PEDAL SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-21
Abbreviations May Be Used In This Manual
Abbreviations
AABC
ATDC
API
ATF
ALR
AC
A/T
A/C
ABDC
A/F
A-ELRAnti-lock Brake System
After Top Dead Center
American Petroleum Institute
Automatic Transmission Fluid
Automatic Locking Retractor
Alternating Current
Automatic Transmission
Air Conditioning
After Bottom Dead Center
Air Fuel Mixture Ratio
Automatic-Emergency
Locking RetractorEEBCM
ECM
ECT Sensor
EGR
EGRT Sensor
EFE Heater
ELR
EPS
EVAP
EVAP CanisterElectronic Brake Control Module,
ABS Control Module
Engine Control Module
Engine Coolant Temperature
Sensor (Water Temp. Sensor,
WTS)
Exhaust Gas Recirculation
EGR Temperature Sensor
(Recirculated Exhaust Gas Temp.
Sensor, REGTS)
Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
Emergency Locking Retractor
Electronic Power Steering
Evaporative Emission
Evaporative Emission Canister
(Charcoal Canister) BB+
BTDC
BBDCBattery Positive Voltage
Before Top Dead Center
Before Bottom Dead Center
CCKT
CMP Sensor
CO
CPP Switch
CPU
CRSCircuit
Camshaft Position Sensor
(Crank Angle Sensor, CAS)
Carbon Monoxide
Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
Central Processing Unit
Child Restraint SystemF 4WD 4 Wheel Drive
GGEN
GNDGenerator
Ground
HHC
HO2SHydrocarbons
Heated Oxygen Sensor
DDC
DLC
DOHC
DOJ
DRL
DTCDirect Current
Data Link Connector
(Assembly Line Diag. Link, ALDL,
Serial Data Link, SDL)
Double Over Head Camshaft
Double Offset Joint
Daytime Running Light
Diagnostic Trouble Code
(Diagnostic Code)IIAC Valve
IAT Sensor
ICM
IG
ISC ActuatorIdle Air Control Valve (Idle Speed
Control Solenoid Valve, ISC
Solenoid Valve)
Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
Immobilizer Control Module
Ignition
Idle Speed Control Actuator
(Motor)

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-3
IntervalKm (x 1,000) 153045607590
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
CHASSIS AND BODY
Clutch (pedal height and travel)–I–I–I
Brake discs and pads (thickness, wear, damage) I I I I I I
Brake drums and shoes (wear, damage)–I–I–I
Brake hoses and pipes (leakage, damage, clamp)–I–I–I
Brake fluid–R–R–R
Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles) only.
Tires (wear, damage, rotation) I I I I I I
Wheel discs (damage) I I I I I I
Suspension system (tightness, damage, rattle, breakage)–I–I–I
Propeller shafts––I––I
Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I–R––R
Automatic transmission Fluid level–I–I–I
Fluid change Replace every 165,000 km (99,000 miles).
Fluid hose–––R––
Transfer oil (leakage, level) I–I–I–
Differential oil (leakage, level) (R: 1st 15,000 km only) R or I–I–I–
Steering system (tightness, damage, breakage, rattle)–I–I–I
Power steering (if equipped) I I I I I I
All latches, hinges and locks–I–I–I
NOTE:
“R”: Replace or change
“I”: Inspect and correct, replace or lubricate if necessary

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-11
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.

Downloaded from www.Manualslib.com manuals search engine 0B-20 MAINTENANCE AND LUBRICATION
Final Inspection
SEATS
Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front
seat back allows it to be locked at any angle.
SEAT BELT
Inspect belt system including webbing, buckles, latch plates, retractors and anchors for damage or wear.
If “REPLACE BELT” label on front seat belt is visible, replace belt. Check that seat belt is securely locked.
BATTERY ELECTROLYTE LEVEL CHECK
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If bat-
tery is equipped with built-in indicator, check battery condition by the indicator.
ACCELERATOR PEDAL OPERATION
Check that pedal operates smoothly without getting caught or interfered by any other part.
ENGINE START
Check engine start for readiness.
On automatic transmission vehicles, try to start the engine in each select lever position. The starting motor
should crank only in “P” (Park) or “N” (Neutral).
On manual transmission vehicles, place the shift lever in “Neutral,” depress clutch pedal fully any try to start.
EXHAUST SYSTEM CHECK
Check for leakage, cracks or loose supports.
CLUTCH (FOR MANUAL TRANSMISSION)
Check for the following.
Clutch is completely released when depressing clutch pedal,
No slipping clutch occurs when releasing pedal and accelerating.
Clutch itself is free from any abnormal condition. WARNING:
When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to
prevent any accident.
WARNING:
Before performing the following check, be sure to have enough room around the vehicle. Then, firmly
apply both the parking brake and the regular brakes. Do not use the accelerator pedal. If the engine
starts, be ready to turn off the ignition promptly. Take these precautions because the vehicle could
move without warning and possibly cause personal injury or property damage.

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-21
GEARSHIFT OR SELECTOR LEVER (TRANSMISSION)
Check gear shift or selector lever for smooth shifting to all positions and for good performance of transmission in
any position.
With automatic transmission equipped vehicle, also check that shift indicator indicates properly according to
which position selector lever is shifted to.
With automatic transmission equipped vehicle, make sure that vehicle is at complete stop when shifting selector
lever to “P” range position and release all brakes.
BRAKE
Foot Brake
Check the following:
that brake pedal has proper travel,
that brake works properly,
that it is free from noise,
that braking force is applied equally on all wheels,
and that brake do not drag.
Parking Brake
Check that lever has proper travel.
Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
STEERING
Check to ensure that steering wheel is free from instability, or abnormally heavy feeling.
Check that the vehicle does not wander or pull to one side.
ENGINE
Check that engine responds readily at all speeds.
Check that engine is free from abnormal noise and abnormal vibration.
BODY, WHEELS AND POWER TRANSMITTING SYSTEM
Check that body, wheels and power transmitting system are free from abnormal noise and abnormal vibration or
any other abnormal condition.
METERS AND GAUGE
Check that speedometer, odometer, fuel meter, temperature gauge, etc. are operating accurately.
LIGHTS
Check that all lights operate properly.
WINDSHIELD DEFROSTER
Periodically check that air comes out from defroster outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan switch lever to “HI” position for this check. WARNING:
With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any per-
sonal injury or property damage. Be prepared to apply regular brake quickly even if vehicle should
start to move.

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-19
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.

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-21
5) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
6) Lower hoist.
7) Confirm front end (wheel) alignment, referring to “Prelimi-
nary Checks Prior to Adjusting Front Alignment” in Section
3A.
Bump Stopper and Spring Upper Seat
REMOVAL
1) Remove coil spring, refer to “Coil Spring” in this section.
2) Remove bump stopper and spring upper seat.
INSTALLATION
1) Install bump stopper (1) and spring upper seat (2).
2) Install coil spring, refer to “Coil Spring” in this section.
Wheel Hub / Bearing / Oil Seal
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove brake caliper carrier bolts and suspend caliper (1).
3) Remove ABS wheel sensor (if equipped with ABS).
NOTE:
Before installing bump stopper (1), apply soap water on
it.
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.

Downloaded from www.Manualslib.com manuals search engine 3D-38 FRONT SUSPENSION
Front Axle Housing
REMOVAL
1) Hoist vehicle.
2) Remove front wheels.
3) Drain front differential gear oil (for 4WD).
4) Remove caliper carrier bolts (R&L) and suspend caliper.
5) Remove right and left brake disc.
6) Remove wheel speed sensor (if equipped with ABS).
7) Disconnect spindle vacuum hoses from wheel spindle (for
4WD).
8) Remove tie rod (and drag rod) end nuts and disconnect tie
rod (and drag rod) ends (2) from knuckle arm (1) (R&L) with
special tool.
Special tool
(A) : 09913-65210 CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.
NOTE:
If brake disc can not be removed by hand, use 8mm bolts
(1).
CAUTION:
Give match mark to spindle vacuum hose and wheel
spindle before removal.
1. Vacuum hose to lock
2. Vacuum hose to unlock

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-17
16) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load over ten times so as to obtain proper
drum-to shoe clearance.
Adjust parking brake cable. (For adjustment, refer to “Parking
Brake Check and Adjustment” in Section 5.)
17) Tighten parking brake lever cover screws.
18) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
19) Check each installed part for oil leakage.
Rear Axle Shaft Inner Oil Seal
REMOVAL
1) Remove rear axle shaft. For details, refer to “Rear Axle Shaft
and Wheel Bearing” in this section.
2) Remove rear axle shaft inner oil seal by using special tools.
Special tool
(A) : 09942-15510
(B) : 09944-96010 (remover)
(C) : 09921-26010 (collar)
INSTALLATION
1) Using special tools drive in oil seal (1) until it contacts oil seal
protector (2) in axle housing.
Special tool
(A) : 09913-75520
“A” : Grease 99000-25010
2) For procedure hereafter, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
NOTE:
Make sure that oil seal (1) is free from inclination as it
is installed.
Refer to figure so that oil seal (1) is installed in proper
direction.
3. Differential side

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
5
9
10
10A
10B
9
10
10A
10B
SECTION 5
BRAKES
CONTENTS
General Description ......................................... 5-3
Diagnosis .......................................................... 5-4
Road Testing Brakes ...................................... 5-4
Brake Fluid Leaks .......................................... 5-4
Substandard or Contaminated Brake Fluid .... 5-4
Diagnosis Table ............................................. 5-5
Brake Pedal Free Height Adjustment ............. 5-8
Brake Pedal Play Check ................................ 5-8
Stop Light Switch Adjustment ........................ 5-8
Excessive Pedal Travel Check ....................... 5-9
Front Brake Disc Check ................................. 5-9
Front Brake Pad Check .................................. 5-9
Rear Brake Shoe Check .............................. 5-10
Master Cylinder and Brake Fluid Level
Check ........................................................... 5-10
Rear Drum Brake Shoe Adjustment ............. 5-11
Parking Brake Inspection and Adjustment ... 5-11
Booster Operation Check ............................. 5-12Fluid Pressure Test
(If Equipped with LSPV) ............................... 5-15
On-Vehicle Service ........................................ 5-17
Air Bleeding of Brake System ...................... 5-17
Brake Hose and Pipe Inspection.................. 5-18
Front Disc Brake .......................................... 5-19
Brake pad ................................................. 5-20
Caliper assembly...................................... 5-22
Brake Disc.................................................... 5-26
Rear Brake ................................................... 5-29
Brake drum............................................... 5-29
Brake shoe ............................................... 5-32
Wheel Cylinder............................................. 5-33
Brake back plate ...................................... 5-34
Master Cylinder .............................................. 5-36
Master Cylinder Reservoir ........................... 5-36
Master Cylinder Assembly ........................... 5-37 WARNING:
For lifting point of vehicle, refer to Section 0A.
WARNING:
For vehicles equipped with Supplement Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E first.
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
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 specified
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.