2005 SUZUKI JIMNY bolt

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 3B1-6 POWER STEERING (P/S) SYSTEM (If equipped)
Power Steering Belt Check
INSPECTION
Check that belt is free from any damage and properly fitted
in pulley groove.
Check belt tension by measuring how much it deflects when
pushed at mid-point between pulley with about 10 kg (22 lb)
force.
Deflection of oil pump belt
“a” : 6 – 9 mm (0.25 – 0.35 in.)
Power Steering Belt Tension Adjustment
1) Loosen tension pulley bolts (3) and set hexagon wrench to
hexagon hole (5).
2) Turn tension pulley counterclockwise by hexagon wrench in
order to obtain above specification.
3) Tighten tension pulley bolts to specified torque.
Tightening torque
Tension pulley bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Power Steering Fluid Level Check
With engine stopped check fluid level indicated on P/S fluid reser-
voir (1) or level gauge (3), which should be between MAX and
MIN marks. If it is lower than lower limit (MIN), replenish fluid up
to upper limit (MAX) mark.
1. P/S pump pulley 4. A/C compressor pulley (if equipped)
2. Crank pulley
CAUTION:
Make sure to use an equivalent of DEXRON
®-II,
DEXRON
®-IIE or DEXRON®-III for P/S fluid.
Fluid level should be checked when fluid is cool before
starting engine.
2. Cap

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 3B1-12 POWER STEERING (P/S) SYSTEM (If equipped)
On-Vehicle Service
Power Steering Belt
REMOVAL
1) Disconnect negative cable at battery.
2) Loosen tension pulley bolts (2).
3) Remove power steering belt (1).
INSPECTION
Check power steering belt for wear and cracks, and replace
as required.
INSTLLATION
1) Install belt to power steering pump pulley (1), crankshaft pul-
ley (2), A/C pulley (if equipped) (3) and tension pulley (4).
2) Adjust belt tension referring to “Power Steering Belt Check”
in this section.
Power Steering (P/S) Pump
REMOVAL
1) Take out fluid in P/S fluid reservoir with syringe or such.
2) Remove P/S belt.
3) Disconnect high pressure hose and low pressure hose.
4) Disconnect pressure switch lead harness.

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