2005 SUZUKI JIMNY Gear box

Downloaded from www.Manualslib.com manuals search engine 3B1-2 POWER STEERING (P/S) SYSTEM (If equipped)
General Description
The power steering system in this vehicle reduces the driver’s effort needed in turning the steering wheel by uti-
lizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an
integral type with the mechanical gear unit, hydraulic pressure cylinder unit and control valve unit all housed in
the gear box.
1. Steering gear box 2. Power steering (P/S) pump 3. P/S fluid reservoir
1. Power steering gear box 3. Spool valve 5. P/S fluid reservoir
2. Control valve section 4. Power steering (P/S) pump

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) 3B1-7
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 POWER STEERING (P/S) SYSTEM (If equipped) 3B1-9
3) After running engine at idling speed for 3 to 5 seconds, stop
it and add fluid up to specified level. Repeat this step a few
times.
4) Set steering gear box (1) to state [A] as shown.
5) With engine running at idling speed, turn input shaft by using
special tool in both directions as far as it locks till all foams
are gone.
Special tool
(B) : 09944-18211
6) Perform Step 5) but with steering gear box in state [B] this
time and then in state [C].
7) Set input shaft at neutral position (straight position).
8) Remove (special) tools and install steering gear box to vehi-
cle and P/S pipe / hose to steering gear box referring to
“Power Steering (P/S) Gear Box” in this section.
9) Bleed air in P/S system referring to “Air Bleeding Procedure”
in this section.
10) Install pitman arm and steering lower shaft to steering gear
box. NOTE:
Don’t operate steering system for this step.
NOTE:
Add fluid into P/S fluid reservoir whenever its level
lowers while servicing.
Turn input shaft till it locks, return it a little and turn it
again in the same direction till it locks. Repeat this
some times.
NOTE:
To change of state of gear box from [A] to [B] and from
[B] to [C], turn gear box in arrow direction in figures [A]
and [B].
NOTE:
As input shaft makes 4 full turns from lock to lock, neu-
tral position is obtained by turning it till it locks and turn-
ing it back by 2 full turns.
2. Vinyl tube (See-through tube)
NOTE:
Don’t install pitman arm and steering lower shaft to
steering gear box.
Installation of these parts will cause input shaft and/or
sector shaft to turn, allowing air to enter gear box.
Plug up opening after pipe or hose disconnection.

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