2005 SUZUKI JIMNY Locking

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Diagnosis
Diagnosis Table
For description not found in the table below, refer to “Diagnosis Table” in Section 3.
4WD CONTROL SYSTEM
4WD CONTROL SYSTEM DIAGNOSTIC FLOW TABLE
Before performing the trouble diagnosis, check that the air locking hub assemblies are in good condition and
there is no air leakage from vacuum hoses and vacuum pipe. Refer to “4WD Control System Check” in this sec-
tion for air leakage.
[NOTES ON SYSTEM CIRCUIT INSPECTION]
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before circuit inspection and
observe what is written there.
For system circuit, refer to the figure of “System Circuit” in this section. Condition Possible Cause Correction
4WD Indicator light
flashingHub locking procedure error
Defective VSV2
Defective vacuum switch
Defective check valve or vacuum tank
Air leak from vacuum circuit
Clogged vacuum hose or pipe
Faulty 4WD controllerShift transfer shift control lever
2WD → 4WD once again
Replace
Replace
Replace
Check and repair
Replace
Check and replace
2WD/4WD switching
errorDefective air locking hub assembly
Abnormality in 4WD control system
Air leakage from vacuum circuit
Clogged vacuum hose or pipe
Defective check valve or vacuum tankReplace
Inspect referring to “4WD Control
System Diagnostic Flow Table”
Check and replace
Replace
Replace
Step Action Yes No
1 Check ground circuit.
1) Disconnect coupler from 4WD controller
with ignition switch OFF.
2) Check for proper connection to 4WD con-
troller at all terminals.
3) If OK, check continuity between A5 terminal
and body ground.
Is there continuity between A5 terminal and
body ground?Go to Step 2.“B” wire is open.
2 Check power circuit.
1) Disconnect coupler from 4WD controller.
2) Turn ignition switch ON.
3) Check voltage between A10 terminal and
ground.
Is it 10 – 14 V?Go to Step 3.“Y/R” circuit is open or
short.

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4WD Control System Check
AIR LOCKING HUB
1) Start engine and shift transfer shift control lever to 2H posi-
tion.
2) Connect vacuum pump gauge (special tool) to the spindle
hose (2) which is disconnected from upper side pipe as
shown. Apply vacuum and check operating sound from air
locking hub (1).
If there is not operating sound, replace air locking hub
assembly.
Vacuum specification
More than 40 kPa (0.40 kg/cm
2, 5.70 Psi)
Special tool
(A) : 09917-47910
3) Connect hose, then start engine and shift transfer shift con-
trol lever to 4H or 4L position.
4) Connect vacuum pump gauge to the spindle hose (2) dis-
connected from lower side pipe.
Apply vacuum and check operating sound from air locking
hub (1).
If there is no operating sound, replace air locking hub
assembly.
Vacuum specification
More than 40 kPa (0.40 kg/cm
2, 5.70 Psi)
Special tool
(A) : 09917-47910
VSV1 AND VSV2
1) Disconnect coupler from VSV1 (1) (VSV2) (2) and check
resistance between two terminals of VSV1 (1) (VSV2) (2).
If resistance is out of specification, replace.
Resistance of VSV1 and VSV2
: 33 – 39
Ω

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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

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5) Apply lithium grease to lip portion and hollow of oil seal (1).
“A” : Grease 99000-25010
6) Install sensor rotor (3) as shown (if equipped with ABS).
7) Apply lithium grease inside wheel bearing thin.
“A” : Grease 99000-25010
8) Install wheel hub complete with bearings and oil seal onto
front wheel spindle.
9) Install bearing washer.
10) Tighten wheel bearing lock nut to specified torque while turn-
ing wheel hub by hand.
Special tool
(A) : 09944-77020 (For 4WD)
(A) : 09951-16050 (For 2WD)
Tightening torque
Wheel bearing lock nut
(a) : 220 N·m (22.0 kg-m, 160 lb-ft)
11) Install hub cap (for 2WD model) or air locking hub assembly
(for 4WD model) as follows. NOTE:
Amount of grease applied to hollow in oil seal (1) should
be more than 60% of its vacant space.
2. Wheel hub
NOTE:
Pipe (2) used here should have inner diameter of
90 mm (3.55 in.) – 96 mm (3.77 in.) and its outside
should not contact teeth of sensor rotor (3).
Use care not to insert wheel hub (4) diagonally.
1. Steel plate
5. Hydraulic press

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c) Install front axle shaft circlip (1) and apply thin coat of
grease to spline part of axle shaft.
“A” : Grease 99000-25010
d) Clean mating surface of air locking hub and wheel hub.
Install air locking hub assembly to wheel hub and tighten
bolts to specified torque.
Tightening torque
Air locking hub bolts
(a) : 48 N·m (4.8 kg-m, 35.0 lb-ft)
12) Install ABS wheel sensor (if equipped with ABS).
13) Install 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)
14) Install wheel and tighten wheel nuts specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)
15) Lower hoist.
16) For 4WD model:
Check air locking hub for air leakage, refer to “4WD System
Check” in this section. NOTE:
When installing circlip (1) to front axle shaft, utilize screw
hole in axle shaft to pull it out and bring large diameter
(2) of circlip at right as shown.

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8) Press-fit spindle bushing (2) to wheel spindle (1) by using
special tool.
Set cut part (4) of spindle bushing (2) as shown in figure
(opposite side of the groove (3) of wheel spindle).
Special tool
(A) : 09922-55131
9) Press-fit spindle oil seal (1) until it becomes flush with wheel
spindle (2) surface by using special tool, and then apply
grease to its lip.
Special tool
(A) : 09944-66020
10) Apply grease to spindle oil seal lip.
“A” : Grease 99000-25010
11) Apply grease to spindle bushing inside surface and flange
(2).
“A” : Grease 99000-25010
12) Install wheel spindle to knuckle, coat their mating surface
with sealant.
“B” : Sealant 99000-31110 or 99000-31090
13) Install wheel spindle (1) and disc dust cover (2) to steering
knuckle. Tighten wheel spindle bolts to specified torque.
Tightening torque
Wheel spindle bolts
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
CAUTION:
As this hole is a part of the passage of the vacuum that
activates the air locking hub, if it is clogged with grease,
the air locking hub cannot be locked or unlocked.
Therefore, be careful not to apply too much grease to
avoid clogging the vacuum passage.

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14) Blow air into pipes at the top and the front of wheel spindle
and check that it comes out of the hole as shown in figure
(for 4WD).
15) Connect spindle vacuum hoses to wheel spindle (for 4WD).
16) Connect tie rod and drag rod to steering knuckle, refer to
“Tie rod and Drag Rod” in Section 3B.
17) Install wheel hub assembly, refer to “Wheel Hub / Bearing /
Oil Seal” in this section.
18) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
: 95 N·m (9.5 kg-m, 69.0 lb-ft)
19) Lower hoist.
Front Axle Shaft / Oil Seal / Kingpin Bearing
Outer Race
REMOVAL
1) Hoist vehicle.
2) Drain differential gear oil from front axle housing by loosing
drain plug (for 4WD).
3) Remove steering knuckle. For details, refer to “Steering
Knuckle / Wheel Spindle” in this section.
4) Draw out axle shaft (2).CAUTION:
As this hole is a part of the passage of the vacuum that
activates the air locking hub, if it is clogged with grease,
the air locking hub cannot be locked or unlocked.
Therefore, be careful not to apply too much grease to
avoid clogging the vacuum passage.
1. Front axle housing

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Leading Arm / Bushing
REMOVAL
1) Hoist vehicle.
2) Remove air locking hub vacuum pipe clamp bolts (2) (for
4WD).
3) Support front axle housing by using floor jack.
4) Remove shock absorber lower mounting bolt, refer to “Front
Shock Absorber” in this section.
5) Remove mounting bolts and leading arm (1).
6) Remove bushings by using hydraulic press and special
tools.
Special tool
(A) : 09924-74510
(B) : 09951-16030
(C) : 09951-26010
1. Leading arm (right side)