steering SUZUKI JIMNY 2005 3.G Service Manual Online

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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)

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Shock Absorber and/or Coil Spring Check
1) Inspect shock absorber for oil leakage. If shock absorber is
found faulty, replace it as an assembly unit, because it can
not be disassembled.
2) Shock absorber function check
Check and adjust tire pressures as specified.
Bounce body three or four times continuously by pushing
front end on the side with shock absorber to be checked.
Apply the same amount of force at each push and note
shock absorber resistance both when pushed and rebound-
ing.
Also, note how many times vehicle body rebounds before
coming to stop after hands are off. Do the same for shock
absorber on the other side.
Compare shock absorber resistance and number of rebound
on the right with those on the left.
And they must be equal in both. With proper shock absorber,
body should come to stop the moment hands are off or after
only one or two small rebounds. If shock absorbers are sus-
pected, compare them with known good vehicle or shock
absorber.
3) Inspect for damage or deformation.
4) Inspect for cracks or deformation in spring seat.
5) Inspect for deterioration of bump stopper.
6) Inspect shock absorber mount for wear, cracks or deforma-
tion.Replace any parts found defective in steps 2) – 6).
Leading Arm / Lateral Rod / Steering Knuckle
Check
Inspect for cracks, deformation or damage.

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Leading Arm Bushing / Lateral Rod Bushing
Check
Inspect for damage, wear or deterioration.
If defective, replace.
Kingpin / Kingpin Bearing Check
1) Inspect for wear or deterioration.
2) Inspect for crack, damage or deformation of kingpin.
If defective, replace.
Barfield Joint Check
To be checked on this joint is its axial play, which shows up when
a push-and-pull motion is given to live axle shaft and wheel spin-
dle held in both hands, as shown in figure. There should be no
play at all but a play of up to 1.5 mm (0.06 in.) is permissible. If
play exceeds service limit, replace it.
Axial play in barfield joint
Steering Knuckle Seal Check
The knuckle seal used at the spherical sliding joint between the
knuckle and the inner case accomplishes the additional purposes
of keeping out road dust and of acting as the damper for the
steering handwheel. As the wear of this seal advances, its damp-
ing effect decreases and thus make the front wheel develop a ten-
dency to “shimmy” not only that road dust begins to creep into the
sliding clearance to promote the wear of the spherical sliding sur-
faces.
Check the knuckle seal for wear or damage. If defective, replace
with new one.
Standard Service Limit
0 mm (no play) 1.5 mm (0.06 in.)

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Steering Knuckle / Wheel Spindle
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove wheel hub assembly, refer to “Wheel Hub / Bearing /
Oil Seal” in this section.
3) Disconnect spindle vacuum hoses (1) from wheel spindle (for
4WD).
4) Remove disc dust cover (1) and wheel spindle (2).
5) Remove tie rod end (and drag rod end) nut(s) and discon-
nect tie rod end (and drag rod end) (2) from steering knuckle
(1) with special tool.
Special tool
(A) : 09913-65210
6) Remove knuckle seal cover bolts. Then remove knuckle seal
cover (1), knuckle seal and knuckle seal retainer from
knuckle. CAUTION:
Give match mark to each spindle vacuum hoses before
removing hose.

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7) Remove lower and upper kingpins (1).
8) Remove steering knuckle (1).
9) Remove knuckle seal cover (1), knuckle seal (2) and knuckle
seal retainer (3) from front axle housing (4).
10) Remove spindle oil seal by using special tool.
Special tool
(A) : 09913-50121
11) Remove spindle bushing by using special tools.
Special tool
(A) : 09917-88210
(B) : 09916-58210 NOTE:
Upper and lower kingpins (1), when removed, must be
marked off one from the other.
NOTE:
When steering knuckle (1) is pulled, lower kingpin
bearing sometimes falls off. So remove bearing while
pulling off the knuckle gradually.
Upper and lower kingpin bearings must be also
marked off one from the other.
1. Wheel spindle

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INSTALLATION
1) Set knuckle seal cover (2), knuckle seal (4) and knuckle seal
retainer (5) on front axle housing (6).
2) Apply grease within the knuckle (1). Amount of grease to be
applied within the knuckle (1) is approximately 100 g (for
4WD).
“A” : Grease 99000-25030
3) Apply grease to kingpin bearings (3) and install them to front
axle housing (6).
“A” : Grease 99000-25030
4) Apply sealant to indicated part of kingpin (1).
“A” : Sealant 99000-31090
5) Install steering knuckle (1) and king pins (2) and tighten king-
pin bolts to specified torque.
Tightening torque
Kingpin bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
6) Apply grease to all around of knuckle seal lip.
“A” : Grease 99000-25010
7) Install knuckle seal retainer (1), knuckle seal (2) and knuckle
seal cover (3), tighten bolts to specified torque.
Tightening torque
Knuckle seal cover bolts
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft) NOTE:
When reusing bearing (3), install bearing (3) with sealing
at the top.
NOTE:
Install knuckle seal cover (3) and knuckle seal retainer (1)
so that their split section comes at the top as shown in
figure.
4. Steering knuckle 5. Split part

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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.

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14) Blow air into pipes at the top and the front of wheel spindle
and check that it comes out of the hole as shown in figure
(for 4WD).
15) Connect spindle vacuum hoses to wheel spindle (for 4WD).
16) Connect tie rod and drag rod to steering knuckle, refer to
“Tie rod and Drag Rod” in Section 3B.
17) Install wheel hub assembly, refer to “Wheel Hub / Bearing /
Oil Seal” in this section.
18) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
: 95 N·m (9.5 kg-m, 69.0 lb-ft)
19) Lower hoist.
Front Axle Shaft / Oil Seal / Kingpin Bearing
Outer Race
REMOVAL
1) Hoist vehicle.
2) Drain differential gear oil from front axle housing by loosing
drain plug (for 4WD).
3) Remove steering knuckle. For details, refer to “Steering
Knuckle / Wheel Spindle” in this section.
4) Draw out axle shaft (2).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.
1. Front axle housing

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4) Install axle shaft (2) to front axle housing (1) (for 4WD).
5) Install knuckle to front axle housing. For details, refer to
“Steering Knuckle / Wheel Spindle” in this section.
6) Refill front axle (differential) housing with new specified gear
oil (for 4WD). Refer to “Maintenance Service” in Section 7E
for refill.
7) After servicing, check that no oil leakage exists.
Steering Knuckle Seal
REMOVAL
1) Hoist vehicle.
2) Remove knuckle seal cover bolts and seal cover (1).
3) Cut oil seal in place with scissors or knife, and take it off.
INSTALLATION
1) Cut replacement oil seal at one place with scissors or a
knife.

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2) Apply grease to oil seal lip.
“A” : Grease 99000-25010
3) Install oil seal retainer (1), oil seal (2) and oil seal cover (3) to
steering knuckle (4).
Tighten bolts to specified Torque
Tightening torque
Knuckle seal cover bolts
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
Lateral Rod
REMOVAL
1) Hoist vehicle.
2) Remove mounting bolts of lateral rod (1).
3) Remove lateral rod (1).
INSTALLATION
1) Install lateral rod (1) to vehicle body and front axle housing,
referring to figure for proper installing direction of bolts.
Bolt and nut should not be tightened.
2) Lower hoist and with vehicle in non-loaded condition, tighten
bolt and nut of lateral rod to specified torque.
Tightening torque
Lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft) NOTE:
Install the seal (2) in oil seal retainer (1), bringing the split
part (5) to top side and locating it about 30° off the
matching face of oil seal retainer (1).
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