2005 SUZUKI JIMNY bolts

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 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 3B1-18 POWER STEERING (P/S) SYSTEM (If equipped)
INSTALLATION
Install components in reverse order of removal procedure noting
the following points.
Tighten each bolt as specified below.
Tightening torque
Oil pump mounting bolts
(a) : 25 N·m (2.5 kg-m, 18.5 lb-ft)
Oil pump high pressure union bolt
(b) : 60 N·m (6.0 kg-m, 43.5 lb-ft)
Adjust P/S belt referring to “Power Steering Belt Check” in
this section.
Connect pressure switch terminal.
Power Steering (P/S) Gear Box
REMOVAL
1) Take out fluid in P/S fluid reservoir with syringe or such.
2) Turn steering wheel fully counterclockwise and loosen sector
shaft nut of P/S gear box.
3) Return steering wheel to straightforward state and remove
pitman arm from P/S gear box by using puller.
4) Remove radiator (for left-steering vehicle) referring to “Radi-
ator” in Section 6B
5) Remove radiator support member.
6) Disconnect suction hose and return hose from P/S fluid res-
ervoir, and remove P/S fluid reservoir assembly (for left-
steering vehicle).
7) Remove steering lower shaft joint bolt (2).CAUTION:
After installation, fill A/T fluid (an equivalent to
DEXRON
®-II, DEXRON®-IIE or DEXRON®-III) and be sure
to bleed air referring to “Air Bleeding Procedure” in this
section.
1. Union bolt
1. Steering lower shaft

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-21
Tightening Torque Specifications
Required Service Materials
Special Tools
Fastening partTightening torque
Nm kg-m lb-ft
Tension pulley bolt 25 2.5 18.0
Oil pump mounting bolt 25 2.5 18.5
Oil pump high pressure union bolt 60 6.0 43.5
Oil pump cover bolts 28 2.8 20.0
Pressure switch 28 2.8 20.0
Suction connector bolt 12 1.2 8.5
Power steering gear box mounting bolt
and nuts80 8.0 58.0
Gear box high pressure union bolt 35 3.5 25.5
Pitman arm mounting nut 135 13.5 98.0
Steering shaft joint bolt 25 2.5 18.5
Plug 60 6.0 43.5
MaterialRecommended SUZUKI product
(Part Number)Use
Power steering
fluidAn equivalent of DEXRON
®-II,
DEXRON
®-IIE or DEXRON®-III.To fill P/S fluid reservoir
Parts lubrication when installing
Lithium greaseSUPER GREASE (A)
(99000-25010)Oil seal lip of P/S pump pulley shaft
09915-77411 09915-77420 09944-18211 09945-35010
Oil pressure gauge Oil pressure gauge
attachment & hose setTorque check socket Air bleeding hose set

Downloaded from www.Manualslib.com manuals search engine 3C-2 STEERING WHEEL AND COLUMN
General Description
This double tube type steering column has the following three important features in addition to the steering func-
tion:
The column is energy absorbing, designed to compress in a front-end collision.
The ignition switch and lock are mounted conveniently on this column.
With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehi-
cle.
To insure the energy absorbing action, it is important that only the specified screws, bolts and nuts be used as
designated and that they are tightened to the specified torque.
When the column assembly is removed from the vehicle, special care must be taken in handling it. Use of a
steering wheel puller other than the one recommended in this manual or a sharp blow on the end of the steering
shaft, leaning on the assembly, or dropping the assembly could shear the plastic shear pins which maintain col-
umn length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver’s and passenger’s seat belts by deploying the air bags.
The air bag (inflator) module should be handled with care to prevent accidental deployment. When servicing, be
sure to observe all WARNINGS and CAUTIONS in this section and “Service Precautions” in Section 10B.
1. Driver air bag (inflator) module 6. Steering column upper cover 11. Steering lower shaft
2. Steering wheel 7. Steering column lower cover [A] : For vehicle with air bag system
3. Steering wheel side cap 8. Steering column assembly [B] : For vehicle without air bag system
4. Steering wheel nut 9. Steering lock assembly (ignition switch)
5. Combination switch or contact coil and com-
bination switch assembly10. Steering column hole cover

Downloaded from www.Manualslib.com manuals search engine 3C-4 STEERING WHEEL AND COLUMN
Drive Air Bag (Inflator) Module (For Vehicle
with Air Bag System)
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) Disable air bag system. Refer to “Disabling Air Bag System”
in Section 10B.
3) Remove steering wheel side cap (1) of left side.
4) Loosen 2 bolts (2) mounting driver air bag (inflator) module
till it turns freely, pull them out and fix them to bolt clamps (3).
5) Remove driver air bag (inflator) module (1) from steering
wheel.
6) Disconnect yellow connector (2) in order a) – b) as shown.
INSPECTION
WARNING:
When handling an air bag (inflator) module, be sure to
read “Service Precautions” given earlier in this section
and observe each instruction. Failure to follow them
could cause a damage to the air bag (inflator) module or
result in personal injury.
WARNING:
Never disassemble driver air bag (inflator) module or
measure its resistance. Otherwise, personal injury may
result.
CAUTION:
If air bag (inflator) module was dropped from a height of
90 cm (3 ft) or more, it should be replaced.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-5
Check air bag (inflator) module visually and if any of the following
is found, replace it with a new one.
Air bag being deployed
Trim cover (1) (pad surface) being cracked
Wire harness (3) or connector being damaged
Air bag (inflator) module being damaged or having been
exposed to strong impact (dropped)
INSTALLATION
1) Check that horn wire is connected to horn terminal securely.
2) Connect yellow connector (1) of driver air bag (inflator) mod-
ule (3) pushing connector till it is locked.
3) Install driver air bag (inflator) module to steering wheel, tak-
ing care so that no part of wire harness is caught between
them.
4) Make sure that clearance between module and steering
wheel is uniform all the way.
5) Tighten driver air bag (inflator) module mounting bolts (1) to
specified torque.
Tightening torque
Driver air bag (inflator) module mounting bolts
(a) : 9 N·m (0.9 kg-m, 6.5 lb-ft)
6) Install steering wheel side cap (2).
7) Connect negative battery cable.
8) Enable air bag system. Refer to “Enabling Air Bag System”
under “Service Precautions” in Section 10B.
Steering Wheel
2. Inflator case
CAUTION:
For vehicle with air bag system
Removal of the steering wheel allows the contact coil to
turn freely but do not turn the contact coil (on the combi-
nation switch) more than allowable number of turns
(about two and a half turns from the center position
clockwise or counterclockwise respectively), or coil will
break.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-9
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.