2005 SUZUKI JIMNY ATE

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OPERATION
2WD
→ 4WD
When the transfer shift control lever is shifted from the 2WD (2H) position to the 4WD (4H or 4L) position, a 4WD
“ON” signal is transmitted to the 4WD controller which then activates VSV2 to apply vacuum in the intake mani-
fold to the chamber “B” in the hub housing.
When vacuum is applied, the slide gear is separated from the magnet, moves toward the center of the vehicle
body and gets engaged with the outer gear. In this way, the front axle shaft and the front wheel hub rotate as one
unit.
If vacuum in the circuit fails to reach 260 mmHg within 15 seconds after operation of VSV2 due to such trouble
as a hole in the vacuum pipe, the slide gear does not operate and the 4WD indicator light flashes to warn that
the hub is unlocked.
1. ECM 8. Engine speed signal 15. Chamber B 22. Slide gear
2. 4WD controller 9. Intake manifold 16. Piston A 23. Wheel hub
3. 4WD indicator lamp 10. Check valve 17. Magnet 24. Spindle
4.4WD switch 11. Vacuum tank 18. Housing 25. Front axle shaft
5. A/C switch (if equipped) 12. VSV1 19. Spring 26. To opposite side
6. Vacuum switch 13. VSV2 20. Diaphragm 27. A/C controller
7. A/C cut signal (if equipped) 14. Outer gear 21. Sleeve A: Vacuum circuit

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4WD
→ 2WD
When the transfer shift control lever is shifted from the 4WD (4H or 4L) to the 2WD (2H) position, the 4WD con-
troller activates VSV1 and the intake manifold vacuum is applied to the chamber “A” in the hub housing. As the
slide gear is shifted to the wheel side by the vacuum force and disengaged from the outer gear, rotation of the
front wheel hub is not transmitted to the front axle shaft.
1. EPI & A/C controller 8. Engine speed signal 15. Chamber A 22. Slide gear
2. 4WD controller 9. Intake manifold 16. Piston A 23. Wheel hub
3. 4WD indicator lamp 10. Check valve 17. Magnet 24. Spindle
4.4WD switch 11. Vacuum tank 18. Housing 25. Front axle shaft
5. A/C switch (if equipped) 12. VSV1 19. Spring 26. To opposite side
6. Vacuum switch 13. VSV2 20. Diaphragm 27. A/C controller
7. A/C cut signal (if equipped) 14. Outer gear 21. Sleeve A: Vacuum circuit

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4WD Controller and ITS Circuit Check
VOLTAGE CHECK
Check for input or output voltage of 4WD controller (1) (voltage
between each circuit and body ground) with 4WD controller con-
nector connected and ignition switch turned START (engine run).
* : With engine runningCAUTION:
Disable air bag system (if equipped with Air Bag), refer
to “Disabling Air Bag System” in Section 10B.
This check must be carried out in a well-ventilated
place.
Terminal Circuit Wire Color Normal Voltage Condition
A1 VSV1 Gr/Babout 0 V10 seconds after transfer shift con-
trol lever : 4WD → 2WD
10 – 14 V Transfer shift control lever: 4WD
A2 VSV2 Gr/R*about 0 V5 seconds after transfer shift control
lever : 2WD → 4WD
10 – 14 V Transfer shift control lever: 2WD
A34WD indicator
lampBl*about 0 V Transfer shift control lever: 4WD
10 – 14 V Transfer shift control lever: 2WD
A4 A/C controller G/W*10 – 12 V5 – 10 seconds after engine starts or
transfer shift control lever switches.
about 0 VA/C switch and blower fan switch
ON.
A5 Ground B about 0 V any time
A6 Vacuum switch Gr*about 0 V5 seconds after transfer shift control
lever : 2WD → 4WD
10 – 14 V Other than above
A7 4WD switch Bl/Babout 0 V Transfer shift control lever: 4WD
10 – 14 V Transfer shift control lever: 2WD
A8 A/C switch G/Babout 0 VA/C switch ON and blower fan switch
ON
10 – 14 V Other than above
A9 Ignition coil Br0 – 1 V IG: ON
Voltage varies according to engine speed.
A10 Ignition switch Y/R 10 – 14 V IG: ON

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Shock Absorber and/or Coil Spring Check
1) Inspect shock absorber for oil leakage. If shock absorber is
found faulty, replace it as an assembly unit, because it can
not be disassembled.
2) Shock absorber function check
Check and adjust tire pressures as specified.
Bounce body three or four times continuously by pushing
front end on the side with shock absorber to be checked.
Apply the same amount of force at each push and note
shock absorber resistance both when pushed and rebound-
ing.
Also, note how many times vehicle body rebounds before
coming to stop after hands are off. Do the same for shock
absorber on the other side.
Compare shock absorber resistance and number of rebound
on the right with those on the left.
And they must be equal in both. With proper shock absorber,
body should come to stop the moment hands are off or after
only one or two small rebounds. If shock absorbers are sus-
pected, compare them with known good vehicle or shock
absorber.
3) Inspect for damage or deformation.
4) Inspect for cracks or deformation in spring seat.
5) Inspect for deterioration of bump stopper.
6) Inspect shock absorber mount for wear, cracks or deforma-
tion.Replace any parts found defective in steps 2) – 6).
Leading Arm / Lateral Rod / Steering Knuckle
Check
Inspect for cracks, deformation or damage.

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Leading Arm Bushing / Lateral Rod Bushing
Check
Inspect for damage, wear or deterioration.
If defective, replace.
Kingpin / Kingpin Bearing Check
1) Inspect for wear or deterioration.
2) Inspect for crack, damage or deformation of kingpin.
If defective, replace.
Barfield Joint Check
To be checked on this joint is its axial play, which shows up when
a push-and-pull motion is given to live axle shaft and wheel spin-
dle held in both hands, as shown in figure. There should be no
play at all but a play of up to 1.5 mm (0.06 in.) is permissible. If
play exceeds service limit, replace it.
Axial play in barfield joint
Steering Knuckle Seal Check
The knuckle seal used at the spherical sliding joint between the
knuckle and the inner case accomplishes the additional purposes
of keeping out road dust and of acting as the damper for the
steering handwheel. As the wear of this seal advances, its damp-
ing effect decreases and thus make the front wheel develop a ten-
dency to “shimmy” not only that road dust begins to creep into the
sliding clearance to promote the wear of the spherical sliding sur-
faces.
Check the knuckle seal for wear or damage. If defective, replace
with new one.
Standard Service Limit
0 mm (no play) 1.5 mm (0.06 in.)

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4) Support front axle housing by using floor jack.
5) Remove shock absorber lower mounting bolt (1).
6) Lower front axle housing (2) gradually as far down as where
coil spring (1) can be removed.
7) Remove coil spring (1).
INSTALLATION
Install removed parts in reverse order of removal procedures, not-
ing the followings.
1) Install coil spring (3).
2) Install absorber lower mounting bolt, refer to “Front Shock
Absorber” in this section.
3) Install caliper assembly and tighten caliper bolts to specified
torque.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
4) Connect stabilizer ball joint to axle housing and tighten nut
referring to “Stabilizer Bar” in this section for tightening
torque specification. NOTE:
When supporting axle housing, it should be in non-load
condition.
NOTE:
Make sure that coil spring direction as shown.
When seating coil spring, mate spring end with
stepped part (4) of lower spring seat (2).
1. Front axle housing
U : Upper side
A : Small
B : Large

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5) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
6) Lower hoist.
7) Confirm front end (wheel) alignment, referring to “Prelimi-
nary Checks Prior to Adjusting Front Alignment” in Section
3A.
Bump Stopper and Spring Upper Seat
REMOVAL
1) Remove coil spring, refer to “Coil Spring” in this section.
2) Remove bump stopper and spring upper seat.
INSTALLATION
1) Install bump stopper (1) and spring upper seat (2).
2) Install coil spring, refer to “Coil Spring” in this section.
Wheel Hub / Bearing / Oil Seal
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove brake caliper carrier bolts and suspend caliper (1).
3) Remove ABS wheel sensor (if equipped with ABS).
NOTE:
Before installing bump stopper (1), apply soap water on
it.
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.

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4) Remove brake disc.
5) Remove front wheel bearing lock nut as follows.
For 2WD model :
a) Remove hub cap.
b) Remove front wheel bearing lock plate (1) by loosening 4
screws (2).
For 4WD model :
a) Remove air locking hub assembly (1).
b) Remove front axle shaft circlip and wheel spindle thrust
washer.
c) Uncaulk front wheel bearing lock nut. NOTE:
If brake disc can not be removed by hand, using 8 mm
bolts.
1. Wheel hub