manual transmission SUZUKI JIMNY 2019 Owner's Manual

INSPECTION AND MAINTENANCE
Interval: This interval should be judged byl, -----------------------=~"-f""'~----a'ica-l--i;ee+ odometer reading or months, whicheveq,r ___________________ =='='c~:,f-"'ii"-+-:;;;'----!-km (x100D) 10 I 20 I 30 I 40 I 50 I 60 miles (x1000) 6.25 I 12.5 I 18.75 I 25 I 31,25 I 37.5 comes first. I
BRAKE *5-1. Brake discs and pads (front) Brake drums and shoes (rear) *5-2. Brake hoses and pipes 5-3. Brake fluid (#3)
months
Check, *Replacement *5-4. Brake (Pedal and fluid level) 5-5. Brake lever and cable Check, *Adjustment (1st 20000 km only) CHASSIS ANO BODY *6-1. Clutch fluid (#3) *6-2. Clutch (Pedal and fluid level) 6-3. Tyres/Wheels *6-4. Wheel bearings *6-5. Propeller shafts *6-6. Suspension system *6-7. Steering system *6-8. Manual transmission oil
6-9. Automatic transmission
*6-10. Transfer oil
*6-11. Differential all 6-12. All latches, hinges and locks *6-13. Air conditioner filter elemenr·3
Genuine "SUZUKI GEAR OIL 75W"
Other than "SUZUKI GEAR OIL 75W"
Genuine "SUZUKI GEAR OIL 75W"
Other than "SUZUKI GEAR OIL 75W"
Fluid level *Fluid change *Fluid hose
Genuine "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC"
#3: Clutch fiuid is supplied from brake fiuid reservoir.
A WARNING
6 I 12 I 18 I 24 I 30 I 36
-I -I -I ---I -----I -----R ---I -I -I -I ----
---R ---I -I -I -I -I -I -I -I -I -I -I -I ---I -----I --Inspect every 20000 km (12500 miles) or 12 months. Replace every 80000 km (50000 miles) or 48 months.
= I ~ I = I ~ I = I ~ Replace every 30000 km (18000 miles). Inspect every 60000 km (37500 miles). Inspect every 20000 km (12500 miles) or 12 months. Replace every 80000 km (50000 miles) or 48. months. -R -R -R -R ---R
R
The shock absorbers are filled with high pressure gas. Never attempt to disassemble them or throw them into a fire. Avoid storing them near a heater or heating device. When scrapping the absorber, the gas must be released from the absorber safely. Ask your dealer for assistance.
6-21

INSPECTION AND MAINTENANCE
Interval: This interval should be judged byI km (x1000)I 70 I 80 I 90 I 100 I 110 120 odometer reading or months, whicheveq miles (x1000l/ 43.75 50 56.25 I 62.5 I 68. 75 75 comes first. I months 42 48 54 I 60 I 66 72 BRAKE *5-1. Brake discs and pads (front) -I -I -I Brake drums and shoes (rear) -I ---I *5-2. Brake hoses and pipes -I ---I 5-3. Brake fluid (#3) Check, *Replacement -R ---R *5-4. Brake (Pedal and fluid level) -I -I -I 5-5. Brake lever and cable Check, *Adjustment (1 st 20000 km onlv ------CHASSIS AND BODY *6-1. Clutch fluid (#3) *6-2. Clutch (Pedal and fluid level) 6-3. Tyres/Wheels *6-4. Wheel bearings *6-5. Propeller shafts *6-6. Suspension system *6-7. Steering system *6-8. Manual transmission oil Genuine "SUZUKI GEAR OIL 75W"
Other than "SUZUKI GEAR OIL 75W" 6-9. Automatic transmission Fluid level *Fluid change *Fluid hose *6-10. Transfer oil Genuine "SUZUKI GEAR OIL 75W"
Other than "SUZUKI GEAR OIL 75W" *6-11. Differential oil Genuine "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC" 6-12. All latches, hinges and locks *6-13. Air conditioner filter element *3
#3: Clutch fluid 1s supplied from brake fluid reservoir.
NOTE: This table shows the service schedule up to 120000 km (75000 miles).
-R ---R -I -I -I -I -I -I -I -I -I -I ---I -I ---I -I ---I Inspect every 20000 km (12500 miles) or 12 months. Replace every 80000 km (50000 miles) or 48 months.
-I R I -I R I -I R -I -I -I Replace every 30000 km (18000 miles). Inspect every 60000 km (37500 miles). Inspect every 20000 km (12500 miles) or 12 months. Replace every 80000 km (50000 mlles) or48 months. -R -R -R ---R ---I ---I -I -I -R
Beyond 120000 km (75000 miles), perform the same services at the same intervals shown in the chart. •1 Inspect more frequently if the vehicle is used under dusty conditions. •2 Check or replace as necessary if you usually drive with high speed or high engine revolutions. •3 Clean more frequently if the air flow from the air conditioner decreases.
6-22

INSPECTION AND MAINTENANCE
60G160
NOTICE
When installing the spark plugs, screw them in with your fingers to avoid stripping the threads. Tighten the spark plugs with a torque wrench to 17.5 Nm (1.7 kg­m, 12.9 lb-ft). Do not allow contami­nants to enter the engine through the spark plug holes when the plugs are removed. Never use spark plugs with the wrong thread size.
6-31
Spark plug gap "a":
ZXU20PR11 1.0-1.1 mm (0.039-0.043 in.) KR6A-10 0.95-1.0Smm (0.037-0.041 in.)
NOTICE
54G106
When replacing spark plugs, you ".hould use the ~rand and type speci­fied for your vehicle. For the specified plugs, refer to "SPECIFICATIONS" section in the end of this book. If you wish to use a brand of spark plug other than the specified plugs, con­sult a SUZUKI dealer.
Gear oil
Manual transmission oil / transfer
oil/ rear differential oil
When adding gear oil, use gear oil with the appropriate viscosity and grade as shown in the chart below.
We highly recommend you use "SUZUKI GEAR OIL 75W" for manual transmission oil and transfer oil.
Manual transmission oil Transfer oil
<: ==:llil:::======> 75W
°C-30 -20 -10 0 10 20 30 40 °F-22 -4 14 32 50 68 86 104
54P120706
We highly recommend you use "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC" for front/rear differential oil.
Front/rear differential oil
<~==~7[fil5Wtfi-B~5====>
'C-30 -~0 -10 Of.22 4 14 0 ' 32
20 ' 68 83,60 4p 104
78RB07007

Gear oil level check
Manual transmission
(2)
(1) Oil filler and level plug (2) Oil drain plug
78RB07008
Transfer
4)
(3) Oil filter and level plug (4) Oil drain plug
Front/rear differential
(5) Oil filter and level plug (6) Oil drain plug
INSPECTION AND MAINTENANCE
To check the gear oil level, use the fol­lowing procedure:
1) Park the vehicle on a level surface with the parking brake applied. Then, stop the engine. 2) Remove the oil filler and level plug.
For the manual transmission;
3) If gear oil fiows from the plug hole, the oil level is correct. Reinstall the plug. If gear oil does not fiow from the plug hole, add oil through the filler plug hole until oil fiows a little from the plug hole.
78Rs0100, For the transfer and front/rear differential;
78RB07010
3) Check the inside of the hole with your finger. If the oil level comes up to the bottom of the plug hole, the oil level is correct. If so, reinstall the plug. 4) If the oil level is low, add gear oil through the oil filler and level plug hole until the oil level reaches the bottom of the filler hole, and then reinstall the plug.
Tightening torque for oil filler and level plug
Manual transmission (1 )(2): 23 Nm (2.3 kg-m, 16.6 lb-ft)
Transfer (3)(4): 23 Nm (2.3 kg-m, 16.6 lb-ft)
Front/rear differential (5)(6): (5)50 Nm (5.0 kg-m, 36.2 lb-ft) (6)55 Nm (5.6 kg-m, 40.5 lb-ft)
6-32

EMERGENCY SERVICE
Tyre changing tool
0
57
(3) (1) (2)
78RB08001
(1) Jack (2) Jack handle (3) Wheel wrench
The tyre changing tools are stowed in the luggage compartment. Refer to "LUGGAGE COMPARTMENT" in "ILLUSTRATED TABLE OF CONTENTS" section.
7-1
Jacking instructions
75F062
1) Place the vehicle on level, hard ground. 2) Set the parking brake firmly and shift into "P" (Park) if your vehicle has an automatic transmission, or shift int6 "R" (Reverse) if your vehicle has a manual transmission.
A WARNING
Shift into "P" (Park) for an automatic transmission, or into "R" (Reverse) for a manual transmission vehicle when you jack up the vehicle. • Never jack up the vehicle with the transmission in 11N" (Neutral). Oth­erwise, unstable jack may cause an accident.
3) Turn on the hazard warning switch if your vehicle is near traffic. 4) Block the front and rear of the wheel diagonally opposite of the wheel being lifted. 5) Place the spare wheel near the wheel being lifted as shown in the illustration in case that the jack is slipped.

NOTICE
Never apply a garage jack to the exhaust pipe, front fender splash guard, side sill splash, rear fender splash guard, front differential or rear differential.
NOTE: For more details, contact a SUZUKI dealer.
Changing wheels
To change a wheel, use the following pro­
cedure: 1) Prepare the jack, tools and spare tyre. 2) Loosen, but do not remove the wheel nuts. 3) Jack up the vehicle (follow the jacking instructions in this section).
A WARNING
Shift into "P" (Park) for an automatic transmission, or into 11R" (Reverse) for a manual transmission vehicle when you jack up the vehicle. Never jack up the vehicle with the transmission in "N" (Neutral). OthR erwise, unstable jack may cause an accident.
4) Remove the wheel nuts and wheel.
65J4033
5) Clean any mud or dirt off from the sur­face of the wheel (1 ), hub (2), thread part (3) and surface of the wheel nuts (4) with a clean cloth. Clean the hub carefully; it may be hot from driving.
EMERGENCY SERVICE
6) Install the new wheel and replace the wheel nuts with their cone shaped end facing the wheel. Tighten each nut snugly by hand until the wheel is securely seated on the hub.
78RB08003
Tightening torque for wheel nut 100 Nm (10.0 kg-m, 72.3 lb-ft)
7) Lower the jack and fully tighten the nuts with a wheel wrench in numerical order as shown in the illustration.
7-4

EMERGENCY SERVICE
Rear wheels lifted (all models)
"ON"__.. "ACC"
UNLOCKED
78RB08006
7-9
Rear wheels lifted Your vehicle may be towed by a tow truck with the rear wheels lifted and the front wheels on the ground. Towing speed should not exceed 90 km/h (55 mph).
For this type of towing: 1) Shift the manual transmission to Neu­tral or the automatic transmission to "P" position and start the. engine. 2) Shift the transfer lever to 2WD position ("2H"). 3) Make sure the 4WD indicator on the instrument cluster is turned off.
NOTICE
If the air-locking hubs cannot be unlocked, tow the vehicle with the rear wheels lifted and a dolly under the front wheels.
4) Turn the ignition key to the "ACC" posi­tion to stop the engine and to unlock the steering wheel.
NOTICE
The steering column lock is not strong enough to withstand shocks transmitted from the front wheels during towing.
5) Make sure the front wheels are facing straight forward and secure the steering wheel with a steering wheel clamping device designed for towing service.

SPECIFICATION
Specifications
NOTE: Specifications are subject to change without notice.
MIT: Manual transmission NT: Automatic transmission
ITEM: Dimensions UNIT: mm (in.)
Overall length 3625 (142.7) (Front bumper to spare tyre) 3645 (143.5) (Front bumper to spare wheel half cover)
Overall width 1645 (64.8)
Overall height 1720 (67.7)
Wheelbase 2250 (88.6)
Track I Front 1395 (54.9)
I Rear 1405 (55.3)
Ground clearance 210 (8.2)
9-3

SPECIFICATION
ITEM: Recommended fuel/ lubricants and capacities (approx.)
Manual transmission oil "SUZUKI GEAR OIL 75W" 1.2 L (2.1 Imp pt)
Automatic transmission oil "SUZUKI ATF 3317 or Mobil ATF3309 or equivalent to DEXRON® -111" 5.7 L (10.0 Imp pt)
Differential oil Front 1.6 L (2.8 Imp pt) "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC" Rear 1.3 L (2.3 Imp pt)
Transfer oil "SUZUKI GEAR OIL 75W" 1.21 L (2.1 Imp pt)
Brake fluid / Clutch fiuid SAE J1703 or DOT3 -
9-8

INDEX
Listening to a CD ................................................................. 5-48
Listening to an iPod ............................................................ 5-58
Listening to an MP3/WMA/AAC disc .................................. 5-51
Listening to files stored in a USB device .......................... 5-55
Listening to the radio ................................................. 5-41, 5-43
Low engine coolant temperature light (blue color) .......... 2-48
Low fuel warning light ......................................................... 2-47
Low tyre pressure warning light ............................... 2-39, 3-64
M
Main beam (high beam) indicator light .............................. 2-52
Maintenance recommended under severe
driving conditions .............................................................. 10-25
Maintenance recommended under severe
driving conditions (except for EU countries and Israel) .... 6-8
Maintenance recommended under severe
driving conditions (for EU countries and Israel) .............. 6-18
Maintenance schedule .......................................................... 6-2
Malfunction indicator light .................................................. 2-45
Manual heating and air conditioning system .................... 5-17
Manual transmission ............................................................. 3-8
Master warning indicator light ............................................ 2-54
Mirrors .................................................................................. 2-13
0
Odometer ..................................................................... 2-20, 2-32
Oil change reminder light ................................................... 2-53
Oil filter replacement ........................................................•.. 6-27
Oil level check ...................................................................... 6-24
Oil pressure light ...................................•.................•........... 2-44
Open door warning light ..................................................... 2-47
Outside rearview mirrors ..........................•......................... 2-13
Outside rearview mirrors folding switch ........................... 2-14
11-4
p
Parking brake ....................................................................... 6-35
Parking brake lever ................................................................ 3-5
Pedal ........•............................................................................... 3-6
Periodic maintenance schedule
(except for EU countries and lsrael) ..................................... 6-3
Periodic maintenance schedule
(for EU countries and Israel) ............................................... 6-13
Pinching prevention function ............................................. 2-12
Power-assisted brakes ........................................................ 3-53
R
Radio antenna ...................................................................... 5-30
Raising vehicle with garage jack .......................................... 7-3
RDS (Radio Data System) .................................................... 5-45
Rear combination light ........................................................ 6-51
Rear differential oil.. ............................................................. 6-31
Rear fog light indicator light ............................................... 2-53
Rear fog light switch ............................................................ 2-60
Rear passenger's seat belt reminder light... ...................... 2-45
Rear seats ............................................................................... 1-5
Rear window wiper/washer switch ..................................... 2-69
Refill with oil and oil leakage check ................................... 6-28
Refilling ................................................................................. 6-25
Remote audio controls ........................................................ 5-74
Replacing tyres and/or wheels ........................................... 3-71
Running-in .............................................................................• 4-8
s
Seat adjustment ..................................................................... 1-2
Seat belt inspection ............................................................. 1-17
Seat belt pretensioner system ............................................ 1-33
Seat belt reminder ................................................................ 1-15