lock SUZUKI JIMNY 2005 3.G Service Repair Manual

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Diagnosis
Diagnosis Table
For description not found in the table below, refer to “Diagnosis Table” in Section 3.
4WD CONTROL SYSTEM
4WD CONTROL SYSTEM DIAGNOSTIC FLOW TABLE
Before performing the trouble diagnosis, check that the air locking hub assemblies are in good condition and
there is no air leakage from vacuum hoses and vacuum pipe. Refer to “4WD Control System Check” in this sec-
tion for air leakage.
[NOTES ON SYSTEM CIRCUIT INSPECTION]
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before circuit inspection and
observe what is written there.
For system circuit, refer to the figure of “System Circuit” in this section. Condition Possible Cause Correction
4WD Indicator light
flashingHub locking procedure error
Defective VSV2
Defective vacuum switch
Defective check valve or vacuum tank
Air leak from vacuum circuit
Clogged vacuum hose or pipe
Faulty 4WD controllerShift transfer shift control lever
2WD → 4WD once again
Replace
Replace
Replace
Check and repair
Replace
Check and replace
2WD/4WD switching
errorDefective air locking hub assembly
Abnormality in 4WD control system
Air leakage from vacuum circuit
Clogged vacuum hose or pipe
Defective check valve or vacuum tankReplace
Inspect referring to “4WD Control
System Diagnostic Flow Table”
Check and replace
Replace
Replace
Step Action Yes No
1 Check ground circuit.
1) Disconnect coupler from 4WD controller
with ignition switch OFF.
2) Check for proper connection to 4WD con-
troller at all terminals.
3) If OK, check continuity between A5 terminal
and body ground.
Is there continuity between A5 terminal and
body ground?Go to Step 2.“B” wire is open.
2 Check power circuit.
1) Disconnect coupler from 4WD controller.
2) Turn ignition switch ON.
3) Check voltage between A10 terminal and
ground.
Is it 10 – 14 V?Go to Step 3.“Y/R” circuit is open or
short.

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4WD Control System Check
AIR LOCKING HUB
1) Start engine and shift transfer shift control lever to 2H posi-
tion.
2) Connect vacuum pump gauge (special tool) to the spindle
hose (2) which is disconnected from upper side pipe as
shown. Apply vacuum and check operating sound from air
locking hub (1).
If there is not operating sound, replace air locking hub
assembly.
Vacuum specification
More than 40 kPa (0.40 kg/cm
2, 5.70 Psi)
Special tool
(A) : 09917-47910
3) Connect hose, then start engine and shift transfer shift con-
trol lever to 4H or 4L position.
4) Connect vacuum pump gauge to the spindle hose (2) dis-
connected from lower side pipe.
Apply vacuum and check operating sound from air locking
hub (1).
If there is no operating sound, replace air locking hub
assembly.
Vacuum specification
More than 40 kPa (0.40 kg/cm
2, 5.70 Psi)
Special tool
(A) : 09917-47910
VSV1 AND VSV2
1) Disconnect coupler from VSV1 (1) (VSV2) (2) and check
resistance between two terminals of VSV1 (1) (VSV2) (2).
If resistance is out of specification, replace.
Resistance of VSV1 and VSV2
: 33 – 39
Ω

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Wheel Disc, Nut and Bearing Check
1) Inspect each wheel disc for dents, distortion and cracks.
Disc in badly damaged condition must be replaced.
2) Check wheel nuts for tightness and as necessary, retighten
them to specification.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
3) Check wheel bearing for wear. After retightening lock nut to
specified torque, apply dial gauge to wheel hub center and
measure thrust play.
Wheel bearing thrust play limit
: 0.05 mm (0.002 in)
When measurement exceeds limit, replace bearing.
4) By rotating wheel actually, check wheel bearing for noise and
smooth rotation. If defective, replace bearing.

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Front Shock Absorber
REMOVAL
1) Hoist vehicle.
2) Support front axle housing by using floor jack to prevent it
from lowering, refer to “When Using Floor Jack” under “Vehi-
cle Lifting Points” in Section 0A.
3) Remove shock absorber lower mounting bolt (6).
4) Remove shock absorber upper mounting lock nut (2) and
absorber nut (3). Then remove shock absorber (1).
INSTALLATION
Install removed parts in reverse order of removal proceeded, not-
ing the followings.
As shown in figure, install washer (4) and bush (5) first and
after tightening absorber nut (3) tighten lock nut (2) to speci-
fied torque.
Tightening torque
Shock absorber lock nut
(a) : 29 N·m (2.9 kg-m, 21.0 lb-ft)
Install absorber lower mounting bolt (6) in proper direction as
shown in the figure and tighten it with no load applied to axle
housing.
Tightening torque
Shock absorber lower nut
(b) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Confirm front end (wheel) alignment referring to “Preliminary
Checks Prior to Adjusting Front Alignment” in Section 3A.
Coil Spring
REMOVAL
1) Hoist vehicle and remove wheel.
2) Disconnect stabilizer ball joint from axle housing.
3) Remove brake caliper carrier bolts and suspend caliper.
W: Wheel side
7. Lower mounting nut
CAUTION:
During removal, be careful not to damage brake flexible
hose and wheel speed sensor harness (vehicle with ABS)
and not to depress brake pedal.

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4) Remove brake disc.
5) Remove front wheel bearing lock nut as follows.
For 2WD model :
a) Remove hub cap.
b) Remove front wheel bearing lock plate (1) by loosening 4
screws (2).
For 4WD model :
a) Remove air locking hub assembly (1).
b) Remove front axle shaft circlip and wheel spindle thrust
washer.
c) Uncaulk front wheel bearing lock nut. NOTE:
If brake disc can not be removed by hand, using 8 mm
bolts.
1. Wheel hub

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6) Remove front wheel bearing lock nut by using special tool.
Special tool
(A) : 09944-77020 (For 4WD)
(A) : 09951-16050 (For 2WD)
7) Remove front wheel bearing washer.
8) Remove wheel hub complete (1) with bearings (2) and oil
seal (4).
Special tool
(A) : 09943-35511 or 09943-35512
(B) : 09942-15510
9) Remove sensor rotor from wheel hub as shown (if equipped
with ABS).
10) Remove wheel bearing oil seal and circlip.
3. Circlip
NOTE:
If wheel hub can not be removed by hand, use special
tools as shown.
CAUTION:
Pull out sensor rotor from wheel hub gradually and
evenly.
Attempt to pull it out partially may cause it to be
deformed.
1. Sensor rotor
2. Wheel hub
3. Vise
4. Flat end rod

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5) Apply lithium grease to lip portion and hollow of oil seal (1).
“A” : Grease 99000-25010
6) Install sensor rotor (3) as shown (if equipped with ABS).
7) Apply lithium grease inside wheel bearing thin.
“A” : Grease 99000-25010
8) Install wheel hub complete with bearings and oil seal onto
front wheel spindle.
9) Install bearing washer.
10) Tighten wheel bearing lock nut to specified torque while turn-
ing wheel hub by hand.
Special tool
(A) : 09944-77020 (For 4WD)
(A) : 09951-16050 (For 2WD)
Tightening torque
Wheel bearing lock nut
(a) : 220 N·m (22.0 kg-m, 160 lb-ft)
11) Install hub cap (for 2WD model) or air locking hub assembly
(for 4WD model) as follows. NOTE:
Amount of grease applied to hollow in oil seal (1) should
be more than 60% of its vacant space.
2. Wheel hub
NOTE:
Pipe (2) used here should have inner diameter of
90 mm (3.55 in.) – 96 mm (3.77 in.) and its outside
should not contact teeth of sensor rotor (3).
Use care not to insert wheel hub (4) diagonally.
1. Steel plate
5. Hydraulic press

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For 2WD model:
a) Using lock plate (1), lock bearing lock nut. If lock screw hole
is not aligned with screw hole in lock nut, turn lock nut in
tightening direction till they align.
Tightening torque
Wheel bearing lock washer screw
(a) : 1.5 N·m (0.15 kg-m, 1.0 lb-ft)
b) Remove grease, old sealant and dusts from mating sur-
faces of hub cap (1) and wheel hub (2) to clean, apply
water tight sealant to hub cap mating surface evenly, and
install hub cap (1) to wheel hub (2).
“A” : Sealant 99000-31090
For 4WD model:
a) Caulk front wheel bearing lock nut at groove of spindle.
b) Apply lithium grease thinly to both surface, all around of
front spindle thrust washer (1).
“A” : Grease 99000-25010
NOTE:
When installing hub cap (1), hammer lightly several
locations on the collar of cap until collar comes closely
into contact with wheel hub (2).
If fitting part of cap is deformed or damaged or if it is
fitted loosely, replace with new one.

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c) Install front axle shaft circlip (1) and apply thin coat of
grease to spline part of axle shaft.
“A” : Grease 99000-25010
d) Clean mating surface of air locking hub and wheel hub.
Install air locking hub assembly to wheel hub and tighten
bolts to specified torque.
Tightening torque
Air locking hub bolts
(a) : 48 N·m (4.8 kg-m, 35.0 lb-ft)
12) Install ABS wheel sensor (if equipped with ABS).
13) Install brake disc and caliper assembly.
Tighten carrier bolts to specified torque.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
14) Install wheel and tighten wheel nuts specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
15) Lower hoist.
16) For 4WD model:
Check air locking hub for air leakage, refer to “4WD System
Check” in this section. NOTE:
When installing circlip (1) to front axle shaft, utilize screw
hole in axle shaft to pull it out and bring large diameter
(2) of circlip at right as shown.

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8) Press-fit spindle bushing (2) to wheel spindle (1) by using
special tool.
Set cut part (4) of spindle bushing (2) as shown in figure
(opposite side of the groove (3) of wheel spindle).
Special tool
(A) : 09922-55131
9) Press-fit spindle oil seal (1) until it becomes flush with wheel
spindle (2) surface by using special tool, and then apply
grease to its lip.
Special tool
(A) : 09944-66020
10) Apply grease to spindle oil seal lip.
“A” : Grease 99000-25010
11) Apply grease to spindle bushing inside surface and flange
(2).
“A” : Grease 99000-25010
12) Install wheel spindle to knuckle, coat their mating surface
with sealant.
“B” : Sealant 99000-31110 or 99000-31090
13) Install wheel spindle (1) and disc dust cover (2) to steering
knuckle. Tighten wheel spindle bolts to specified torque.
Tightening torque
Wheel spindle bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
CAUTION:
As this hole is a part of the passage of the vacuum that
activates the air locking hub, if it is clogged with grease,
the air locking hub cannot be locked or unlocked.
Therefore, be careful not to apply too much grease to
avoid clogging the vacuum passage.