Power steering SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine TABLE OF CONTENTS
GENERAL INFORMATIONGeneral Information0A0A
Maintenance and Lubrication0B
0B
HEATING AND AIR CONDITIONINGHeater and Ventilation1A
1A
Air Conditioning (Optional)1B
1B
STEERING, SUSPENSION, WHEELS AND
TIRESSteering, Suspension, Wheels and Tires3
3
Front Wheel Alignment3A
3A
Steering Gear Box (Manual Type) and Linkage3B
3B
Power Steering (P/S) System (if equipped)3B1
3B1
Steering Wheel and Column3C
3C
Front Suspension3D
3D
Rear Suspension3E
3E
Wheels and Tires3F
3F
DRIVE SHAFT AND PROPELLER SHAFT
Propeller Shafts4B
4B
BRAKE SYSTEMBrakes5
5
Antilock Brake System (ABS)5E
5E
ENGINEEngine General Information and Diagnosis6
6
Engine Mechanical (M13 Engine)6A1
6A1
Engine Cooling6B
6B
Engine Fuel6C
6C
Engine and Emission Control System6E
6E
Ignition System (Electronic Ignition System)6F
6F
Cranking System6G
6G
Charging System6H
6H
Exhaust System6K
6K
TRANSMISSION, CLUTCH AND
DIFFERENTIALManual Transmission7A
7A
Automatic Transmission (4 A/T)7B
7B
Clutch7C
7C
Transfer7D
7D
Front Differential7E
7E
Rear Differential7F
7F
ELECTRICAL SYSTEMBody Electrical System8
8
Immobilizer Control System (if equipped)8G
8G
BODY SERVICE9
9
RESTRAINT SYSTEMRestraint System10
10
Air Bag System10B
10B

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 0A-22 GENERAL INFORMATION
LLH
LSPVLeft Hand
Load Sensing Proportioning Valve
TTBI
TCC
TCM
TP Sensor
TVV
TWC
2WDThrottle Body Fuel Injection
(Single-Point Fuel Injection, SPI)
Torque Converter Clutch
Transmission Control Module
(A/T Controller, A/T Control Mod-
ule)
Throttle Position Sensor
Thermal Vacuum Valve
(Thermal Vacuum Switching Valve,
TVSV, Bimetal Vacuum Switching
Valve, BVSV)
Three Way Catalytic Converter
(Three Way Catalyst)
2 Wheel Drive MMAF Sensor
MAP Sensor
Max
MFI
Min
MIL
M/TMass Air Flow Sensor
(Air Flow Sensor, AFS, Air Flow
Meter, AFM)
Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Maximum
Multiport Fuel Injection
(Multipoint Fuel Injection)
Minimum
Malfunction Indicator Lamp
(“CHECK ENGINE” Light)
Manual Transmission
N NOx Nitrogen Oxides VVIN
VSSVehicle Identification Number
Vehicle Speed Sensor
OOBD
O/D
OHCOn-Board Diagnostic System
(Self-Diagnosis Function)
Overdrive
Over Head CamshaftWWU-OC
WU-TWCWarm Up Oxidation Catalytic
Converter
Warm Up Three Way Catalytic
Converter
PPNP
P/S
PSP Switch
PCM
PCVPark/Neutral Position
Power Steering
Power Steering Pressure Switch
(P/S Pressure Switch)
Powertrain Control Module
Positive Crankcase Ventilation
R RH Right Hand
SSAE
SDM
SFI
SOHCSociety of Automotive Engineers
Sensing and Diagnostic Module
(Air bag controller, Air bag control
module)
Sequential Multiport Fuel Injection
Single Over Head Camshaft

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-23
SYMBOLS
WIRE COLOR SYMBOLS
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure). SYMBOL DEFINITION SYMBOL DEFINITION
Tightening torque Apply SUZUKI BOND NO. 1216
99000-31160
Apply oil (engine, transmission, trans-
fer, differential)Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid)Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25010
Apply SUZUKI SUPER GREASE C
99000-25030Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25120Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110Do not reuse
Apply SUZUKI BOND NO. 1207C
99000-31150Note on reassembly
Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
GGRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-1
0A 6F1
0B
0B
6G
1A 6H
1B 6K
37A
3A 7A1
3B1 7B1
3C1 7C1
3D 7D
3E 7E
3F 7F
4A2 8A
4B 8B
8C
58D
5A 8E
5B
5C 9
5E
5E1 10
10A
610B
6-1
6A1
6A2
6A4
6B
6C
6E1
6E2
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule .................................. 0B-2
Maintenance Schedule Under Normal
Driving Conditions ........................................ 0B-2
Maintenance Recommended Under Severe
Driving Conditions ........................................ 0B-4
Maintenance Service...................................... 0B-5
Engine .......................................................... 0B-5
Drive Belt .................................................. 0B-5
Valve Lash................................................ 0B-6
Engine Oil and Filter ................................. 0B-6
Engine Coolant ......................................... 0B-8
Exhaust System ....................................... 0B-8
Ignition System ............................................. 0B-9
Spark Plugs .............................................. 0B-9
Fuel System ................................................. 0B-9
Air Cleaner Filter ...................................... 0B-9
Fuel Lines and Connections ................... 0B-10
Fuel Filter ............................................... 0B-10
Fuel Tank ............................................... 0B-10
Emission Control System ........................... 0B-10
Crankcase Ventilation Hoses and
Connections ........................................... 0B-10
PCV (Positive Crankcase Ventilation)
Valve ..................................................... 0B-11Fuel Evaporative Emission Control
System ................................................... 0B-11
Chassis and Body ...................................... 0B-11
Clutch ..................................................... 0B-11
Brake Discs and Pads ............................ 0B-11
Brake Drums and Shoes ........................ 0B-12
Brake Hoses and Pipes.......................... 0B-12
Brake Fluid ............................................. 0B-12
Parking Brake Lever and Cable ............. 0B-13
Tires/Wheels .......................................... 0B-13
Suspension System ............................... 0B-14
Propeller Shafts...................................... 0B-15
Manual Transmission Oil........................ 0B-16
Automatic Transmission Fluid ................ 0B-16
Transfer and Differential Oil ................... 0B-17
Steering System ..................................... 0B-18
Steering Knuckle Seal ............................ 0B-18
Power Steering (P/S) System
(if equipped) ........................................... 0B-19
All Hinges, Latches and Locks ............... 0B-19
Final Inspection............................................ 0B-20
Recommended Fluids and Lubricants ....... 0B-22

WARNING:
For vehicles equipped with Supplemental 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).

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

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Maintenance Service
Engine
Drive Belt
WATER PUMP AND GENERATOR DRIVE BELT INSPEC-
TION
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace.
Check belt for tension.
Water pump and generator belt tension
“a”: 4.5 – 5.5 mm (0.18 – 0.22 in.) deflection under 100 N
(10 kg, 22 lb) pressure
3) If belt is too tight or too loose, adjust it to specification by
adjusting alternator position.
4) Tighten alternator adjusting bolts and pivot bolt.
5) Connect negative cable to battery.
REPLACEMENT
Replace belt. Refer to “Water Pump Belt and Cooling Fan” in Sec-
tion 6B for replacement procedure of pump belt.
POWER STEERING PUMP AND/OR A/C COMPRESSOR
DRIVE BELTS INSPECTION (IF EQUIPPED)
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace. WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
NOTE:
When replacing belt with a new one, adjust belt tension
to 3 – 4 mm (0.12 – 0.16 in.).

Downloaded from www.Manualslib.com manuals search engine 0B-6 MAINTENANCE AND LUBRICATION
3) Check belt for tension.
Power steering pump and/or A/C compressor drive belt
tension
“a”: 6 – 9 mm (0.24 – 0.35 in.) deflection under 100 N
(10 kg, 22 lb) pressure.
4) If belt tension is out of above specification, adjust it referring
to “Compressor Drive Belt” in Section 1B or “Power Steering
Belt Check” in Section 3B1.
5) Connect negative cable to battery.
REPLACEMENT
Replace belt with new one referring to “Compressor Drive Belt” in
Section 1B or “Power Steering Belt Check” in Section 3B1.
Valve Lash
INSPECTION
1) Inspect intake and exhaust valve lash and adjust as neces-
sary.
Refer to “Valve Lash (Clearance)” in Section 6A1 for valve
lash inspection and adjustment procedure.
Engine Oil and Filter
CHANGE
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.
1. P/S pump pulley
2. Camshaft pulley
3. A/C compressor pulley (if equipped)
4. Belt tension pulley
1. Camshaft
2. Thickness gauge
WARNING:
 New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
 Step 1) – 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

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Power Steering (P/S) System (if equipped)
INSPECTION
1) Visually check power steering system for fluid leakage and
hose for damage and deterioration.
Repair or replace defective parts, if any.
2) With engine stopped, check fluid level indicated on fluid tank
or level gauge of tank cap, which should be between MAX
and MIN marks. If it is lower than MIN, fill fluid up to MAX
mark.
3) Visually check pump drive belt for cracks and wear.
4) Check belt for tension, referring to “Drive Belt” in this section.
If necessary, have belt adjusted or replaced.
All Hinges, Latches and Locks
DOORS INSPECTION
Check that each door of front and back doors opens and closes
smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair
door lock system.
ENGINE HOOD INSPECTION
Check that secondary latch operates properly (check that sec-
ondary latch keeps hood from opening all the way even when pull-
ing hood release handle inside vehicle.) Also check that hood
opens and closes smoothly and properly and hood locks securely
when closed.
If any malfunction is found, lubricate hinge and latch, or repair
hood lock system. Check hood latch bolt for tightness.
Tightening torque
Hood latch bolts
10 N·m (1.0 kg-m, 7.5 lb-ft)
NOTE:
 Be sure to use an equivalent of DEXRON
®-II,
DEXRON
®-IIE or DEXRON®-III for P/S fluid.
 Fluid level should be checked when fluid is cool.

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.