2005 SUZUKI JIMNY AIR CON

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Drive Air Bag (Inflator) Module (For Vehicle
with Air Bag System)
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to “Disabling Air Bag System”
in Section 10B.
3) Remove steering wheel side cap (1) of left side.
4) Loosen 2 bolts (2) mounting driver air bag (inflator) module
till it turns freely, pull them out and fix them to bolt clamps (3).
5) Remove driver air bag (inflator) module (1) from steering
wheel.
6) Disconnect yellow connector (2) in order a) – b) as shown.
INSPECTION
WARNING:
When handling an air bag (inflator) module, be sure to
read “Service Precautions” given earlier in this section
and observe each instruction. Failure to follow them
could cause a damage to the air bag (inflator) module or
result in personal injury.
WARNING:
Never disassemble driver air bag (inflator) module or
measure its resistance. Otherwise, personal injury may
result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.

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Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.
Air bag being deployed
Trim cover (1) (pad surface) being cracked
Wire harness (3) or connector being damaged
Air bag (inflator) module being damaged or having been
exposed to strong impact (dropped)
INSTALLATION
1) Check that horn wire is connected to horn terminal securely.
2) Connect yellow connector (1) of driver air bag (inflator) mod-
ule (3) pushing connector till it is locked.
3) Install driver air bag (inflator) module to steering wheel, tak-
ing care so that no part of wire harness is caught between
them.
4) Make sure that clearance between module and steering
wheel is uniform all the way.
5) Tighten driver air bag (inflator) module mounting bolts (1) to
specified torque.
Tightening torque
Driver air bag (inflator) module mounting bolts
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
6) Install steering wheel side cap (2).
7) Connect negative battery cable.
8) Enable air bag system. Refer to “Enabling Air Bag System”
under “Service Precautions” in Section 10B.
Steering Wheel
2. Inflator case
CAUTION:
For vehicle with air bag system
Removal of the steering wheel allows the contact coil to
turn freely but do not turn the contact coil (on the combi-
nation switch) more than allowable number of turns
(about two and a half turns from the center position
clockwise or counterclockwise respectively), or coil will
break.

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REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Remove steering wheel pad (for vehicle without air bag sys-
tem) or driver air bag (inflator) module (for vehicle with air
bag system) as follows.
Vehicle without air bag system for TYPE A
a) Remove steering wheel pad.
b) Disconnect horn connector.
Vehicle without air bag system for TYPE B
a) As shown in the figure, while pushing the set spring (1) with
a screwdriver or the like inserted in the hole of the steering
wheel, pull the lower part of the pad forward and remove
the steering wheel pad.
Vehicle with air bag system
a) Remove driver air bag (inflator) module from steering wheel
referring to “Driver Air Bag (Inflator) Module” in this section.
3) Remove steering shaft nut.
4) Make alignment marks (1) on steering wheel and shaft for a
guide during reinstallation.
[A] : For TYPE A
[B] : For TYPE B

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5) Remove steering wheel (1) with special tool.
Special tool
(A) : 09944-36011
INSTALLATION
1) Check that vehicle’s front tires are at straight-ahead position.
If equipped with air bag system, align contact coil to original
position referring to “Centering Contact Coil” in this section.
2) Install steering wheel as follows.
For vehicle without air bag system
a) Apply grease to contact plate (1).
“A” : Grease 99000-25290
b) Install steering wheel onto shaft, aligning them by match
marks.
For vehicle with air bag system
Install steering wheel to steering shaft with 2 lugs (2) on con-
tact coil fitted in two grooves (3) in the back of steering wheel
and also aligning marks (4) on steering wheel and steering
shaft. CAUTION:
Do not hammer the end of the shaft. Hammering it will
loosen the plastic shear pins which maintain the column
length and impair the collapsible design of the column.
CAUTION:
For vehicle with air bag system
These two conditions are prerequisite for installation of
steering wheel. If steering wheel has been installed with-
out these conditions, contact coil will break when steer-
ing wheel is turned.
[A] : For vehicle without air bag system
[B] : For vehicle with air bag system

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3) Tighten steering shaft nut to specified torque.
Tightening torque
Steering shaft nut (a) : 33 N·m (3.3 kg-m, 23.5 lb-ft)
4) Install steering wheel pad (for vehicle without air bag system)
or driver air bag (inflator) module (for vehicle with air bag
system) as follows.
For vehicle without air bag system
–For TYPE A
a) Connect horn connector.
b) Install steering wheel pad.
–For TYPE B
a) To install the pad, hook (1) the upper part of the pad to the
pawl of the steering wheel and push in the lower part of the
pad until it fits to the set spring securely.
For vehicle with air bag system
a) Install driver air bag (inflator) module to steering wheel.
Refer to “Driver Air Bag (Inflator) Module” in this section.
Centering contact coil (for vehicle with air bag sys-
tem)
1) Check that vehicle’s wheels (front tires) are set at straight-
ahead position.
2) Check that ignition switch is at “LOCK” position.
3) Turn contact coil counterclockwise slowly with a light force till
contact coil will not turn any further. NOTE:
After installing the steering wheel, turn the steering
wheel about 1 full rotation so that the cancel cam pin fits
into the pin hole in the steering wheel and then check the
turn signal lever for proper function.
NOTE:
Contact coil can turn about 5 turns at maximum, that is, if
it is at the center position, can turn about two and a half
turns both clockwise and counterclockwise.

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4) From the position where contact coil became unable to turn
any further (it stopped), turn it back clockwise about two and
a half rotations and align center mark with alignment mark
(1).
Combination Switch (For Vehicle without Air
Bag System)/Contact Coil and Combination
Switch Assembly (For Vehicle with Air Bag
System)
REMOVAL
1) Remove steering wheel from steering column referring to
“Steering Wheel” in this section.
2) Remove steering column hole cover (1).
3) Remove steering column cover standard screw (1) and tap-
ping screws (2).
4) Loosen steering column mounting bolts and nuts referring to
“Steering Column” in this section.
5) Separate upper cover (3) and lower cover (4), then remove
them.
6) Disconnect all connectors for combination switch/contact coil
and combination switch assembly.
CAUTION:
For vehicle with air bag system
Do not turn contact coil (on combination switch) more
than allowable number of turns (about two and a half
turns from the center position clockwise or counter-
clockwise respectively), or coil will break.

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7) Remove combination switch/contact coil and combination
switch assembly (1) from steering column.
INSPECTION
For vehicle with air bag system
Check contact coil and combination switch wire harness for
any signs of scorching, melting or other damage. If it is dam-
aged, replace.
INSTALLATION
1) Check to make sure that vehicle’s front tires are set at
straight-ahead position and then ignition switch is at “LOCK”
position.
2) Install combination switch/contact coil and combination
switch assembly to steering column.
3) Connect all connectors that have been disconnected in
“REMOVAL”.
4) Install steering column upper (3) and lower cover (4), and
then tighten steering column cover standard screw (1) and
tapping screws (2).
1. Contact coil and combination switch assembly
2. To horn
3. Connector to driver air bag (inflator) module
4. Connector to air bag wire harness
NOTE:
For vehicle with air bag system
New contact coil and combination switch assembly is
supplied with contact coil set and held at its center posi-
tion with a lock pin (2) and seal (1). Remove this lock pin
after installing contact coil and combination switch
assembly to steering column.
CAUTION:
When installing lower cover (3) and upper cover (2), be
careful so that combination switch/contact coil and com-
bination switch lead wirer is not caught between covers.

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REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) For vehicle equipped with air bag system, disable air bag
system referring to “Disabling Air Bag System” in Section
10B.
3) If necessary, remove steering wheel and combination switch
assembly referring to “Steering Wheel” and “Combination
switch/Contact Coil and Combination Switch Assembly” in
this section.
If not removing steering wheel and/or combination switch
assembly, perform the following procedure.
a) Turn steering wheel so that vehicle’s front tires are at
straight ahead position.
b) Turn ignition switch to “LOCK” position and remove key.
4) Remove steering column hole cover (1).
5) Disconnect all connectors of the following parts.
Combination switch/contact coil and combination switch
assembly.
Ignition switch.
Immobilizer control system parts (if equipped).
6) Remove joint bolt (steering column side) (3) and loosen joint
bolt (steering gear box side).
7) Remove steering column mounting nuts (2) and bolts (1).WARNING:
For vehicle with air bag system
Never rest a steering column assembly on the steering
wheel with the air bag (inflator) module face down and
column vertical. Otherwise, personal injury may result.