front suspension SUZUKI JIMNY 2005 3.G Service Workshop Manual

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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 0A-20 GENERAL INFORMATION
When Using Floor Jack
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of the front axle housing
(1) or rear axle housing (2).
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands (1) under chassis frame so that
body is securely supported. And then check to ensure that chas-
sis frame does not slide on safety stands (1) and the vehicle is
held stable for safety’s sake. WARNING:
If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
CAUTION:
Never apply jack against suspension parts (i.e., stabi-
lizer, etc.) or vehicle floor, or it may get deformed.
[A]: Front
[B]: Rear

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3) Rotate tires.
For details, refer to “Tire Rotation” in Section 3F.
WHEEL DISCS INSPECTION
Inspect each wheel disc for dents, distortion and cracks. A disc in
badly damaged condition must be replaced.
WHEEL BEARING INSPECTION
1) Check front wheel bearing for wear, damage, abnormal
noise or rattles. For details, refer to “Wheel Disc, Nut and
Bearing Check” in Section 3D.
2) Check rear wheel bearing for wear, damage, abnormal noise
or rattles. For details, refer to “Wheel Disc, Nut and Bearing
Check” in Section 3E.
Suspension System
INSPECTION
Check suspension bolts and nuts for tightness and retighten them
as necessary.
Repair or replace defective parts, if any.
FRONT
1) Check stabilizer bar (6) for damage or deformation.
2) Check bushing (8) for damage, wear or deterioration.
3) Check coil spring (1), lateral rod (5) and leading arm (3) for
deformation and damage.
4) Check lateral rod (5) and leading arm bushings for wear,
damage and deterioration.
5) Inspect absorbers (2) for evidence of oil leakage, dents or
any other damage on sleeves; and inspect anchor ends for
deterioration.
6) Inspect for cracks or deformation in spring seat.
7) Inspect for deterioration of bump stopper.NOTE:
For details of check points, refer to tables of “Tightening
Torque Specification” in Section 3D and 3E.
4. Front axle housing
7. Ball joint

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REAR
1) Check shock absorber (1) for damage, deformation, oil leak-
age and operation.
2) Check bushings for wear and damage.
3) Check coil spring (4), trailing arm (6) and lateral rod (5) for
deformation and damage.
4) Check trailing arm (6) and lateral rod bushings and bump
stopper (2) for wear, damage and deterioration.
5) Check other suspension parts for damage, loose or missing
parts; also for parts showing signs of wear or lack of lubrica-
tion.
Replace any parts found defective in steps 1) to 5).
Propeller Shafts
INSPECTION
1) Check universal joint and spline of propeller shaft for rattle. If
rattle is found, replace defective part with a new one.
2) Check propeller shaft (front & rear) flange yoke bolts for
tightness, and retighten them as necessary.
Refer to “Components” in Section 4B for tightening torque.
LUBRICATION
Grease splines of propeller shaft No.2 (1) and No.3 (2).
“A”: Chassis Grease
3. Spring seat
3. Nipple

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6F1
6F2
6G
3
7B1
7C1
7B1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3
STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
FRONT END ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3A-1
STEERING GEAR BOX AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3B-1
POWER STEERING SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3B1-1
STEERING WHEEL, COLUMN AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3C-1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3D-1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3E-1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3F-1
CONTENTS
General Diagnosis............................................. 3-2
Diagnosis Table .............................................. 3-2
Tire Diagnosis ................................................... 3-5
Irregular and/or Premature Wear .................... 3-5Wear Indicators ............................................... 3-5
Radial Tire Waddle ......................................... 3-5
Radial Tire Lead.............................................. 3-7
Vibration Diagnosis .......................................... 3-7

Downloaded from www.Manualslib.com manuals search engine 3-2 STEERING, SUSPENSION, WHEELS AND TIRES
General Diagnosis
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be consid-
ered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged
parts.
3) Spin front wheel. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and/or rough wheel
bearings.
Diagnosis Table
Condition Possible Cause Correction
Vehicle Pulls (Leads)
Mismatched or uneven tires Replace tire.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging springs Replace spring.
Radial tire lateral force Replace tire.
Disturbed front wheel alignment Check and adjust wheel alignment.
Disturbed rear wheel alignment Check and adjust wheel alignment.
Brake dragging in one road wheel Repair front brake.
Loose, bent or broken front or rear suspension
partsTighten or replace suspension part.
Abnormal or
Excessive Tire WearSagging or broken springs Replace spring.
Tire out of balance Adjust balance or replace tire.
Disturbed front wheel alignment Check wheel alignment.
Faulty shock absorber Replace shock absorber.
Hard driving Replace tire.
Overloaded vehicle Replace tire.
Not rotating tire Replace or rotate tire.
Worn or loose road wheel bearings Replace wheel bearing.
Wobbly wheel or tires Replace wheel or tire.
Tires not adequately inflated Adjust the pressure.
Wheel Tramp
Blister or bump on tire Replace tire.
Improper shock absorber action Replace shock absorber.

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Shimmy, Shake or
VibrationTire or wheel out of balance Balance wheels or replace tire
and/or wheel.
Loose wheel bearings Replace wheel bearing.
Loose wheel hub nuts Retighten.
Worn tie rod ends Replace tie rod end.
Worn king pin bearings or king pins Replace king pin bearing and/or
king pin.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire / wheel
assemblyReplace tire or wheel.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear box bolts Tighten box bolts.
Worn steering knuckle oil seal Replace.
Hard Steering
Bind in tie rod end ball studs or king pin bear-
ingsReplace tie rod end or king pin
bearing.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Steering gear box adjustment Check and adjust steering gear
box.
Tire not adequately inflated Inflate tires to proper pressure.
Bind in steering column Repair or replace.
Low fluid level, loose drive belt or malfunction of
power steering system (if equipped with P/S)Check and correct.
Too Much Play in
SteeringWheel bearings worn Replace wheel bearing.
Steering gear box attachments loose Tighten or repair.
Steering gear box adjustments Check and adjust steering gear
box.
Worn steering shaft joints Replace joint.
Worn tie rod ends drug rod ball joints Replace tie rod end.
Worn king pin bearings or king pin Replace king pin bearing and/or
king pin.
Poor Returnability
Bind in tie rod end ball studs Replace tie rod end.
Bind in king pin bearings Replace king pin bearing.
Bind in steering column Repair or replace.
Steering gear box needing lubricant Check, repair or lubricate steering
gear box.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Steering gear box not properly adjusted Check and adjust steering gear box
torque.
Tires not adequately inflated Adjust pressure.
Steering Noise
(Rattle or Chuckle)Loose bolts and nuts Retighten.
Broken or otherwise damaged wheel bearings Replace wheel bearing.
Worn or sticky tie rod ends Replace tire rod end.
Linkage joints needing grease Lubricate or replace. Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine 3-4 STEERING, SUSPENSION, WHEELS AND TIRES
Abnormal Noise,
Front EndWorn, sticky or loose tie rod ends, drug rod ball
joints, king pin bearings or axle shaft jointsReplace tie rod end, king pin bear-
ing or axle shaft joint.
Damaged shock absorbers or mountings Replace or repair.
Worn leading arm bushings Replace.
Worn stabilizer bar bushings Replace.
Worn Iateral rod bushings Replace.
Loose stabilizer bar Tighten bolts or replace bushes.
Loose wheel nuts Tighten wheel nuts.
Loose suspension bolts or nuts Tighten suspension bolts or nuts.
Broken or otherwise damaged wheel bearings Replace wheel bearing.
Broken suspension springs Replace spring.
Wander or Poor
Steering StabilityMismatched or uneven tires Replace tire or inflate tires to
proper pressure.
Loose king pin bearings and tie rod ends Replace king pin bearing or tie rod
end.
Faulty shock absorbers or mounting Replace absorber or repair mount-
ing.
Loose stabilizer bar Tighten or replace stabilizer bar or
bushes.
Broken or sagging springs Replace spring.
Steering gear box not properly adjusted Check or adjust steering gear box
torque.
Front wheel alignment Check and adjust front wheel align-
ment.
Erratic Steering when
BrakingWorn wheel bearings Replace wheel bearing.
Broken or sagging springs Replace spring.
Leaking wheel cylinder or caliper Repair or replace wheel cylinder or
caliper.
Warped discs Replace brake disc.
Badly worn brake linings Replace brake shoe lining.
Drum is out of round in some brakes Replace brake drum.
Wheel tires are inflated unequally Inflate tires to proper pressure.
Defective wheel cylinders Replace or repair wheel cylinder.
Disturbed front wheel alignment Check front wheel alignment
Ride Too Soft
Faulty shock absorber Replace shock absorber.
Suspension bottoms
Overloaded Check loading.
Faulty shocks absorber Replace shock absorber.
Incorrect, broken or sagging springs Replace spring.
Body Leans or Sways
in CornersLoose stabilizer bar Tighten stabilizer bar bolts or
replace bushes.
Faulty shocks absorbers or mounting Replace shock absorber or tighten
mounting.
Broken or sagging springs Replace spring.
Overloaded Check loading.
Cupped Tires
Worn wheel bearings Replace wheel bearing.
Excessive tire or wheel run-out Replace tire or wheel disc.
Tire out of balance Adjust tire balance. Condition Possible Cause Correction

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Tire Diagnosis
Irregular and/or Premature Wear
Irregular and premature wear has many possible causes. Some
of them are: incorrect inflation pressures lack of tire rotation, driv-
ing habits, improper alignment.
If the following conditions are noted rotation is in order:
Front tire wear is different from rear.
Uneven wear exists across the tread of any tire.
Left front and right front tire wear is unequal.
Left rear and right rear tire wear is unequal.
There is cupping, flat spotting, etc.
A wheel alignment check is in order if the following conditions are
noted:
Left front and right front tire wear is unequal.
Wear is uneven across the tread of any front tire.
Front tire treads have scuffed appearance with “feather”
edges on one side of tread ribs or blocks.
Wear Indicators
The original equipment tires have built-in tread wear indicators to
show when tires need replacement. These indicators will appear
as 12 mm (0.47 inch) wide bands when the tire tread depth
becomes 1.6 mm (0.063 inch). When the indicators appear in 3 or
more grooves at 6 locations, tire replacement is recommended.
Radial Tire Waddle
Waddle is side to side movement at the front and/or rear of the
vehicle. It is caused by the steel belt not being straight within the
tire. It is most noticeable at low speed, 5 to 30 mph. It is possible
to road test a vehicle and tell on which end of the vehicle the
faulty tire is located. If the waddle tire is on the rear, the rear end
of the vehicle will shake from side to side or “waddle”. From the
driver’s seat it feels as though someone is pushing on the side of
the vehicle. If the faulty tire is on the front, the waddle is more
visual. The front sheet metal appears to be moving back and forth
and the driver feels as though he is at the pivot point in the vehi-
cle. Waddle can be quickly diagnosed by using a Tire Problem
Detector (TPD) and following the equipment manufacturer’s rec-
ommendations.
If a TPD is not available, the more time consuming method of sub-
stituting known good tire / wheel assemblies on the problem vehi-
cle can be used as follows:
[A] : Hard cornering, under inflation or lack of tire rotation
[B] : Incorrect wheel alignment, tire construction not uniform or wheel heavy acceleration

Downloaded from www.Manualslib.com manuals search engine 3-6 STEERING, SUSPENSION, WHEELS AND TIRES
1) Ride vehicle to determine whether the front or rear waddles.
2) Install tires and wheels that are known to be good (on similar vehicle) in place of those on wadding end of
vehicle. If wadding end cannot be identified, substitute rear ones.
3) Road test again. If improvement is noted, reinstall originals one at a time till waddle causal tire is found. If no
improvement is noted, install known good tires in place of all four. Then reinstall originals in the same man-
ner as above.
EQUIPMENT MANUFACTURE’S RECOMMENDATIONS
INFLATE TIRES TO RECOMMENDED
PRESSURE
ROAD TEST VEHICLE LEVEL
UNCROWNED ROAD IN
BOTH DIRECTIONS
SWITCH FRONT TIRES
SIDE TO SIDE AND
ROAD TEST AGAIN
LEAD CORRECTED IF
ROUGHNESS RESULTS.
REPLACE TIRES
INSTALL A KNOWN GOOD TIRE
ON ONE FRONT SIDE
LEAD REMAING
INSTALL A KNOWN GOOD TIRE IN
PLACE OF OTHER FRONT TIRE
LEAD REMAING
KNOWN GOOD TIRES ARE NOT GOOD
LEAD CORRECTED
REPLACE TIRE
LEAD REVERSES
DIRECTION
PUT TIRES BACK IN
ORIGINAL POSITION
AND CHECK ALIGNMENT
LEAD IN SAME
DIRECTION
LEAD CORRECTED
REPLACE TIRE