2005 SUZUKI JIMNY bearing

Downloaded from www.Manualslib.com manuals search engine STEERING, SUSPENSION, WHEELS AND TIRES 3-3
Shimmy, Shake or
VibrationTire or wheel out of balance Balance wheels or replace tire
and/or wheel.
Loose wheel bearings Replace wheel bearing.
Loose wheel hub nuts Retighten.
Worn tie rod ends Replace tie rod end.
Worn king pin bearings or king pins Replace king pin bearing and/or
king pin.
Excessive wheel runout Repair or replace wheel and/or tire.
Blister or bump on tire Replace tire.
Excessively loaded radial runout of tire / wheel
assemblyReplace tire or wheel.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Loose or worn steering linkage Tighten or replace steering linkage.
Loose steering gear box bolts Tighten box bolts.
Worn steering knuckle oil seal Replace.
Hard Steering
Bind in tie rod end ball studs or king pin bear-
ingsReplace tie rod end or king pin
bearing.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Steering gear box adjustment Check and adjust steering gear
box.
Tire not adequately inflated Inflate tires to proper pressure.
Bind in steering column Repair or replace.
Low fluid level, loose drive belt or malfunction of
power steering system (if equipped with P/S)Check and correct.
Too Much Play in
SteeringWheel bearings worn Replace wheel bearing.
Steering gear box attachments loose Tighten or repair.
Steering gear box adjustments Check and adjust steering gear
box.
Worn steering shaft joints Replace joint.
Worn tie rod ends drug rod ball joints Replace tie rod end.
Worn king pin bearings or king pin Replace king pin bearing and/or
king pin.
Poor Returnability
Bind in tie rod end ball studs Replace tie rod end.
Bind in king pin bearings Replace king pin bearing.
Bind in steering column Repair or replace.
Steering gear box needing lubricant Check, repair or lubricate steering
gear box.
Disturbed front wheel alignment Check and adjust front wheel align-
ment.
Steering gear box not properly adjusted Check and adjust steering gear box
torque.
Tires not adequately inflated Adjust pressure.
Steering Noise
(Rattle or Chuckle)Loose bolts and nuts Retighten.
Broken or otherwise damaged wheel bearings Replace wheel bearing.
Worn or sticky tie rod ends Replace tire rod end.
Linkage joints needing grease Lubricate or replace. Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine 3-4 STEERING, SUSPENSION, WHEELS AND TIRES
Abnormal Noise,
Front EndWorn, sticky or loose tie rod ends, drug rod ball
joints, king pin bearings or axle shaft jointsReplace tie rod end, king pin bear-
ing or axle shaft joint.
Damaged shock absorbers or mountings Replace or repair.
Worn leading arm bushings Replace.
Worn stabilizer bar bushings Replace.
Worn Iateral rod bushings Replace.
Loose stabilizer bar Tighten bolts or replace bushes.
Loose wheel nuts Tighten wheel nuts.
Loose suspension bolts or nuts Tighten suspension bolts or nuts.
Broken or otherwise damaged wheel bearings Replace wheel bearing.
Broken suspension springs Replace spring.
Wander or Poor
Steering StabilityMismatched or uneven tires Replace tire or inflate tires to
proper pressure.
Loose king pin bearings and tie rod ends Replace king pin bearing or tie rod
end.
Faulty shock absorbers or mounting Replace absorber or repair mount-
ing.
Loose stabilizer bar Tighten or replace stabilizer bar or
bushes.
Broken or sagging springs Replace spring.
Steering gear box not properly adjusted Check or adjust steering gear box
torque.
Front wheel alignment Check and adjust front wheel align-
ment.
Erratic Steering when
BrakingWorn wheel bearings Replace wheel bearing.
Broken or sagging springs Replace spring.
Leaking wheel cylinder or caliper Repair or replace wheel cylinder or
caliper.
Warped discs Replace brake disc.
Badly worn brake linings Replace brake shoe lining.
Drum is out of round in some brakes Replace brake drum.
Wheel tires are inflated unequally Inflate tires to proper pressure.
Defective wheel cylinders Replace or repair wheel cylinder.
Disturbed front wheel alignment Check front wheel alignment
Ride Too Soft
Faulty shock absorber Replace shock absorber.
Suspension bottoms
Overloaded Check loading.
Faulty shocks absorber Replace shock absorber.
Incorrect, broken or sagging springs Replace spring.
Body Leans or Sways
in CornersLoose stabilizer bar Tighten stabilizer bar bolts or
replace bushes.
Faulty shocks absorbers or mounting Replace shock absorber or tighten
mounting.
Broken or sagging springs Replace spring.
Overloaded Check loading.
Cupped Tires
Worn wheel bearings Replace wheel bearing.
Excessive tire or wheel run-out Replace tire or wheel disc.
Tire out of balance Adjust tire balance. Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine FRONT WHEEL ALIGNMENT 3A-3
Diagnosis
Diagnosis Table
For the details, refer to “Diagnosis Table” in Section 3.
Preliminary Checks Prior To Adjusting Front Wheel Alignment
Steering and vibration complaints are not always the result of improper alignment. An additional item to be
checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the
vehicle from a straight path on a level road without hand pressure on the steering wheel. Section 3 of this man-
ual contains a procedure for determining the presence of a tire lead problem. Before making any adjustment
affecting toe setting, the following checks and inspections should be made to ensure correctness of alignment
readings and alignment adjustments:
1) Check all tires for proper inflation pressures and approximately the same tread wear.
2) Check for loose of king pin bearings. Check tie rod ends; if excessive looseness is noted, it must be cor-
rected before adjusting.
3) Check for run-out of wheels and tires.
4) Check vehicle trim heights; if out of limits and a correction is to be made, it must be made before adjusting
toe.
5) Check for loose of suspension arms.
6) Check for loose or missing stabilizer bar attachments.
7) Consideration must be given to excess loads, such as tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment checks.
8) Consider condition of equipment being used to check alignment and follow manufacturer's instructions.
9) Regardless of equipment used to check alignment, vehicle must be on a level surface both fore and aft and
transversely.
Toe Adjustment
Toe is adjusted by changing tie rod length. Loosen right and left
tie rod end lock nuts first and then rotate tie rod to align toe-in to
specification.
In this adjustment, right and left tie rod should become equal in
length (“A”).
After adjustment, tighten lock nuts to specified torque.
Tightening torque
Tie rod end lock nuts
(a) : 65 N·m (6.5 kg-m, 47.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-3
Diagnosis
Diagnosis Table
Refer to “Diagnosis Table” in Section 3.
Steering Wheel Play Check
Check steering wheel for play and rattle, holding vehicle in
straight forward condition on ground.
Steering wheel play
“a” : 10 – 30 mm (0.4 – 1.2 in.)
If play is not within specification, inspect for the following. If found
defective, replace.
Wear of tie rod end ball stud.
Wear of king pin bearing
Wear of steering shaft joint.
Loosely install or joined parts.
Wear of steering rack / sector gear.
Tie Rod And Drag Rod Check
Inspect deformation or damage. Replace any defective part.
INSPECTION
1) Inspect for play in tie rod end ball joint (1). If found defective,
replace.
2) Inspect boot (2) for tear. If even a small tear is noted, replace
with new one.

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 FRONT SUSPENSION 3D-1
6F1
6F2
6G
1A
6K
7A
7A1
3D
7F
8A
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3D
FRONT SUSPENSION
CONTENTS
General Description ....................................... 3D-2
4WD Control System .................................... 3D-2
Diagnosis ........................................................ 3D-8
Diagnosis Table ........................................... 3D-8
4WD Controller and ITS Circuit Check ....... 3D-10
4WD Control System Check ...................... 3D-11
Stabilizer bar / bushing check ................ 3D-13
Shock Absorber and/or Coil Spring
Check ......................................................... 3D-14
Leading Arm / Lateral Rod / Steering
Knuckle Check ........................................... 3D-14
Leading Arm Bushing / Lateral Rod
Bushing Check ........................................... 3D-15
Kingpin / Kingpin Bearing Check ................ 3D-15
Barfield Joint Check ................................... 3D-15
Steering Knuckle Seal Check ..................... 3D-15
Wheel Disc, Nut and Bearing Check .......... 3D-16On-Vehicle Service ...................................... 3D-17
Stabilizer Bar / Bushings ............................ 3D-17
Front Shock Absorber ................................ 3D-19
Coil Spring ................................................. 3D-19
Bump Stopper and Spring Upper Seat ...... 3D-21
Wheel Hub / Bearing / Oil Seal .................. 3D-21
Steering Knuckle / Wheel Spindle.............. 3D-28
Front Axle Shaft / Oil Seal / Kingpin
Bearing Outer Race ................................... 3D-32
Steering Knuckle Seal................................ 3D-34
Lateral Rod ................................................ 3D-35
Leading Arm / Bushing............................... 3D-36
Front Axle Housing .................................... 3D-38
Tightening Torque Specifications .............. 3D-44
Required Service Material ........................... 3D-44
Special Tool .................................................. 3D-45

WARNING:
When hoisting vehicle, be sure to select the lifting point suitable for the service work referring to Sec-
tion 0A.
NOTE:
All front suspension fasteners are an important attaching part in that it could affect the performance
of vital parts and systems, and/or could result in major repair expense. They must be replaced with
one of the same part number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as speci-
fied during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any front suspension part. Replace it with a new part or
damage to the part may result.

Downloaded from www.Manualslib.com manuals search engine 3D-2 FRONT SUSPENSION
General Description
4WD Control System
The 4WD control system consists of a 4WD switch, a vacuum switch, a vacuum tank, two vacuum switching
valves (VSV1 and VSV2) and air locking hub assemblies.
The 4WD controller controls locking or unlocking of the air locking hub according to operation of the transfer shift
control lever.
Vacuum generated in the intake manifold passes through the check valve and stored in the vacuum tank.
According to signals from the 4WD switch, the 4WD controller activates VSV1 (for unlocking) or VSV2 (for lock-
ing) to apply vacuum from the vacuum tank so that the front axle and the wheel hub are disengaged or engaged.
1. Front axle housing 3. Steering knuckle 5. Wheel spindle 7. Wheel bearing
2. Shock absorber 4. Kingpin 6. Wheel hub 8. Front axle shaft (4WD)