2005 SUZUKI JIMNY check oil

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-3
Diagnosis
Diagnosis Table
Refer to “Diagnosis Table” in Section 3.
Rear Shock Absorber Check
Inspect for deformation or damage.
Inspect bushings for wear or damage.
Inspect for evidence of oil leakage.
Replace any defective part.
Trailing Arm, Lateral Rod, Axle Housing and
Coil Spring Check
Inspect for cracks, deformation or damage.
Replace any defective part.
Trailing Arm and Lateral Rod Bush Check
Inspect for wear and breakage. If found defective, replace.WARNING:
When handling rear shock absorber in which high-pres-
sure gas is sealed, make sure to observe the following
precautions.
Don’t disassemble it.
Don’t put it into the fire.
Don’t store it where it gets hot.
Before disposing it, be sure to drill a hole in it where
shown by an arrow in the figure and let gas and oil out.
Lay it down sideways for this work.
The gas itself is harmless but it may issue out of the
hole together with chips generated by the drill. There-
fore, be sure to wear goggle.
A : Drill hole with approximately 3 mm (0.12 in.) diameter.

Downloaded from www.Manualslib.com manuals search engine 3E-4 REAR SUSPENSION
Rear Suspension Fasteners
Check each bolt and nut fastening suspension parts for tightness.
Tighten loose one, if any, to specified torque, referring to “Tighten-
ing Torque Specifications” of this section.
Bearing Retainer and Axle Shaft Oil Seal
Check
When brake drum has been removed, check inside of brake
drum for gear oil leakage.
Also, check backside of brake back plate for oil leakage.If oil
leakage is found, replace defective oil seal.
Whenever it is possible to check oil seal during disassembly,
check its lip for wear.
If oil leakage or worn lip is found, replace defective oil seal.
Bump Stopper and Spring Rubber Seat Check
Inspect for wear and breakage. If found defective, replace.
Wheel Disc, Nut and Bearing Check
Inspect each wheel disc for dents, distortion and cracks. A
disc in badly damaged condition must be replaced.
Check wheel hub nuts for tightness and, as necessary,
retighten to specification.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft)

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-17
16) Upon completion of all jobs, depress brake pedal with about
30 kg (66 lbs) load over ten times so as to obtain proper
drum-to shoe clearance.
Adjust parking brake cable. (For adjustment, refer to “Parking
Brake Check and Adjustment” in Section 5.)
17) Tighten parking brake lever cover screws.
18) Check to ensure that brake drum is free from dragging and
proper braking is obtained. Then remove vehicle from hoist
and perform brake test (foot brake and parking brake).
19) Check each installed part for oil leakage.
Rear Axle Shaft Inner Oil Seal
REMOVAL
1) Remove rear axle shaft. For details, refer to “Rear Axle Shaft
and Wheel Bearing” in this section.
2) Remove rear axle shaft inner oil seal by using special tools.
Special tool
(A) : 09942-15510
(B) : 09944-96010 (remover)
(C) : 09921-26010 (collar)
INSTALLATION
1) Using special tools drive in oil seal (1) until it contacts oil seal
protector (2) in axle housing.
Special tool
(A) : 09913-75520
“A” : Grease 99000-25010
2) For procedure hereafter, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
NOTE:
Make sure that oil seal (1) is free from inclination as it
is installed.
Refer to figure so that oil seal (1) is installed in proper
direction.
3. Differential side

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-21
11) Connect brake flexible hose (2) to bracket on axle housing
and secure it with E-ring (1).
12) Connect brake pipe to brake flexible hose and tighten brake
pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut
(a) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
13) Clean mating surface of axle housing (2) (right & left) with
brake back plate and apply sealant as shown.
“B” : Sealant 99000-31090
14) Apply grease to axle shaft oil seals lip (1) (right & left) as
shown.
“A” : Grease 99000-25010
15) Install rear axle shafts, brake shoes, brake drums and
wheels. For details, refer to “Rear Axle Shaft and Wheel
Bearing” in this section.
16) Lower hoist.
17) Tighten right and left trailing arm nuts and shock absorber
lower bolts to specified torque.
Tighten lateral rod bolt and nut to specified torque.
Tightening torque
Trailing arm nuts and lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Shock absorber lower bolts
(b) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
18) Check to ensure that brake drum is free from dragging and
proper braking is obtained.
19) Perform brake test (foot brake and parking brake). (For
brake test, see Section 5.)
20) Check each installed part for oil leakage.
NOTE:
When tightening these bolts and nuts, be sure that vehi-
cle is off hoist and in non loaded condition.
1. Shock absorber
2. Trailing arm
3. Lateral rod

Downloaded from www.Manualslib.com manuals search engine 5-4 BRAKES
Diagnosis
Road Testing Brakes
Brakes should be tested on dry, clean, smooth and reasonably level roadway which is not crowned. Road test
brakes by making brake applications with both light and heavy pedal forces at various speeds to determine if the
vehicle stops evenly and effectively.
Also drive vehicle to see if it leads to one side or the other without brake application. If it does, check the tire
pressure, front end alignment and front suspension attachments for looseness. See diagnosis table for other
causes.
Brake Fluid Leaks
Check the master cylinder fluid levels. While a slight drop in reservoir level does result from normal lining wear,
an abnormally low level indicates a leak in the system. In such a case, check the entire brake system for leak-
age. If even a slight evidence of leakage is noted, the cause should be corrected or defective parts should be
replaced.
If fluid level is lower than the minimum level of reservoir, refilling is necessary. Fill reservoir with specified brake
fluid.
Brake fluid: Refer to reservoir tank cap.
Substandard or Contaminated Brake Fluid
Improper brake fluid, mineral oil or water in the fluid may cause the brake fluid to boil or the rubber components
in the hydraulic system to deteriorate.
If primary piston cups are swollen, then rubber parts have deteriorated. This deterioration may also be evi-
denced by swollen wheel cylinder piston cups on the drum brake wheels.
If deterioration of rubber is evident, disassemble all hydraulic parts and wash with alcohol. Dry these parts with
compressed air before assembly to keep alcohol out of the system. Replace all rubber parts in the system,
including hoses. Also, when working on the brake mechanisms, check for fluid on the linings. If excessive fluid is
found, replace the linings.
If master cylinder piston seals are satisfactory, check for leakage or excessive heat conditions. If condition is not
found, drain fluid, flush with brake fluid, refill and bleed the system.
The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used
which contained parts that have been subjected to contaminated fluid.CAUTION:
Since brake system of this vehicle is factory-filled with brake fluid indicated on reservoir tank cap, do
not use or mix different type of fluid when refilling; otherwise serious damage will occur.
Do not use old or used brake fluid, or any fluid from a unsealed container.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-5
Diagnosis Table
Condition Possible Cause Correction
Not enough braking
forceBrake oil leakage from brake lines Locate leaking point and repair.
Brake disc or pads stained with oil Clean or replace.
Overheated brakes Determine cause and repair.
Poor contact of shoes on brake drum Repair for proper contact.
Brake shoes linings stained with oil or wet with
waterReplace.
Badly worn brake shoe linings Replace.
Defective wheel cylinders Repair or replace.
Malfunctioning caliper assembly Repair or replace.
Air in system Bleed system.
Maladjusted sensor spring length of LSPV Check or adjust.
Broken sensor spring of LSPV Replace.
Defective collar of LSPV Replace.
Malfunctioning ABS (Antilock brake system), if
equippedCheck system and replace as nec-
essary.
Brake pull (Brakes not
working in unison)Pad or shoe linings are wet with water or
stained with oil in some brakesReplace.
Drum-to-shoe clearance out of adjustment in
some brakes (Malfunctioning auto adjusting
mechanism)Check for inoperative auto adjusting
mechanism.
Drum is out of round in some brakes Replace.
Wheel tires are inflated unequally Inflate equally.
Malfunctioning wheel cylinders Repair or replace.
Disturbed front wheel alignment Adjust as prescribed.
Unmatched tires on same axle Tires with approximately the same
amount of tread should be used on
the same axle.
Restricted brake tubes or hoses Check for soft hoses and damaged
lines.
Replace with new hoses and new
double-walled steel brake tubing.
Malfunctioning caliper assembly Check for stuck or sluggish pistons
and proper lubrication of caliper
slide bush.
Loose suspension parts Caliper should slide.
Check all suspension mountings.
Loose calipers Check and torque bolts to specifica-
tions.
Noise (high pitched
squeak without brake
applied)Front lining worn out Replace brake pads.
Rear brake locked pre-
maturelyMaladjusted sensor spring length of LSPV Check or adjust.
Malfunctioning LSPV assembly Replace assembly.
Brake locked
(For vehicles
equipped with ABS)Malfunctioning ABS, if equipped Check system and replace as nec-
essary.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-11
Rear Drum Brake Shoe Adjustment
Rear brake has self-adjusting mechanism but it does require
adjustment for proper drum to shoe clearance when brake shoe
has been replaced or brake drum has been removed for some
other service.
Adjustment is automatically accomplished by depressing brake
pedal about 30 times with approximately 30 kg (66 Ibs) load after
all parts are installed.
Then check brake drum for dragging and brake system for proper
performance. After lowering vehicle from hoist, brake test should
be performed.
Parking Brake Inspection and Adjustment
INSPECTION
Hold center of parking brake lever grip and pull it up with 20 kg
(44 Ibs) force.
With parking brake lever pulled up as above, count ratchet
notches.
There should be 6 to 8 notches.
Also, check if both right and left rear wheels are locked firmly. To
count number of notches easily, listen to click sounds that ratchet
makes while pulling parking brake lever without pressing its but-
ton.
One click sound corresponds to one notch.NOTE:
Be sure to use particular brake fluid either as indicated
on reservoir cap of that vehicle or recommended in
owner’s manual which comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked
on reservoir.
When brake warning lamp lights sometimes during driv-
ing, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake system for
leakage.
Correct leaky points and then refill to specified level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has
been used for mineral oil or a container which is wet from
water. Mineral oil will cause swelling and distortion of
rubber parts in hydraulic brake system and water mixed
into brake fluid will lower fluid boiling point. Keep all fluid
containers capped to prevent contamination.

Downloaded from www.Manualslib.com manuals search engine 5-26 BRAKES
3) Install brake flexible hose (4) as shown and torque hose
mounting bolt (3) to specification.
Tightening torque
Front brake flexible hose bolt
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
4) Install wheel and torque wheel nuts to specification.
5) After completing installation, fill reservoir with brake fluid and
bleed brake system. Perform brake test and check each
installed part for oil leakage.
Brake Disc
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove caliper assembly by loosening carrier bolts (2 pcs).
3) Pull brake disc off by using 8 mm bolts (1) (2 pcs).
1. Brake caliper
2. Washer
CAUTION:
During removal, be careful not to damage brake flexible
hose and not to depress brake pedal.