2005 SUZUKI JIMNY bolt

Downloaded from www.Manualslib.com manuals search engine 3D-40 FRONT SUSPENSION
19) Lower floor jack until tension of suspension coil spring
becomes a little loose and remove right and left sides lower
mounting bolt of shock absorber (1).
20) Remove front mounting bolts of leading arm.
21) Lower front axle housing gradually.
22) Remove axle housing.
INSTALLATION
1) Place rear axle housing on floor jack. Then install leading
arm front mounting bolts (right & left) in proper direction as
shown. At this time, mount nuts but don’t tighten them.
2) Install lower part of shock absorber (1) to right and left sides
of axle housing and install bolts (2) in proper direction as
shown in figure. At this time, mount nuts (3) but don’t tighten
them.
A : Body outside

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-41
3) Install air locking hub vacuum pipe and tighten clamp bolts to
specified torque (for 4WD).
Tightening torque
Vacuum pipe clamp bolts
(a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
4) Install stabilizer bar, refer to “Stabilizer Bar / Bushings” in
this section.
5) Install lateral rod (1) to vehicle body and axle housing.
Install bolts in proper direction as shown in figure.
At this time, mount bolt and nut but don't tighten them.
6) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side (for 4WD).
“A” : Sealant 99000-31110
7) Install differential carrier assembly (2) to axle housing and
tighten carrier bolts to specified torque (for 4WD).
Tightening torque
Front differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Install front propeller shaft (1) to joint flange aligning match
marks (3) and torque flange bolts to specification (for 4WD).
Tightening torque
Front propeller shaft flange bolts
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
NOTE:
For left hand steering vehicle, install lateral rod with its
bending point (2) placed to right side of vehicle.
[A] : Right hand steering vehicle
[B] : Left hand steering vehicle

Downloaded from www.Manualslib.com manuals search engine 3D-42 FRONT SUSPENSION
9) Install right and left axle shafts to axle housing (for 4WD).
Install knuckle to axle housing (for 2WD).
10) Install kingpins (2) and knuckle seal cover (1) to steering
knuckle (R&L), refer to “Steering Knuckle / Wheel Spindle” in
this section.
11) Install right and left brake disc and caliper assembly.
Tighten carrier bolts to specified torque.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
12) Connect spindle vacuum hoses to wheel spindle (for 4WD),
while aligning the match mark.
13) Install ABS wheel sensor to steering knuckle (if equipped
with ABS).
14) Install tie rod ends and drag rod end to knuckle arm (1)
(R&L). Tighten new nuts to specified torque.
Tightening torque
Tie rod end nuts and drag rod end nut (Knuckle side)
(a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)
15) Install wheels and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
: 95 N·m (9.5 kg-m, 69.0 lb-ft)
16) Lower hoist.NOTE:
Place knuckle seal and retainer in axle housing before
installing axle shaft (knuckle), using care for installation
direction of knuckle seal.
NOTE:
To prevent ball stud from being rotated while tightening
tie rod end nut, tighten Nut (M12 x 1.25) to about 20 N·m
(2.0 kg-m, 14.5 Ib-ft) and remove it. Then tighten new nut
to specified torque.

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-43
17) Tighten lateral rod (1) mounting bolt and nut to specified
torque.
Tightening torque
Lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
18) Tighten right and left shock absorber lower mounting nuts
and leading arm mounting nuts to specified torque.
Tightening torque
Shock absorber lower nuts and leading arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
19) Refill front axle (differential) housing with new specified gear
oil. Refer to “Maintenance Service” in Section 7E for refill.
20) Confirm front end (wheel) alignment referring to “Preliminary
Checks Prior to Adjusting Front Alignment” in Section 3A. NOTE:
When tightening bolt and nut, be sure that vehicle is off
hoist and in non loaded condition.
NOTE:
When tightening these nuts, be sure that vehicle is off
hoist and in non loaded condition.
1. Shock absorber
2. Leading arm

Downloaded from www.Manualslib.com manuals search engine 3D-44 FRONT SUSPENSION
Tightening Torque Specifications
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Stabilizer mount bracket bolt 20 2.0 14.5
Stabilizer ball joint nut 50 5.0 36.5
Shock absorber lock nut 29 2.9 21.0
Shock absorber lower nut 90 9.0 65.0
Brake caliper carrier bolt 85 8.5 61.5
Wheel bearing lock nut 220 22.0 160.0
Wheel bearing lock washer screw 1.5 0.15 1.0
Air locking hub bolt 48 4.8 35.0
Wheel spindle bolt 50 5.0 36.5
Kingpin bolt 25 2.5 18.0
Knuckle seal cover bolt 10 1.0 7.5
Tie-rod end nut
43 4.3 31.5
Drag-rod end nut (Knuckle side)
Lateral rod bolt and nut
90 9.0 65.0
Leading arm nut
Front differential carrier bolt 23 2.3 17.0
Front propeller shaft flange bolt 50 5.0 36.5
Wheel nut 95 9.5 69.0
Vacuum pipe clamp bolt 5.5 0.55 4.0
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE (A)
(99000-25010)Knuckle seal / axle shaft oil seal
Recess of wheel spindles
Wheel hub oil seal
Wheel bearing
Spindle thrust washer
Spindle bush (inside and flange
part)
Spindle oil seal
SUZUKI SUPER GREASE (C)
(99000-25030)Kingpin bearing
Axle shaft joint (for 4WD)
Sealant SUZUKI BOND NO. 1215
(99000-31110)Mating surfaces of wheel spindle
and knuckle
Mating surface of differential carrier
and axle housing
Sealing compound SUZUKI SEALING COMPOUND
366E
(99000-31090)Mating surface of wheel spindle and
knuckle
Kingpin
Mating surfaces of hub cap and
wheel hub

Downloaded from www.Manualslib.com manuals search engine 3E-4 REAR SUSPENSION
Rear Suspension Fasteners
Check each bolt and nut fastening suspension parts for tightness.
Tighten loose one, if any, to specified torque, referring to “Tighten-
ing Torque Specifications” of this section.
Bearing Retainer and Axle Shaft Oil Seal
Check
When brake drum has been removed, check inside of brake
drum for gear oil leakage.
Also, check backside of brake back plate for oil leakage.If oil
leakage is found, replace defective oil seal.
Whenever it is possible to check oil seal during disassembly,
check its lip for wear.
If oil leakage or worn lip is found, replace defective oil seal.
Bump Stopper and Spring Rubber Seat Check
Inspect for wear and breakage. If found defective, replace.
Wheel Disc, Nut and Bearing Check
Inspect each wheel disc for dents, distortion and cracks. A
disc in badly damaged condition must be replaced.
Check wheel hub nuts for tightness and, as necessary,
retighten to specification.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine 3E-6 REAR SUSPENSION
3) Remove upper mounting bolt (2).
4) Remove lower mounting bolt (3).
5) Remove shock absorber (1).
INSTALLATION
1) Install shock absorber (1), refer to figure for proper installing
direction of bush and washer (2).
Tighten bolts (3) temporarily by hand.
2) Remove floor jack.
3) Lower hoist.
4) Tighten shock absorber bolts (3) to specified torque.
Tightening torque
Shock absorber upper and lower bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
Coil Spring
REMOVAL
1) Hoist vehicle and remove wheel.
2) Support rear axle housing (1) by using floor jack (2).
3) Remove brake flexible hose E-ring (2).
NOTE:
Tighten lower bolt with vehicle off hoist and in non-
loaded condition.
1. Brake flexible hose

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-7
4) Remove shock absorber lower mounting bolt (2).
5) Lower rear axle housing (2) gradually as far down as where
coil spring (1) can be removed.
6) Remove coil spring (1).
7) Remove spring rubber seat (1).
1. Shock absorber