2005 SUZUKI JIMNY Engine belt

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Abnormal Noise Diagnosis
There are various types of noise, ranging from those produced in the engine compartment to those from the
passenger compartment, also from rumbling noises to whistling noises.
Abnormal noise from compressor
Abnormal noise from magnetic clutch
Abnormal noise from tubing
Abnormal noise from condenser
Condition Possible Cause Correction
During compressor
operation, a rumbling
noise is heard propor-
tional to engine revo-
lutions.Inadequate clearance in piston area (piston or
swash-plate).Repair or replace compressor as
necessary
A loud noise is heard
at a certain rpm, dis-
proportionately to
engine revolution.Loose or faulty compressor drive belt. Adjust drive belt tension, or replace
belt.
Loose compressor mounting bolts. Retighten mounting bolts.
A loud rattle is heard
at low engine rpm.Loose compressor clutch plate bolt. Retighten clutch plate bolt.
Replace compressor if it was oper-
ated in this condition for a long
time.
Condition Possible Cause Correction
A rumbling noise is
heard when compres-
sor is not operating.Worn or damaged bearings. Replace magnet clutch assembly.
A chattering noise is
heard when compres-
sor is engaged.Faulty clutch clearance (excessive). Adjust clutch clearance.
Worn clutch friction surface. Replace magnet clutch assembly.
Compressor oil leaked from lip type seal. Replace lip type seal.
Contaminating the friction surface. Replace compressor body assem-
bly.
Condition Possible Cause Correction
A droning noise is
heard inside vehicle,
but not particularly
noticeable in engine
compartment.Faulty tubing clamps. Reposition clamps or increase the
number of clamps.
Resonance caused by pulsation from variations
in refrigerant pressure.Attach a silencer to tubing, or mod-
ify its position and length.
Condition Possible Cause Correction
Considerable vibra-
tion in condenser.Resonance from condenser bracket and body. Firmly insert a silencer between
condenser bracket and body.

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Compressor Drive Belt
INSPECTION
Check belt for wear and cracks, and replace as required.
Check belt tension by measuring how much it deflects when
pushed at intermediate point between compressor pulley (1)
and crankshaft pulley (2) with about 100 N (10 kg, 22 lb)
force.
If belt tension is out of above specification, adjust belt ten-
sion according to the following procedures.
Deflection of compressor drive belt
“a” : 6 – 9 mm (0.24 – 0.35 in.)
ADJUSTMENT
For Vehicle With P/S
1) Loosen tension pulley bolts (3) and set hexagon wrench (4)
to hexagon hole.
2) Turn tension pulley (5) counterclockwise by hexagon wrench
in order to obtain above specified tension.
3) Tighten tension pulley bolts (3) to specified torque.
Tightening torque
Tension pulley bolts
(a) : 25N·m (2.5 kg-m, 18.0 lb-ft)
For Vehicle Without P/S
1) Loosen tension pulley tightening nut (6).
2) Adjust belt tension by tighten or loosen tension pulley adjust-
ing bolt (7) in order to obtain above specified tension.
3) Tighten tension pulley tightening nut (6).
[A] : Vehicle with P/S
[B] : Vehicle without P/S

Downloaded from www.Manualslib.com manuals search engine 1B-40 AIR CONDITIONING (OPTIONAL)
4) Remove compressor drive belt (1) as follows.
For vehicle with P/S
Loosen tension pulley bolts (2).
For vehicle without P/S
Loosen tension pulley tightening nut (3) and adjusting bolt
(4).
5) Disconnect thermal switch connector.
6) Disconnect suction and discharge hoses from compressor.
7) Remove compressor (1) from its bracket (2).
INSTALLATION
Reverse removal procedure for installation, and then noting the
following instructions.
Replenish specified amount of compressor oil to compressor
suction side by referring to “Replenishing Compressor Oil” in
this section.
Evacuate and charge system by referring to “Recovery” in
this section.
Adjust drive belt tension by referring to “Compressor Drive
Belt” in this section.
[A] : Vehicle with P/S
[B] : Vehicle without P/S
NOTE:
Cap open fittings immediately to keep moisture out of
system.
NOTE:
If compressor is replaced, drain oil from removed com-
pressor. And then, measure its amount.

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

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Tire Diagnosis
Irregular and/or Premature Wear
Irregular and premature wear has many possible causes. Some
of them are: incorrect inflation pressures lack of tire rotation, driv-
ing habits, improper alignment.
If the following conditions are noted rotation is in order:
Front tire wear is different from rear.
Uneven wear exists across the tread of any tire.
Left front and right front tire wear is unequal.
Left rear and right rear tire wear is unequal.
There is cupping, flat spotting, etc.
A wheel alignment check is in order if the following conditions are
noted:
Left front and right front tire wear is unequal.
Wear is uneven across the tread of any front tire.
Front tire treads have scuffed appearance with “feather”
edges on one side of tread ribs or blocks.
Wear Indicators
The original equipment tires have built-in tread wear indicators to
show when tires need replacement. These indicators will appear
as 12 mm (0.47 inch) wide bands when the tire tread depth
becomes 1.6 mm (0.063 inch). When the indicators appear in 3 or
more grooves at 6 locations, tire replacement is recommended.
Radial Tire Waddle
Waddle is side to side movement at the front and/or rear of the
vehicle. It is caused by the steel belt not being straight within the
tire. It is most noticeable at low speed, 5 to 30 mph. It is possible
to road test a vehicle and tell on which end of the vehicle the
faulty tire is located. If the waddle tire is on the rear, the rear end
of the vehicle will shake from side to side or “waddle”. From the
driver’s seat it feels as though someone is pushing on the side of
the vehicle. If the faulty tire is on the front, the waddle is more
visual. The front sheet metal appears to be moving back and forth
and the driver feels as though he is at the pivot point in the vehi-
cle. Waddle can be quickly diagnosed by using a Tire Problem
Detector (TPD) and following the equipment manufacturer’s rec-
ommendations.
If a TPD is not available, the more time consuming method of sub-
stituting known good tire / wheel assemblies on the problem vehi-
cle can be used as follows:
[A] : Hard cornering, under inflation or lack of tire rotation
[B] : Incorrect wheel alignment, tire construction not uniform or wheel heavy acceleration

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Radial Tire Lead
“Lead” is the deviation of the vehicle from a straight path on a level rod even with no pressure on the steering
wheel.
Lead is usually caused by:
1) Incorrect alignment.
2) Uneven brake adjustment.
3) Tire construction.
The way in which a tire is built can produce lead in a vehicle. An example of this is placement of the belt. Off
center belts on radial tires can cause the tire to develop a side force while rolling straight down the road. If one
side of the tire has a little larger diameter than the other, the tire will tend to roll to one side. This will develop a
side force which can produce vehicle lead.
The procedure in above figure (Lead Diagnosis) should be used to make sure that front alignment is not mis-
taken for tire lead.
1) Part of the lead diagnosis procedure is different from the proper tire rotation pattern currently in the owner
and service manuals. If a medium to high mileage tire is moved to the other side of the vehicle, be sure to
check that ride roughness has not developed.
2) Rear tires will not cause lead.
Vibration Diagnosis
Wheel unbalance causes most of the highway speed vibration problems. If a vibration remains after dynamic
balancing, its possible causes are as follows.
1) Tire runout.
2) Wheel runout.
3) Tire stiffness variation.
Measuring tire and/or wheel free runout will uncover only part of the problem. All three causes, known as loaded
radial runout, must be checked by using a Tire Problem Detector (TPD). If TPD is not available, alternative
method of substituting known good tire and wheel assemblies on the problem vehicle can be used, although it
takes a longer time.
[A] : Tire out of round 1. Smooth road
[B] : Tire stiffness variation 2. Suspension movement (loaded runout)
[C] : Rim bent or out of round

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-1
6F1
6F2
6G
6H
6K
3B1
7D
7E
7F
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B1
POWER STEERING (P/S) SYSTEM
(If equipped)
CONTENTS
General Description ......................................3B1-2
Diagnosis .......................................................3B1-3
Diagnosis Table .......................................... 3B1-3
Steering Wheel Play Check ........................ 3B1-5
Steering Force Check ................................. 3B1-5
Power Steering Belt Check ......................... 3B1-6
Power Steering Belt Tension Adjustment .... 3B1-6
Power Steering Fluid Level Check .............. 3B1-6
Idle-Up System Check ................................ 3B1-7
Power Steering Fluid Leakage Check ......... 3B1-7Air Bleeding Procedure ............................... 3B1-8
Hydraulic Pressure In P/S Circuit Check .. 3B1-10
On-Vehicle Service ..................................... 3B1-12
Power Steering Belt .................................. 3B1-12
Power Steering (P/S) Pump ...................... 3B1-12
Power Steering (P/S) Gear Box ................ 3B1-18
Tightening Torque Specifications ............. 3B1-21
Required Service Materials ........................ 3B1-21
Special Tools ............................................... 3B1-21 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. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system 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.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
All steering gear fasteners are important attaching parts in that they 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 specified dur-
ing reassembly to assure proper retention of these parts.

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.