2005 SUZUKI JIMNY Steering assembly

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-3
Diagnosis
Diagnosis Table
Condition Possible Cause Correction
Steering wheel feels
heavy
(at low speed)Fluid deteriorated, low viscosity, different type of
fluid mixedChange fluid.
Pipes or hoses deformed, air entering through
jointCorrect or replace.
Insufficient air bleeding from piping Bleed air.
Belt worn, lacking in tension Adjust belt tension or replace belt
as necessary.
Tire inflation pressure too low Inflate tire.
Wheel alignment out of adjustment Adjust front wheel alignment.
Steering wheel installed improperly (twisted) Install steering wheel correctly.
Hydraulic pressure failing to rise (See NOTE
“A”.)Replace P/S pump.
Slow hydraulic pressure rise (See NOTE “A”.)
Steering wheel feels
heavy momentarily
when turning it to the
left or right.Air drawn in due to insufficient amount of fluid Add fluid and bleed air.
Slipping belt Adjust belt tension or replace belt
as necessary.
No idle-up (See NOTE
“B”.)Defective pressure switch Replace pressure switch
(terminal set).
NOTE:
“A” : Be sure to warm up engine fully before performing this check. Pump vanes are sometimes
hard to come out where temperature is low.
“B” : Acceptable if idling speed does not drop.
Condition Possible Cause Correction
Steering wheel returns
slowly from turns.
(See NOTE “C”.)Dust or foreign object mixed in fluid Change fluid.
Deformed pipes or hoses Correct or replace.
Steering column installed improperly Install correctly.
Wheel alignment maladjusted Adjust.
Linkage or joints not operating smoothly Correct.
Vehicle pulls to one
side during straight
driving.Low or uneven tire inflation pressure Inflate tire (s) as necessary.
Wheel alignment maladjusted Adjust.
Defective spool valve Replace gear box assembly.
Steering wheel play is
large and vehicle wan-
ders.Loose steering shaft nut Retighten.
Loose linkage or joint Retighten.
Loose gear box fixing bolt Retighten.
Front wheel bearing worn Replace.
Fluid leakage
Loose joints of hydraulic pressure pipes and
hosesRetighten.
Deformed or damaged pipes or hoses Correct or replace.
Gear box Replace gear box assembly.

Downloaded from www.Manualslib.com manuals search engine 3B1-4 POWER STEERING (P/S) SYSTEM (If equipped)
Abnormal noise
(See NOTE “D”.)Air drawn in due to insufficient fluid Replenish fluid.
Air drawn in through pipe or hose joints Retighten or replace.
Belt slipping (loose) Adjust.
Worn belt Replace.
Loose steering linkage Retighten.
Loose gear box fixing bolt Retighten.
Loose pitman arm Retighten.
Pipes or hoses in contact with chassis Correct.
Defective pump vane Replace pump assembly.
Malfunction of flow control valve Replace gear box assembly.
Defective pump shaft bearing Replace pump assembly. Condition Possible Cause Correction
NOTE:
“C” : Turn steering wheel 90° at 35 km/h (22 mile/h) and let it free. If it returns more than 60° then, it
is normal.
“D” : Some hissing noise may be heard through steering column when turning steering wheel with
vehicle halted. It is from operation of the valve in the gear box and indicates nothing abnormal.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-13
5) Remove P/S pump (1) removing 3 mounting bolts (3).
DISASSEMBLY
1) Clean its exterior thoroughly.
2) With aluminum plates placed on vise first, grip pump case
with it.
3) Remove suction connector (10) and O-ring from pump body
(1).
4) Remove power steering pressure switch (3) from pump body
(1).
5) Remove relief valve (flow control valve) (2) and spring from
pump body (1).
6) Remove pump cover (11), O-ring and cam ring (6) from
pump body (1).
7) Remove vanes (9) from rotor (5).
8) Remove snap ring (8) from pump shaft (4) and pull out rotor
(5) and pulley (shaft) (4).
9) Remove side plate (7) and O-ring from pump body (1).
10) Remove oil seal from pump body (1).
INSPECTION
Pump body, cover and shaft
Check sliding surfaces of each part for wear and damage.
If any defect is found, replace pump assembly.CAUTION:
Clean couplers at intake and discharge ports com-
pletely before disconnection.
Plug ports of removed pump to prevent dust and any
foreign object from entering.
2. P/S pump bracket
1. Pulley 3. Pump cover
2. Pump body

Downloaded from www.Manualslib.com manuals search engine 3B1-14 POWER STEERING (P/S) SYSTEM (If equipped)
CAM RING AND SIDE PLATE
Check vane sliding surface of cam ring (2) for wear and damage.
If any defect is found, replace pump assembly.
ROTOR AND VANE
Check sliding surfaces of rotor and vane for wear and dam-
age.
Check clearance between rotor and vane.
Replace pump assembly if any defect is found.
Clearance between rotor and vane
Standard : 0.01 mm (0.0004 in.)
Limit : 0.06 mm (0.0023 in.)
RELIEF VALVE (FLOW CONTROL VALVE) AND ITS SPRING
Check fluid passage of relief valve and orifice of connector
for obstruction (clogged).
Check sliding surface of relief valve for wear and damage.
2. Side plate
1. Thickness gauge

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-15
Check free length of relief valve spring (1).
Replace pump assembly if any defective is found.
Relief valve spring free length
Standard : 36.5 mm (1.44 in.)
Limit : 33.5 mm (1.32 in.)
ASSEMBLY
Reverse disassembly procedure for assembly, noting the follow-
ing.
1) Apply power steering fluid to shaft (2) outer surface and
grease to oil seal lip (1) and insert it from oil seal side.
“A” : Grease 99000-25010
2) Apply power steering fluid to O-rings and fit them to pump
body.
3) Install side plate (2) to pump body.
4) Apply power steering fluid to sliding surface of rotor (1).
5) Install rotor (1) to shaft, directing “dot” (2) marked side of
rotor toward pump cover (facing up).
6) Install new snap ring to shaft, then make sure to fit snap ring
into shaft groove securely.
NOTE:
Carefully align the dowel pins (3) on the side plate (2) at
bolt hole (1) as shown in figure.
NOTE:
Never reuse the removed snap ring.

Downloaded from www.Manualslib.com manuals search engine 3B1-18 POWER STEERING (P/S) SYSTEM (If equipped)
INSTALLATION
Install components in reverse order of removal procedure noting
the following points.
Tighten each bolt as specified below.
Tightening torque
Oil pump mounting bolts
(a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)
Oil pump high pressure union bolt
(b) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
Adjust P/S belt referring to “Power Steering Belt Check” in
this section.
Connect pressure switch terminal.
Power Steering (P/S) Gear Box
REMOVAL
1) Take out fluid in P/S fluid reservoir with syringe or such.
2) Turn steering wheel fully counterclockwise and loosen sector
shaft nut of P/S gear box.
3) Return steering wheel to straightforward state and remove
pitman arm from P/S gear box by using puller.
4) Remove radiator (for left-steering vehicle) referring to “Radi-
ator” in Section 6B
5) Remove radiator support member.
6) Disconnect suction hose and return hose from P/S fluid res-
ervoir, and remove P/S fluid reservoir assembly (for left-
steering vehicle).
7) Remove steering lower shaft joint bolt (2).CAUTION:
After installation, fill A/T fluid (an equivalent to
DEXRON
®-II, DEXRON®-IIE or DEXRON®-III) and be sure
to bleed air referring to “Air Bleeding Procedure” in this
section.
1. Union bolt
1. Steering lower shaft

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-1
6F1
6F2
6G
6H
6K
7A
3C
7E
7F
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3C
STEERING WHEEL AND COLUMN
CONTENTS
General Description ....................................... 3C-2
Diagnosis ........................................................ 3C-3
Inspection and Repair Required
After Accident ............................................... 3C-3
On-Vehicle Service......................................... 3C-3
Service Precautions (For Vehicle with
Air Bag System) ........................................... 3C-3
Diagnosis and servicing ........................... 3C-3
Disabling air bag system .......................... 3C-3
Enabling air bag system ........................... 3C-3
Handling and storage ............................... 3C-3
Disposal.................................................... 3C-3
Drive Air Bag (Inflator) Module (For Vehicle
with Air Bag System) .................................... 3C-4
Steering Wheel ............................................. 3C-5Centering contact coil (for vehicle with
air bag system)......................................... 3C-8
Combination Switch (For Vehicle without
Air Bag System)/Contact Coil and
Combination Switch Assembly (For Vehicle
with Air Bag System).................................... 3C-9
Steering Column Assembly........................ 3C-11
Steering Lock Assembly
(Ignition Switch) ......................................... 3C-15
Steering Lower Shaft ................................. 3C-16
Checking Steering Column for Accident
Damage ......................................................... 3C-18
Tightening Torque Specifications .............. 3C-19
Required Service Material ........................... 3C-19
Special Tool .................................................. 3C-19

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem components or wiring. Failure to follow WARNINGS could result in unintentional activation of
the system or could render the system inoperative. Either of these two conditions may result in
severe injury.
The procedures in this section must be followed in the order listed to temporarily disable the air
bag system and prevent false diagnostic codes from setting. Failure to follow procedures could
result in possible air bag system activation, personal injury or otherwise unneeded air bag system
repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.

Downloaded from www.Manualslib.com manuals search engine 3C-2 STEERING WHEEL AND COLUMN
General Description
This double tube type steering column has the following three important features in addition to the steering func-
tion:
The column is energy absorbing, designed to compress in a front-end collision.
The ignition switch and lock are mounted conveniently on this column.
With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehi-
cle.
To insure the energy absorbing action, it is important that only the specified screws, bolts and nuts be used as
designated and that they are tightened to the specified torque.
When the column assembly is removed from the vehicle, special care must be taken in handling it. Use of a
steering wheel puller other than the one recommended in this manual or a sharp blow on the end of the steering
shaft, leaning on the assembly, or dropping the assembly could shear the plastic shear pins which maintain col-
umn length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver’s and passenger’s seat belts by deploying the air bags.
The air bag (inflator) module should be handled with care to prevent accidental deployment. When servicing, be
sure to observe all WARNINGS and CAUTIONS in this section and “Service Precautions” in Section 10B.
1. Driver air bag (inflator) module 6. Steering column upper cover 11. Steering lower shaft
2. Steering wheel 7. Steering column lower cover [A] : For vehicle with air bag system
3. Steering wheel side cap 8. Steering column assembly [B] : For vehicle without air bag system
4. Steering wheel nut 9. Steering lock assembly (ignition switch)
5. Combination switch or contact coil and com-
bination switch assembly10. Steering column hole cover