2005 SUZUKI JIMNY bolt

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 3B-4 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
Steering Gear Box Oil Level Check
Oil surface should be up to the level as shown in figure. If not, add
prescribed gear oil, SAE 90.
Steering gear box oil level
“a” : 23 mm (0.91 in.)
Apply sealant to thread parts of breathing plug and tighten breath-
ing plug to specified torque.
(A) : Sealant 99000-31110
Tightening torque
Breathing plug
(a) : 4 N·m (0.4 kg-m, 3.0 lb-ft)
Adjustment of Worm Shaft Starting Torque
Steering gear box has adjusting bolt (1) which gives preload to
sector shaft.
Special tool
(A) : 09944-18211
MAKE ADJUSTMENT ACCORDING TO FOLLOWING PRO-
CEDURE.
1) Check worm shaft (1) to ensure that it is free from thrust
play.
2) Position pitman arm (2) in nearly parallel with worm shaft (1)
as shown. (With pitman arm (2) in this position, front wheels
are in straightforward state.)

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-5
3) Measure worm shaft starting torque from its position in
straight forward state as described in Step 2).
Starting Torque for Worm shaft
(a) : 50 – 100 N·cm (5.0-10.0 kg-cm, 0.4-0.7 lb-ft)
Special tool
(A) : 09944-18211

If measured torque is not within specification, carry out adjust-
ment with adjusting bolt (1) to meet specification and check to
confirm it again.
Tightening torque
Steering gear box adjusting bolt lock nut
(a) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
4) If worm shaft starting torque is checked all right, another
check should be carried out on worm shaft operating torque
in its entire operating range (by turning worm shaft all the
way to the right and left).
Worm Shaft (Including sector shaft) Operating Torque
(a) : Under 120 N·cm (12.0 kg-cm, 10.9 lb-ft)
Special tool
(A) : 09944-18211
If measured torque does not conform to specification, readjust
worm shaft starting torque in straightforward state by means of
adjusting bolt (1), and then recheck worm shaft operating torque.
Tightening torque
Steering gear box adjusting bolt lock nut
(b) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
If specified value is not attained even after readjustment, it is
advisable to replace gear box with new gear box assembly.
1. Adjusting bolt
2. Lock nut

Downloaded from www.Manualslib.com manuals search engine 3B-6 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
On-Vehicle Service
Steering Gear Box
REMOVAL
1) Remove steering lower shaft joint bolt (2).
2) Remove drag rod end nut from pitman arm (1).
3) Disconnect drag rod end (2) from pitman arm (1), using spe-
cial tool.
Special tool
(A) : 09913-65210
4) Remove radiator support member.
5) Remove steering gear box bolts, and remove steering gear
box (1).
6) Remove pitman arm mounting nut (4).
7) Make match marks (3) on pitman arm (1) and sector shaft
(2), for a guide during reinstallation.
8) Remove pitman arm (1) by using puller.

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-7
INSTALLATION
Reverse removal procedure to install steering gear box.
1) Install pitman arm (1) to sector shaft (2) of steering gear box
with match marks (3) aligned as shown in figure and torque
to specification.
Tightening torque
Pitman arm mounting nut
(a) : 135 N·m (13.5 kg-m, 98.0 lb-ft)
2) Install sector shaft (2) to steering lower shaft joint (1).
Tighten joint bolt to specified torque.
Tightening torque
Steering lower shaft joint bolt
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
3) Install steering gear box mounting bolts (2), (3) with short
bolt (3) positioned as shown in figure.
Tighten nuts and bolt to specified torque.
Tightening torque
Steering gear box mounting bolt and nuts
(a) : 80 N·m (8.0 kg-m, 58.0 lb-ft)
4) Install radiator support member.
5) Connect drag rod (2) to pitman arm (1).
Tighten new drag rod end nut to specified torque.
Tightening torque
Drag rod end nut (pitman arm side)
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
NOTE:
Align flat part (3) of sector shaft with bolt hole of lower
shaft joint as shown. Then insert sector shaft into lower
shaft joint.
2. Steering gear box
NOTE:
To prevent ball stud from being rotated while tightening
tie rod end nut, tighten Nut (M12 × 1.25) to about 20 N·m
(2.0 kg-m, 14.5 Ib-ft) and remove it.
Then tighten new nut to specified torque.

Downloaded from www.Manualslib.com manuals search engine 3B-10 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
Tightening Torque Specifications
Required Service Material
Special Tools
Fastening partTightening torque
Nm kg-m lb-ft
Steering gear box oil plug 4 0.4 3.0
Steering gear box adjusting bolt lock nut 30 3.0 22.0
Pitman arm mounting nut 135 13.5 98.0
Steering shaft joint bolt 25 2.5 18.0
Steering gear box nuts and bolt 80 8.0 58.0
Tie rod end nut and drag rod end nut
(knuckle side)43 4.3 31.5
Wheel nut 95 9.5 69.0
Tie rod end lock nut 65 6.5 47.0
Drag rod end nut (pitman arm side) 50 5.0 36.5
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant SUZUKI BOND NO. 1215
(99000-31110)Thread of oil breathing plug
09913-65210 09944-18211
Tie-rod end remover Pinion torque checking socket

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.