2005 SUZUKI JIMNY Steering assembly

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4) From the position where contact coil became unable to turn
any further (it stopped), turn it back clockwise about two and
a half rotations and align center mark with alignment mark
(1).
Combination Switch (For Vehicle without Air
Bag System)/Contact Coil and Combination
Switch Assembly (For Vehicle with Air Bag
System)
REMOVAL
1) Remove steering wheel from steering column referring to
“Steering Wheel” in this section.
2) Remove steering column hole cover (1).
3) Remove steering column cover standard screw (1) and tap-
ping screws (2).
4) Loosen steering column mounting bolts and nuts referring to
“Steering Column” in this section.
5) Separate upper cover (3) and lower cover (4), then remove
them.
6) Disconnect all connectors for combination switch/contact coil
and combination switch assembly.
CAUTION:
For vehicle with air bag system
Do not turn contact coil (on combination switch) more
than allowable number of turns (about two and a half
turns from the center position clockwise or counter-
clockwise respectively), or coil will break.

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7) Remove combination switch/contact coil and combination
switch assembly (1) from steering column.
INSPECTION
For vehicle with air bag system
Check contact coil and combination switch wire harness for
any signs of scorching, melting or other damage. If it is dam-
aged, replace.
INSTALLATION
1) Check to make sure that vehicle’s front tires are set at
straight-ahead position and then ignition switch is at “LOCK”
position.
2) Install combination switch/contact coil and combination
switch assembly to steering column.
3) Connect all connectors that have been disconnected in
“REMOVAL”.
4) Install steering column upper (3) and lower cover (4), and
then tighten steering column cover standard screw (1) and
tapping screws (2).
1. Contact coil and combination switch assembly
2. To horn
3. Connector to driver air bag (inflator) module
4. Connector to air bag wire harness
NOTE:
For vehicle with air bag system
New contact coil and combination switch assembly is
supplied with contact coil set and held at its center posi-
tion with a lock pin (2) and seal (1). Remove this lock pin
after installing contact coil and combination switch
assembly to steering column.
CAUTION:
When installing lower cover (3) and upper cover (2), be
careful so that combination switch/contact coil and com-
bination switch lead wirer is not caught between covers.

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5) Tighten steering column mounting nuts and bolts by hand
and then tighten mounting nuts (1) first, and then tighten
mounting bolts (2).
Tightening torque
Steering column mounting bolts and nuts
(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
6) Install steering column hole cover (1).
7) Install steering wheel to steering column referring to “Steer-
ing Wheel” in this section.
Steering Column Assembly
CAUTION:
Once the steering column is removed from the vehicle,
the column is extremely susceptible to damage.
Dropping the column assembly on its end could col-
lapse the steering shaft or loosen the plastic shear
pins which maintain column length.
Leaning on the column assembly could cause it to
bend or deform.
Any of the above damage could impair the column’s col-
lapsible design.
NOTE:
When servicing steering column or any column-mounted
component, remove steering wheel. But when removing
steering column simply to gain access to instrument
panel components, leave steering wheel installed on
steering column.

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REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) For vehicle equipped with air bag system, disable air bag
system referring to “Disabling Air Bag System” in Section
10B.
3) If necessary, remove steering wheel and combination switch
assembly referring to “Steering Wheel” and “Combination
switch/Contact Coil and Combination Switch Assembly” in
this section.
If not removing steering wheel and/or combination switch
assembly, perform the following procedure.
a) Turn steering wheel so that vehicle’s front tires are at
straight ahead position.
b) Turn ignition switch to “LOCK” position and remove key.
4) Remove steering column hole cover (1).
5) Disconnect all connectors of the following parts.
Combination switch/contact coil and combination switch
assembly.
Ignition switch.
Immobilizer control system parts (if equipped).
6) Remove joint bolt (steering column side) (3) and loosen joint
bolt (steering gear box side).
7) Remove steering column mounting nuts (2) and bolts (1).WARNING:
For vehicle with air bag system
Never rest a steering column assembly on the steering
wheel with the air bag (inflator) module face down and
column vertical. Otherwise, personal injury may result.

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8) If equipped with shift (key) interlock cable (1), remove shift
(key) interlock cable screw (2) and then disconnect its cable
from ignition switch in order a) – c) as shown in the figure.
9) Remove steering column from vehicle.
10) Remove steering column seal (1) from steering column lower
bracket.
INSPECTION
CHECKING PROCEDURE
1) Check that two capsules (1) are attached to steering column
bracket (2) securely. Check clearance between capsules and
steering column bracket. Clearance should be 0.0 mm (0.0
in.) on both sides.
If found loose or clearance, replace steering column assem-
bly.
2) Check two plates (3) for any damages such as crack or
breakage.
If anything is found faulty, replace as steering column
assembly.
CAUTION:
Don’t separate double tube type steering column assem-
bly into steering column and shaft. If column or shaft is
defective, replace as and assembly.
NOTE:
Vehicles involved in accidents resulting in body damage,
where steering column has been impacted (or air bag
deployed), may have a damaged or misaligned steering
column.

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3) Take measurement “a” as shown.
If it is shorter than specified length, replace column assem-
bly (1) with new one.
Steering column assembly length
“a” : 733.2 – 734.8 mm (28.87 – 28.93 in.)
4) Check steering shaft joints and shaft for any damages such
as crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as lower joint assembly or
column assembly.
5) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
6) Check steering shaft and column for bend, cracks or defor-
mation.
If found defective, replace.
7) Check steering column lower seal (1) for breakage or defor-
mation. If found defective, replace.
INSTALLATION
1) Be sure that front wheels and steering wheel are in straight
forward state.
2) If equipped, install shift (key) interlock cable to ignition
switch.
3) Apply sealant to the steering column lower bracket (shaded
section in the figure) and fit the steering column seal (1) to
the stepped part of the steering column lower bracket
securely.
“A” : Sealant 99000-31090
CAUTION:
After tightening steering column mounting bolts and
nuts shaft joint bolts should be tightened.

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4) Insert steering lower shaft (1) to steering shaft.
5) Put the steering column upper cover (3) on top of the steer-
ing column (2), if necessary and then tighten steering col-
umn mounting nuts (5) and bolts (4) by hand.
6) Tighten mounting nuts (5) first and then mounting bolts (4) to
specified torque.
Tightening torque
Steering column mounting bolts and nuts
(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
7) Tighten steering column side joint bolt (1) first, and then
tighten steering gear box side joint bolt (2).
Tightening torque
Steering shaft joint bolts (b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
8) If combination switch is removed, install combination switch
referring to “Combination Switch/Contact Coil and Combina-
tion Switch Assembly” in this section.
9) Connect all connectors that have been removed in
“removal”.
10) Install steering column hole cover (1).
11) If steering wheel is removed, install steering wheel referring
to “Steering Wheel” in this section.
12) If the vehicle equipped with air bag system, enable air bag
system referring to “Enabling Air Bag System” in Section
10B.
13) Connect negative battery cable.
Steering Lock Assembly (Ignition Switch)
REMOVAL
1) Remove steering column (1) referring to “Steering Column”
in this section.
2. Steering lock

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2) Loosen and remove steering lock mounting bolts (2) using
center punch (1) as shown.
3) Turn ignition key to “ACC” or “ON” position and remove
steering lock assembly from steering column.
INSTALLATION
1) Position oblong hole (1) of steering shaft in the center of hole
(3) in column (4).
2) Turn ignition key to “ACC” or “ON” position and install steer-
ing lock assembly (5) onto column (4).
3) Now turn ignition key to “LOCK” position and pull it out.
4) Align hub on lock with oblong hole (1) of steering shaft and
rotate shaft to assure that steering shaft (2) is locked.
5) Tighten new bolts until head of each bolt is broken off.
6) Turn ignition key to “ACC” or “ON” position and check to be
sure that steering shaft rotates smoothly. Also check for lock
operation.
7) Install steering column referring to “Steering Column” in this
section.
Steering Lower Shaft
REMOVAL
1) Turn steering wheel so that vehicle’s front tires are at
straight-ahead position.
2) Turn ignition switch to “LOCK” position and remove key. NOTE:
Use care not to damage aluminum part of steering lock
body with center punch.
CAUTION:
For vehicle with air bag system
Never turn steering wheel while steering shaft lower joint
is removed.
Should it have been turned and contact coil (on combina-
tion switch) have got out of its centered position, it needs
to be centered again. Also, turning steering wheel more
than about two and a half turns will break contact coil.