2005 SUZUKI JIMNY king

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 FRONT WHEEL ALIGNMENT 3A-3
Diagnosis
Diagnosis Table
For the details, refer to “Diagnosis Table” in Section 3.
Preliminary Checks Prior To Adjusting Front Wheel Alignment
Steering and vibration complaints are not always the result of improper alignment. An additional item to be
checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the
vehicle from a straight path on a level road without hand pressure on the steering wheel. Section 3 of this man-
ual contains a procedure for determining the presence of a tire lead problem. Before making any adjustment
affecting toe setting, the following checks and inspections should be made to ensure correctness of alignment
readings and alignment adjustments:
1) Check all tires for proper inflation pressures and approximately the same tread wear.
2) Check for loose of king pin bearings. Check tie rod ends; if excessive looseness is noted, it must be cor-
rected before adjusting.
3) Check for run-out of wheels and tires.
4) Check vehicle trim heights; if out of limits and a correction is to be made, it must be made before adjusting
toe.
5) Check for loose of suspension arms.
6) Check for loose or missing stabilizer bar attachments.
7) Consideration must be given to excess loads, such as tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment checks.
8) Consider condition of equipment being used to check alignment and follow manufacturer's instructions.
9) Regardless of equipment used to check alignment, vehicle must be on a level surface both fore and aft and
transversely.
Toe Adjustment
Toe is adjusted by changing tie rod length. Loosen right and left
tie rod end lock nuts first and then rotate tie rod to align toe-in to
specification.
In this adjustment, right and left tie rod should become equal in
length (“A”).
After adjustment, tighten lock nuts to specified torque.
Tightening torque
Tie rod end lock nuts
(a) : 65 N·m (6.5 kg-m, 47.0 lb-ft)

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Diagnosis
Diagnosis Table
Refer to “Diagnosis Table” in Section 3.
Steering Wheel Play Check
Check steering wheel for play and rattle, holding vehicle in
straight forward condition on ground.
Steering wheel play
“a” : 10 – 30 mm (0.4 – 1.2 in.)
If play is not within specification, inspect for the following. If found
defective, replace.
Wear of tie rod end ball stud.
Wear of king pin bearing
Wear of steering shaft joint.
Loosely install or joined parts.
Wear of steering rack / sector gear.
Tie Rod And Drag Rod Check
Inspect deformation or damage. Replace any defective part.
INSPECTION
1) Inspect for play in tie rod end ball joint (1). If found defective,
replace.
2) Inspect boot (2) for tear. If even a small tear is noted, replace
with new one.

Downloaded from www.Manualslib.com manuals search engine 3B-8 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
Tie Rod And Drag Rod
REMOVAL
1) Hoist vehicle and remove wheel (s).
2) Remove tie rod end nut from steering knuckle.
3) Mark (3) one end of tie rod before removing the rod as
shown in figure to distinguish the correct installing direction
easy.
4) Disconnect tie rod end (2) from knuckle (1), using special
tool.
Special tool
(A) : 09913-65210
5) For ease of adjustment after installation, make marking (3) of
tie rod end lock nut position on tie rod thread. Then loosen
lock nut (2) and remove tie rod end (1) from tie rod.
INSTALLATION
1) Install tie rod end lock nut (2) and tie rod end (1) to tie rod
and/or drag rod. Align lock nut with mark (3) on tie rod
thread.

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.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-1
6F1
6F2
6G
6H
6K
7A
3C
7E
7F
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3C
STEERING WHEEL AND COLUMN
CONTENTS
General Description ....................................... 3C-2
Diagnosis ........................................................ 3C-3
Inspection and Repair Required
After Accident ............................................... 3C-3
On-Vehicle Service......................................... 3C-3
Service Precautions (For Vehicle with
Air Bag System) ........................................... 3C-3
Diagnosis and servicing ........................... 3C-3
Disabling air bag system .......................... 3C-3
Enabling air bag system ........................... 3C-3
Handling and storage ............................... 3C-3
Disposal.................................................... 3C-3
Drive Air Bag (Inflator) Module (For Vehicle
with Air Bag System) .................................... 3C-4
Steering Wheel ............................................. 3C-5Centering contact coil (for vehicle with
air bag system)......................................... 3C-8
Combination Switch (For Vehicle without
Air Bag System)/Contact Coil and
Combination Switch Assembly (For Vehicle
with Air Bag System).................................... 3C-9
Steering Column Assembly........................ 3C-11
Steering Lock Assembly
(Ignition Switch) ......................................... 3C-15
Steering Lower Shaft ................................. 3C-16
Checking Steering Column for Accident
Damage ......................................................... 3C-18
Tightening Torque Specifications .............. 3C-19
Required Service Material ........................... 3C-19
Special Tool .................................................. 3C-19

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem components or wiring. Failure to follow WARNINGS could result in unintentional activation of
the system or could render the system inoperative. Either of these two conditions may result in
severe injury.
The procedures in this section must be followed in the order listed to temporarily disable the air
bag system and prevent false diagnostic codes from setting. Failure to follow procedures could
result in possible air bag system activation, personal injury or otherwise unneeded air bag system
repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-3
Diagnosis
For maintenance service of the steering wheel and column, refer to “Steering System Inspection” in Section 0B.
For diagnosis of the steering wheel and column, refer to “Diagnosis Table” in Section 3.
For diagnosis of the air bag system, refer to “Air Bag Diagnosis System Check Flow Table” in Section 10B.
Inspection and Repair Required After Accident
For vehicle without air bag system
After an accident, be sure to perform checks, inspections and repairs described under “Checking Steering
Column for Accident Damage” in this section.
For vehicle with air bag system
After an accident, whether the air bag has been deployed or not, be sure to perform checks, inspections and
repairs described under “Checking Steering Column for Accident Damage” in this section as well as
“Repairs and Inspections Required after Accident” under “Diagnosis” in Section 10B.
On-Vehicle Service
Service Precautions (For Vehicle with Air Bag System)
Refer to “Service Precautions” in Section 10B.
Diagnosis and servicing
Refer to “Diagnosis and Servicing” in Section 10B.
Disabling air bag system
Refer to “Disabling Air Bag System” in Section 10B.
Enabling air bag system
Refer to “Enabling Air Bag System” in Section 10B.
Handling and storage
Refer to “Handling and Storage” in Section 10B.
Disposal
Refer to “Disposal” in Section 10B.