2005 SUZUKI JIMNY Steering pump

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-7
Idle-Up System Check
1) Warm up engine to normal operating temperature.
2) Turn A/C switch OFF, if equipped.
3) Turn steering wheel fully and check idle speed.
Engine idle speed drops a little momentarily when steering wheel is turned fully but returns to its specified
level immediately. If power steering pressure switch connector is connected, check the same with that con-
nector disconnected. Momentary drop of engine idle speed should be less when it is connected than when
disconnected.
Power Steering Fluid Leakage Check
Start engine and turn steering wheel fully to the right and left so that maximum hydraulic pressure is applied to
system. Then visually check gear box, P/S pump and P/S fluid reservoir respectively and each joint of hydraulic
pressure piping for leakage. During this check, however, never keep steering wheel turned fully for longer than
10 seconds.

Downloaded from www.Manualslib.com manuals search engine 3B1-8 POWER STEERING (P/S) SYSTEM (If equipped)
Air Bleeding Procedure
AIR BLEEDING FROM SYSTEM
1) Jack up the front end of vehicle and apply rigid rack.
2) Fill P/S fluid reservoir with fluid up to specified level.
3) With engine running at idling speed, add fluid up to specified
level.
4) When fluid stops reducing, stop engine and leave P/S sys-
tem as it is for about 10 minutes.
5) After running engine at idling speed for 1 minute, stop it.
6) As a final step, check to make sure that fluid is up to speci-
fied level.
7) Check steering condition and P/S system for fluid leakage.
AIR BLEEDING FROM GEAR BOX
1) Remove steering gear box from vehicle referring to “Power
Steering (P/S) Gear Box” in this section.
2) Install special tool as shown.
Special tool
(A) : 09945-35010 CAUTION:
When air bleeding is not complete, it is indicated by
foaming fluid on level gauge or humming noise from P/S
pump.
NOTE:
Bleed air from system when P/S system has been ser-
viced in any way other than replacement of steering gear
box (e.g., disconnection of piping, replacement of P/S
pump). Never operate steering system while servicing.
Or Air Bleeding from gear box must be performed.
NOTE:
Bleed air from gear box:
When steering gear box has been replaced with a new
one.
When entry of air into hydraulic circuit of steering gear
box is suspected.
1. Steering gear box 3. High pressure hose / pipe
2. Low pressure hose / pipe

Downloaded from www.Manualslib.com manuals search engine 3B1-10 POWER STEERING (P/S) SYSTEM (If equipped)
Hydraulic Pressure In P/S Circuit Check
1) Clean where pipe is connected thoroughly, then disconnect
high pressure hose from high pressure pipe connector and
connect oil pressure gauge (special tool) as shown.
Special tool
(A) : 09915-77410
(B) : 09915-77420
2) Bleed air.
3) With engine running at idling speed, keep turning steering
wheel to the right and left till fluid in P/S fluid reservoir is
warmed to 50 to 60 °C (122 – 140 °F)
4) Back pressure check
With engine running at idling speed and hands off from
steering wheel, check hydraulic pressure.
If back pressure exceeds 980 kPa (10 kg/cm
2, 142 psi),
check control valve and pipes for obstruction.
Back pressure : 980 kPa (10 kg/cm
2, 142 psi)
1. To gear box 4. Union bolt
2. Attachment 5. Pressure hose
3. Washer
1. P/S fluid reservoir 5. Low pressure side
2. P/S pump 6. High pressure side
3. Steering gear box 7. Valve (open)
4. Oil pump pressure gauge

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-11
5) Relief pressure check
a) Increase engine speed to about 1,500 to 1,600 rpm.
Close valve (6) gradually while watching pressure increase
indicated on gauge (4) and take reading of relief pressure
(maximum hydraulic pressure).
If higher than 8,400 kPa (85 kg/cm
2, 1208 psi), malfunction
of relief valve.
If lower than 6,400 kPa (65 kg/cm
2, 925 psi), failure of P/S
pump or settling of relief valve spring.
Relief pressure
6,400 – 8,400 kPa (65 – 85 kg/cm
2, 925 – 1208 psi)
b) Next, open gauge valve (6) fully and increase engine speed
to about 1,500 to 1,600 r/min. Then turn steering wheel to
the left or right fully and take reading of relief pressure.
If lower than 6,400 kPa (65 kg/cm
2, 1280 psi), failure in
steering gear.
Relief pressure
6,400 – 8,400 kPa (65 – 85 kg/cm
2, 925 – 1208 psi) CAUTION:
Be sure not to keep gauge valve closed for longer than
10 seconds.
Never keep steering wheel turned fully for longer than
10 seconds.
1. P/S fluid reservoir 3. Steering gear box
2. P/S pump 5. High pressure side
1. P/S fluid reservoir 4. Oil pressure gauge
2. P/S pump 5. High pressure side
3. Steering gear box

Downloaded from www.Manualslib.com manuals search engine 3B1-12 POWER STEERING (P/S) SYSTEM (If equipped)
On-Vehicle Service
Power Steering Belt
REMOVAL
1) Disconnect negative cable at battery.
2) Loosen tension pulley bolts (2).
3) Remove power steering belt (1).
INSPECTION
Check power steering belt for wear and cracks, and replace
as required.
INSTLLATION
1) Install belt to power steering pump pulley (1), crankshaft pul-
ley (2), A/C pulley (if equipped) (3) and tension pulley (4).
2) Adjust belt tension referring to “Power Steering Belt Check”
in this section.
Power Steering (P/S) Pump
REMOVAL
1) Take out fluid in P/S fluid reservoir with syringe or such.
2) Remove P/S belt.
3) Disconnect high pressure hose and low pressure hose.
4) Disconnect pressure switch lead harness.

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.