wheel SUZUKI JIMNY 2020 Repair Manual

INSPECTION AND MAINTENANCE
INSPECTION AND MAINTENANCE
Maintenance schedule ........................................................ 6-2
Periodic maintenance schedule
(except for EU countries and Israel) .................................. 6-3
Maintenance recommended under severe driving
conditions (except for EU countries and Israel) .............. 6-8
Periodic maintenance schedule
(for EU countries and Israel) .............................................. 6-13
Maintenance recommended under severe driving
conditions (for EU countries and Israel) ........................... 6-18
Drive belt .............................................................................. 6-23 -
Engine oil and filter ............................................................. 6-23
Engine coolant .................................................................... 6-28
Air cleaner ............................................................................ 6-30
Spark plugs .......................................................................... 6-30
Gear oil ................................................................................. 6-31
60G410 Clutch pedal ......................................................................... 6-33
Brakes .................................................................................. 6-33
Steering wheel ..................................................................... 6-36
Tyres ..................................................................................... 6-36
Battery .................................................................................. 6-41
Fuses .................................................................................... 6-42
Headlight aiming ................................................................. 6-46
Headlight Washer Fluid ...................................................... 6-46
Bulb replacement ................................................................ 6-47
Wiper blades ........................................................................ 6-54
Windshield washer fluid ..................................................... 6-57
Air conditioning system ..................................................... 6-58

INSPECTION AND MAINTENANCE
Interval: This interval should be judged byI km (x1000)I 15 I 30 I 45 I 60 I 75 90 odometer reading or months, whichever, miles (x1000)I 9 I 18 I 27 I 36 I 45 54 comes first. 1 monthsI 12 I 24 I 36 I 48 I 60 I 72 BRAKE *5-1. Brake discs and pads (front) I I I I I I Brake drums and shoes (rear) -I -I -I *5-2. Brake hoses and pipes -I -I -I 5-3. Brake fluid (#2) Check, *Replacement -R -R -R *5-4. Brake (Pedal and fluid level) I I I I I I 5-5. Brake lever and cable Check, *Adjustment (1st 15000 km only) I -----CHASSIS AND BODY *6-1. Clutch fluid (#2) -R -R -R *6-2. Clutch (pedal and fluid level) I I I I I I 6-3. Tyres/Wheels I I I I I I *6-4. Wheel bearings -I -I -I *6-5. Propeller shafts --I --I *6-6. Suspension system -I -I -I "6-7. Steering system -I -I -I *6-8. Manual transmission oil Genuine "SUZUKI GEAR OIL 75W" Inspect every 30000 km (18000 miles) or 24 months. Other than "SUZUKI GEAR OIL 75W" (1: 1st 15000 km only) I
I -I
R
I
-
I
-
I
R 6-9. Automatic transmission Fluid level -I -I -I *Fluid change Replace every 165000 km (99000 miles). *Fluid hose -I -I -I I I -I -*6-10. Transfer oil Genuine "SUZUKI GEAR OIL 75W" Inspect every 30000 km (18000 miles) or 24 months. Other than "SUZUKI GEAR OIL 75W" (I: 1st 15000 km only) I -R --R *6-11. Differential oil (R: 1 st 15000 km only) Genuine "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC" R -I -I -
6-12. All latches, hinges and locks -I -I -I *6-13. Air conditioner filter element -I R -I R
#2: Clutch fluid is supplied from brake fluid reservoir.
A WARNING
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.
6-6

INSPECTION AND MAINTENANCE
Interval: This interval should be Judged byll---------------------=cc'c-tci.i;#----,i,c---t-----,ai--t----.sci odometer reading or months, whicheveq km (x1000) 105 120 135 150 165 I 180 miles (x1000) 63 72 81 90 I 99 I 108 comes first. 1>----------------------~=.c..,,-4-___,,.c...--1-___,,c----1----c~ months 84 96 108 120 I 132 I 144 BRAKE *5-1, Brake discs and pads (front) Brake drums and shoes (rear) *5-2. Brake hoses and pipes 5-3. Brake fluid (#2) *5-4. Brake (Pedal and fluid level) 5-5. Brake lever and cable CHASSIS AND BODY *6-1. Clutch fluid (#2) *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 oil
6-12. All latches, hinges and locks *6-13. Air conditioner filter element
Genuine "SUZUKI GEAR OIL 75W" Otllerthan "SUZUKI GEAR OIL 75W"
Genuine "SUZUKI GEAR OIL 75W"
Check, *Replacement
Check, *Adjustment (1st 15000 km only
(I: 1st 15000 km only) Fluid lever *Fluid change *Fluid hose
Other than "SUZUKI GEAR OIL 75W" (I: 1st 15000 km only) (R: 1st 15000 km only) Genuine "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC"
#2: Clutch fluid is supplied from brake fluid reseNoir.
6-7
I I I I I I -I -I -I -I -I -I -R -R -R I I I I I I ------
-R -R -R I I I I I I I I I I I I -I -I -I --I --I -I -I -I -I -I -I Inspect every 30000 km (18000 miles) or 24 months.
= I ~ I ~ I ~ I = I 7 Replace every 165000 km (99000 miles). -I I I -I -I -I I Inspect every 30000 km (18000 m!les) or 24 months. --R --R I -I -I -
R I R

INSPECTION AND MAINTENANCE
Interval: This interval should be judged by1l--------------------=cic-c+T.C~~,'-,--+----,i'--+ odometer reading or months, whicheverI km (x1000) 7.5 I 15 I 22.5 I 30 I 37.5 45 miles (x1000) 4.5 I 9 I 13.5 I 18 I 22.5 27 comes first. 11-------------------~='---'c=cc=l-";c--+----.,,-+ months 6 I 12 I 18 I 24 I 30 36 BRAKE *5-1. Brake discs and pads (front) Brake drums and shoes (rear) *5-2. Brake hoses and pipes 5-3. Brake fluid (#2) *5-4. Brake (Pedal and fluid level) 5-5. Brake lever and cable CHASSIS AND BODY "6-1. Clutch fluid (#2) *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 oil 6-12. All latches, hinges and locks *6-13. Air conditioner filter element •3
Genuine "SUZUKI GEAR OIL 75W"
Other than "SUZUKI GEAR OIL 75W"
Genuine "SUZUKI GEAR OIL 75W"
Other than "SUZUKI GEAR OIL 75W"
Check, *Replacement
Check, *Adjustment (1st 15000 km only)
Flu!d level *Fluid change
*Fluid hose
Genuine "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC"
#2: Clutch fiuid is supplied from brake fiuid reservoir
A WARNING
-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 30000 km (18000 miles) or 24 months. Replace every 60000 km (36000 miles) or 48 months.
= I = I = I 7 I = I = Replace every 30000 km (18000 miles) or 24 months. Inspect every 60000 km (36000 miles) or 48 months. Inspect every 30000 km (18000 miles) or 24 months. Replace every 60000 km (36000 m!les) or 48 months. ---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.
6-11

INSPECTION AND MAINTENANCE
Interval: This interval should be judged byl km (x1000) odometer reading or months, whicheverI miles (x1000) comes first. I months BRAKE *5-1. Brake discs and pads (front) Brake drums and shoes (rear) *5-2. Brake hoses and pipes 5-3. Brake fluid (#2) Check, *Replacement *5-4. Brake (Pedal and fluid level) 5-5. Brake lever and cable Check, *Adjustment (1st 15000 km only) CHASSIS AND BODY *6-1. Clutch fluid (#2) *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
#2: Clutch fluid is supplied from brake fluid reservoir
NOTE: This table shows the service schedule up to 90000 km (54000 miles). Beyond 90000 km (54000 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,
52.5 I 60 I 67.5 I 75 I 82.5 I 90 31.5 36 I 40.5 I 45 I 49.5 I 54 42 48 I 54 I 60 I 66 I 72
-I -I -I -I ---I -I ---I -R ---R -I -I -I ------
-R ---R -I -I -I -I -I -I -I -I -I -I -I -I -I ---I -I ---I Inspect every 30000 km {18000 miles) or 24 months. Replace every 60000 km (36000 miles) or 48 months. -
I
R
I -I
-
I
-
I
R -I ---I Replace every 30000 km (18000 miles) or 24 months. Inspect every 60000 km (36000 miles) or 48 months. Inspect every 30000 km (18000 miles) or 24 months. Replace every 60000 km (36000 miles) or48 months. -R ---R ---R ---I ---I I -I R
6-12

INSPECTION AND MAINTENANCE
Interval: This interval should be judged bylf---------------------a"'-<"~ccfl---c~+--,;;;.-+~ odometer reading or months, whichever1 km (x1000)I 20 I 40 I 60 I 80 I 100 I 120 miles (x1000)I 12.5 I 25 I 37.5 I 50 I 62.5 I 75 comes first. If-----------------------"='-"'-'-=-;?l----'-~+---:a,;-+~ months! 12 24 I 36 I 48 I 60 I 72
EMISSION CONTROL SYSTEM •4-1. PCV valve •4-2. Fuel evaporative emission control system BRAKE *5-1. Brake discs and pads (front) Brake drums and shoes (rear) *5-2. Brake hoses and pipes 5-3. Brake fluid (#3) *5-4. Brake (Pedal and fluid level) 5-5. Brake lever and cable 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
*6-9. Automatic transmission oil
*6-10. Transfer oil
*6-11. Differential oil 6-12. All latches, hinges and locks *6-13. Air conditioner filter element
Check, *Replacement
Check, *Adjustment (1st 20000 km only)
Genuine "SUZUKI GEAR OIL 75W" Other than "SUZUKI GEAR OIL 75W" Fluid level *Fluid change *Fluid hose Genuine "SUZUKI GEAR OIL 75W" Other than "SUZUKI GEAR OIL 75W" Genuine "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC"
#3: Clutch fluid is supplied from brake fluid reservoir.
A WARNING
I
-I -I -I I I -I ------I
I I I I I I -I -I -I -I -I -I -R -R -R I I I I I I I -----
-R -R -R I I I I I I I I I I I I
-I -I -I -I -I -I -I -I -I -I -I -I Inspect every 40000 km (25000 miles) or 24 months.
= I 7 I = I 7 I = I 7 Replace every 165000 km (99000 miles). -I -I I I -I -I I Inspect every 40000 km (25000 miles) or 24 months. -R -R -R R
R I 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.
6-16

INSPECTION AND MAINTENANCE
Interval: This interval should be judged byl-1-----------------------;c"--f'-;~:cfl-....,;,;_:;,-+----;.;;;-+~ odometer reading or months, whichever1 km (x1000) 140 160 180 I 200 I 220 I 240 miles (x1000) 87.5 100 112.5 125 I 137.5 I 150 comes first. rl---------------------===.cc-:;"'1---",;.;::.-+-',:;;.-+--' months 84 96 108 120 I 132 I 144 EMISSION CONTROL SYSTEM *4-1. PCVvalve *4-2. Fuel evaporative emission control system BRAKE *5-1. Brake discs and pads (front) Brake drums and shoes (rear) *5-2. Brake hoses and pipes 5-3. Brake fluid (#3) *5-4. Brake (Pedal and fluid level) 5-5. Brake lever and cable 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 all
*6-9. Automatic transmission oil
*6-10. Transfer oil
*6-11. Differential oil 6-12. All latches, hinges and locks *6-13. Air conditioner filter element
Check, *Replacement
Check, *Adjustment (1st 20000 km only)
Genuine "SUZUKI GEAR OIL 75W" Other than "SUZUKI GEAR OIL 75W" Fluid level *Fluid change *Fluid hose Genuine "SUZUKI GEAR OIL 75W" Other than "SUZUKI GEAR OIL 75W" Genuine "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC"
#3: Clutch fiuid is supplied from brake fiuid reservoir.
6-17
I -I I I -I -I -I I -----I
I I . I I I I -I -I -I -I -I -I -R -R -R I I I I I I ---
-R -R -R I I I I I I I I I I I I -I -I -I -I -I -I -I -I -I -I -I -I Inspect every 40000 km (25000 miles) or 24 months.
= I ~ I = I ~ I = I ~ Replace every 165000 km (99000 miles).
-I -I I I -I -I I Inspect every 40000 km (25000 miles) or 24 months. -R -R -R
R I R

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
With the engine running, measure the dis­tance between the brake pedal and floor carpet when the pedal is depressed with approximately 30 kg (66 lbs) of force. The minimum distance required is as specified. Since your vehicle's brake system is self­adjusting, there is no need for pedal adjustment. If the pedal to floor carpet distance as measured above is less than the minimum distance required, have your vehicle inspected by a SUZUKI dealer.
NOTE: • When measuring the distance between the brake pedal and floor wall, be sure not to include the floor mat or rubber on the floor carpet in your measurement. Measure the distance at the brake pedal's side facing toward the passen­ger's door.
6-35
52RM70500
A WARNING
If you experience any of the following problems with your vehicle's brake system, have the vehicle inspected immediately by a SUZUKI dealer. Poor braking performance Uneven braking (brakes not work­ing uniformly on all wheels.) Excessive pedal travel Brake dragging Excessive noise
Parking brake
~
54G109
Ratchet tooth specification 11b": 4th-9th Lever pull force (1 ): 200 N (20 kg, 45 lbs)
Check the parking brake for proper adjust­ment by counting the number of clicks made by the ratchet teeth as you slowly pull up on the parking brake lever to the point of full engagement. The parking brake lever should stop between the speci­fied ratchet teeth and the rear wheels should be securely locked. If the parking brake is not properly adjusted or the brakes drag is suspected even after the lever has been fully released, have the parking brake inspected and/or adjusted by a SUZUKI dealer.