2005 SUZUKI JIMNY body

Downloaded from www.Manualslib.com manuals search engine 3A-2 FRONT WHEEL ALIGNMENT
General Description
Front alignment refers to the angular relationship between the
front wheels, the front suspension attaching parts and the ground.
Generally, the only adjustment required for front wheel alignment
is toe setting.
Camber and caster can’t be adjusted. Therefore, should camber
or caster be out of specification due to the damage caused by
hazardous road conditions or collision, whether the damage is in
body or in suspension should be determined. If the body is dam-
aged, it should be repaired and if suspension is damaged, it
should be replaced.
Toe Setting
Toe is the turning in or out of the front wheels. The purpose of a
toe specification is to ensure parallel rolling of the front wheels
(Excessive toe-in or toe-out may increase tire wear).
Toe-in
“B” – “A” : 2 – 6 mm (0.08 – 0.24 in.)
For adjusting toe setting, refer to “Toe Adjustment” in this section.
Camber
Camber is the tilting of the front wheels from the vertical, as
viewed from the front of the vehicle. When the wheels tilt outward
at the top, the camber is positive. When the wheels tilt inward at
the top, the camber is negative. The amount of tilt is measured in
degrees.
Camber
“C” : 0° 30’ ± 1°
Alignment Service Data (Reference)
Caster
: 1° 55’ ± 1° NOTE:
Toe-in value was measured by using a toe-in gauge.
[A]: Wheel top view
1. Forward
“A”
“B”1 [A]
1. Body center [A]: Front view
2. Center line of wheel
2
1
90
o
C [A]

Downloaded from www.Manualslib.com manuals search engine 3A-4 FRONT WHEEL ALIGNMENT
Camber And Caster Check And Adjustment
Should camber or caster be found out of specifications upon
inspection, locate its cause first. If it is in damaged, loose, bent,
dented or worn suspension parts and axle housing, they should
be replaced. If it is in vehicle body, repair it so as to attain specifi-
cations.
Steering Angle Check And Adjustment
When tie rod (2) or tie rod end (3) was replaced, check toe and
then also steering angle with turning radius gauge (1).
If steering angle is not correct, check if right and left tie rods are
equal in length “A”.
Steering angle
Inside : 35° ± 3°
Outside : 32° ± 3°
Side Slip(Reference)
For inspecting front wheel side slip with side slip tester:
If side slip exceeds limit, toe or front wheel alignment may out not
be correct.
Side slip limit
: Less than 3 mm/m (Less than 0.118 in/3 ft) NOTE:
To prevent possible incorrect reading of camber or
caster, vehicle front end must be moved up and down a
few times before inspection.
NOTE:
If tie rod lengths were changed to adjust steering angle,
reinspect toe-in.

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 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.

Downloaded from www.Manualslib.com manuals search engine 3B1-16 POWER STEERING (P/S) SYSTEM (If equipped)
7) Apply power steering fluid to sliding surface of cam ring (1).
8) Install cam ring (1) to pump body. The tapered end of cam
ring (1) should face the side plate (2).
9) Apply power steering fluid to each vane (2).
10) Install vanes (10 pipes) (2) to rotor (1).
11) Apply power steering fluid to O-ring (1) and fit it to pump
body.
12) Install O-ring (1) to pump body.
13) Apply power steering fluid to sliding surface of pump cover
(1) and rotor.
14) Match the dowel pins (2) to the holes of the cover plate as
shown and install pump cover to pump body.
15) Tighten pump cover bolts to specified torque.
Tightening torque
Oil pump cover bolts
(a) : 28 N·m (2.8 kg-m, 20.0 lb-ft)
NOTE:
After installing pump cover (1), check to make sure that
shaft can be turned by hand.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-17
16) Apply power steering fluid to relief valve (flow control valve)
(1).
17) Install relief valve (flow control valve) (1) to pump body.
18) Apply power steering fluid to O-ring of plug (3).
19) Install O-ring to plug (3).
20) Tighten plug to specified torque.
Tightening torque
Plug
(a) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
21) Apply power steering fluid to O-rings of pressure switch (1).
22) Install O-rings to pressure switch (1).
23) Install pressure switch (1) to pump body.
Tightening torque
Pressure switch
(a) : 28 N·m (2.8 kg-m, 20.0 lb-ft)
24) Apply power steering fluid to O-ring (2) of suction connector
(1).
25) Install O-ring (2) to suction connector (1).
26) Install suction connector (2) to pump body as shown in fig-
ure. Tighten suction connector bolt (3) to specified torque.
Tightening torque
Suction connector bolt
(a) : 12 N·m (1.2 kg-m, 8.5 lb-ft) NOTE:
Check that relief valve (flow control valve) slides
smoothly.
2. Flow control valve spring
1. P/S pump

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-13
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.

Downloaded from www.Manualslib.com manuals search engine 3C-16 STEERING WHEEL AND COLUMN
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.