Main fuse 14. A/C controller (if equipped)
3. VSV2 6. Blower fan motor 9. 4WD switch 12. IG switch 15. Coupler of 4WD controller

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-5
Components and Functions
Component Function
4WD switch When the transfer shift lever is shifted to 4L or 4H position from 2H, this switch
turns ON and cause the 4WD control system to turn ON.
4WD controller When the 4WD switch turns on, the 4WD controller activates VSV2 to lock the
air locking hubs and when it receives an “ON” signal from the vacuum switch, it
makes VSV2 to complete operation within 5 seconds and causes the 4WD indi-
cator light to light up.
If vacuum in the vacuum circuit fails to reach the specified level due to a leakage
in the vacuum circuit (when no “ON” signal is inputted from the vacuum switch),
the 4WD controller stops operation of VSV2 in 15 seconds and makes the 4WD
indicator light to flash to warn occurrence of a trouble.
When the 4WD switch turns off, the 4WD controller activates VSV1 for 10 sec-
onds to unlock the hubs and at the same time makes the 4WD indicator light
turn off.
VSV1 VSV1 operates according to the signal from the 4WD controller. When it is acti-
vated, the port opens and vacuum in the intake manifold is applied through the
vacuum circuit to unlock to the slide gear in the air locking hub. As a result, the
air locking hubs are unlocked.
VSV2 VSV2 operates according to the signal from the 4WD controller. When it is acti-
vated, the port opens and vacuum in the intake manifold is applied through the
vacuum circuit to lock to the slide gear in the air locking hub. As a result, the air
locking hubs are locked.
Vacuum switch When VSV2 receives the “ON” signal from 4WD switch, vacuum is applied
through its circuit to the vacuum switch. The vacuum switch turns on when it
detects vacuum exceeding 260 mmHg.
“4WD” indicator lamp It lights up when 4WD control system is in the 4WD mode.
It flashes to warn that locking hub operation has not completed (4WD control
system fails to shift 4WD).

Downloaded from www.Manualslib.com manuals search engine 3D-6 FRONT SUSPENSION
OPERATION
2WD
→ 4WD
When the transfer shift control lever is shifted from the 2WD (2H) position to the 4WD (4H or 4L) position, a 4WD
“ON” signal is transmitted to the 4WD controller which then activates VSV2 to apply vacuum in the intake mani-
fold to the chamber “B” in the hub housing.
When vacuum is applied, the slide gear is separated from the magnet, moves toward the center of the vehicle
body and gets engaged with the outer gear. In this way, the front axle shaft and the front wheel hub rotate as one
unit.
If vacuum in the circuit fails to reach 260 mmHg within 15 seconds after operation of VSV2 due to such trouble
as a hole in the vacuum pipe, the slide gear does not operate and the 4WD indicator light flashes to warn that
the hub is unlocked.
1. ECM 8. Engine speed signal 15. Chamber B 22. Slide gear
2. 4WD controller 9. Intake manifold 16. Piston A 23. Wheel hub
3. 4WD indicator lamp 10. Check valve 17. Magnet 24. Spindle
4.4WD switch 11. Vacuum tank 18. Housing 25. Front axle shaft
5. A/C switch (if equipped) 12. VSV1 19. Spring 26. To opposite side
6. Vacuum switch 13. VSV2 20. Diaphragm 27. A/C controller
7. A/C cut signal (if equipped) 14. Outer gear 21. Sleeve A: Vacuum circuit

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-7
4WD
→ 2WD
When the transfer shift control lever is shifted from the 4WD (4H or 4L) to the 2WD (2H) position, the 4WD con-
troller activates VSV1 and the intake manifold vacuum is applied to the chamber “A” in the hub housing. As the
slide gear is shifted to the wheel side by the vacuum force and disengaged from the outer gear, rotation of the
front wheel hub is not transmitted to the front axle shaft.
1. EPI & A/C controller 8. Engine speed signal 15. Chamber A 22. Slide gear
2. 4WD controller 9. Intake manifold 16. Piston A 23. Wheel hub
3. 4WD indicator lamp 10. Check valve 17. Magnet 24. Spindle
4.4WD switch 11. Vacuum tank 18. Housing 25. Front axle shaft
5. A/C switch (if equipped) 12. VSV1 19. Spring 26. To opposite side
6. Vacuum switch 13. VSV2 20. Diaphragm 27. A/C controller
7. A/C cut signal (if equipped) 14. Outer gear 21. Sleeve A: Vacuum circuit