2005 SUZUKI JIMNY Torque

Downloaded from www.Manualslib.com manuals search engine 3E-12 REAR SUSPENSION
Install bushings so that either face of bushing are aligned
with housing edge of leading arm, also the length between
the aligned side end of bushing and trailing arm (1) are
within specification below.
Specification for trailing arm bushing protrusion
“a” : 8.5 – 10.5 mm (0.33 – 0.41 in.)
“b” : 6.0 – 9.0 mm (0.24 – 0.35 in.)
2) Install trailing arm (1) to vehicle body and rear axle housing,
referring to figure for proper installing direction of bolts.
3) Remove floor jack.
4) Connect wheel speed sensor harness clamps to trailing arm
(if equipped with ABS).
5) Connect parking brake cable clamp to trailing arm.
6) Lower hoist and with vehicle in non-loaded condition, tighten
trailing arm nuts to specified torque.
Tightening torque
Trailing arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Rear Axle Shaft and Wheel Bearing
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove rear brake drum and disconnect parking brake
cable from brake back plate. For details, refer to “Brake back
plate” in Section 5.
3) Drain gear oil from rear axle housing by loosening drain plug.

Downloaded from www.Manualslib.com manuals search engine 3E-16 REAR SUSPENSION
7) Install rear axle shaft to rear axle housing (2) and tighten
brake back plate nuts (4) to specified torque.
Tightening torque
Brake back plate nuts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Connect brake pipe (3) to wheel cylinder and tighten brake
pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut
(b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
9) Tighten wheel speed sensor bolt to specified torque (if
equipped with ABS).
Tightening torque
Wheel speed sensor bolt
(c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
10) Install parking brake cable (3) to brake back plate (1).
11) Install brake shoes, referring to “Brake Shoe” in Section 5.
12) Install brake drum. Refer to “Rear Brake Drum” in Section 5.
13) Refill differential housing with new specified gear oil. Refer to
“Maintenance Service” in Section 7E for refill.
14) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “Bleeding Brakes” in Section 5.)
15) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.5 lb-ft) NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing (2).
1. Wheel speed sensor
2. Cable stopper ring

Downloaded from www.Manualslib.com manuals search engine 3E-20 REAR SUSPENSION
3) Install lower part of shock absorber (1) to right and left sides
of axle housing and tighten bolts (2) temporarily by hand.
4) Install lateral rod (1) and install bolts in proper direction as
shown.
At this time, mount bolt and nut but don’t tighten them.
5) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 99000-31110
6) Install differential carrier assembly (3) to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Rear differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
7) Install propeller shaft (2) to joint flange aligning match marks
(1) and tighten flange bolts to specified torque.
Tightening torque
Rear propeller shaft bolts
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
8) Install LSPV stay to axle housing and adjust LSPV stay posi-
tion, referring to “LSPV Assembly Inspection and Adjust-
ment” in Section 5 (if equipped with LSPV).
9) Remove floor jack from axle housing.
10) Connect brake pipes and parking brake cable onto axle
housing and clamp them securely.
For clamping positions, refer to “Rear Brake Hose / Pipe”
and “Parking Brake Cable” in Section 5.

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-21
11) Connect brake flexible hose (2) to bracket on axle housing
and secure it with E-ring (1).
12) Connect brake pipe to brake flexible hose and tighten brake
pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut
(a) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
13) Clean mating surface of axle housing (2) (right & left) with
brake back plate and apply sealant as shown.
“B” : Sealant 99000-31090
14) Apply grease to axle shaft oil seals lip (1) (right & left) as
shown.
“A” : Grease 99000-25010
15) Install rear axle shafts, brake shoes, brake drums and
wheels. For details, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
16) Lower hoist.
17) Tighten right and left trailing arm nuts and shock absorber
lower bolts to specified torque.
Tighten lateral rod bolt and nut to specified torque.
Tightening torque
Trailing arm nuts and lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Shock absorber lower bolts
(b) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
18) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
19) Perform brake test (foot brake and parking brake). (For
brake test, see Section 5.)
20) Check each installed part for oil leakage.
NOTE:
When tightening these bolts and nuts, be sure that vehi-
cle is off hoist and in non loaded condition.
1. Shock absorber
2. Trailing arm
3. Lateral rod

Downloaded from www.Manualslib.com manuals search engine 3E-22 REAR SUSPENSION
Tightening Torque Specifications
Required Service Materials
Fastening portionTightening torque
Nm kg-m lb-ft
Shock absorber upper and lower bolt 85 8.5 61.5
Bump stopper 50 5.0 36.5
Lateral rod bolt and nut
90 9.0 65.0
Trailing arm nut (Front and Rear)
Brake back plate nut 23 2.3 17.0
Brake pipe flare nut 16 1.6 11.5
Rear differential carrier bolt 23 2.3 17.0
Rear propeller shaft bolt (Differential case side) 50 5.0 36.5
Rear propeller shaft bolt (Shaft No.3 transfer case side) 33 3.3 24.0
Wheel nut 95 9.5 69.0
Wheel speed sensor bolt and harness clamp bolt 10 1.0 7.5
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
SealantSUZUKI BOND NO. 1215
(99000-31110)Joint seam of differential carrier and
axle housing
Water tight sealantSEALING COMPOUND 366E
(99000-31090)To apply to mating surfaces of brake
back plate and rear axle.
Gear oilFor gear oil information, refer to “Mainte-
nance Service” in Section 7E of this manual.Differential gear
(Rear axle housing)

Downloaded from www.Manualslib.com manuals search engine WHEELS AND TIRES 3F-1
6F1
6F2
6G
3F
8A
8B
8C
8B
8C
8D
8E
9
10
10A
10B
SECTION 3F
WHEELS AND TIRES
CONTENTS
General Description ........................................ 3F-2
Tires .............................................................. 3F-2
Wheels .......................................................... 3F-2
Replacement Tires ........................................ 3F-2
Replacement Wheels ................................ 3F-3
How To Measure Wheel Runout ............... 3F-3
Metric Lug Nuts and Wheel Studs ............. 3F-3
Diagnosis ......................................................... 3F-4
Diagnosis Table ............................................ 3F-4
Balancing Wheels ......................................... 3F-4
General Balance Procedure .......................... 3F-4
Off-vehicle balancing ................................. 3F-4
On-vehicle balancing ................................. 3F-4
Maintenance and Minor Adjustments ........... 3F-6Wheel and Tire.............................................. 3F-6
Studs ......................................................... 3F-6
Matched tires and wheels
(For vehicle equipped with steel
wheels) ...................................................... 3F-6
Inflation of Tires ............................................ 3F-6
Tire placard ............................................... 3F-7
Tire rotation ............................................... 3F-7
On-Vehicle Service ......................................... 3F-8
Wheel ............................................................ 3F-8
Tire ................................................................ 3F-9
Mounting and demounting......................... 3F-9
Repair........................................................ 3F-9

NOTE:
All wheel 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 the
same part number or with an equivalent part if replacement becomes necessary. Do not use a replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly 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.

Downloaded from www.Manualslib.com manuals search engine 3F-8 WHEELS AND TIRES
On-Vehicle Service
Wheel
REMOVAL
1) Loosen wheel nuts by approximately 180° (half a rotation).
2) Hoist vehicle.
3) Remove wheel.
INSTALLATION
Wheel nuts must be tightened in sequence and to proper torque
to avoid bending wheel or brake drum or disc as shown.
Tightening order
: “A”–“B”–“C”–“D”–“E”
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft) CAUTION:
Never use heat to loosen tight wheel because application
of heat to wheel can shorten life of wheel and damage
wheel bearings.
NOTE:
Before installing wheels, remove any build-up of corro-
sion on wheel mounting surface and brake drum or disc
mounting surface by scraping and wire brushing. Install-
ing wheels without good metal-to-metal contact at
mounting surfaces can cause wheel nuts to loosen,
which can later allow wheel to come off while vehicle is
moving.

Downloaded from www.Manualslib.com manuals search engine PROPELLER SHAFTS 4B-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
4B
8D
8E
9
8E
9
10
10A
10B
SECTION 4B
PROPELLER SHAFTS
CONTENTS
General Description ....................................... 4B-2
Components ................................................. 4B-2
Diagnosis ........................................................ 4B-2
Diagnosis Table ........................................... 4B-2
Propeller Shaft Joint Check .......................... 4B-2
On-Vehicle Service......................................... 4B-3Propeller Shafts ........................................... 4B-3
Universal Joint ............................................. 4B-5
Tightening Torque Specification .................. 4B-7
Required Service Material ............................. 4B-7
Special Tool .................................................... 4B-8

NOTE:
All propeller shaft fasteners are an important attaching part in that it could affect the performance
of vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the 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 speci-
fied during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any propeller shaft part. Replace it with a new part, or
damage to the part may result.