2005 SUZUKI JIMNY Section 7c

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-1
6F1
6F2
6G
6H
3B
7C1
7D
7E
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B
STEERING GEAR BOX (MANUAL TYPE)
AND LINKAGE
CONTENTS
General Description ....................................... 3B-2
Diagnosis ........................................................ 3B-3
Diagnosis Table ........................................... 3B-3
Steering Wheel Play Check ......................... 3B-3
Tie Rod And Drag Rod Check ...................... 3B-3
Steering Gear Box Oil Level Check ............. 3B-4
Adjustment of Worm Shaft Starting Torque . 3B-4On-Vehicle Service ........................................ 3B-6
Steering Gear Box ....................................... 3B-6
Tie Rod And Drag Rod................................. 3B-8
Tightening Torque Specifications .............. 3B-10
Required Service Material ........................... 3B-10
Special Tools ................................................ 3B-10 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. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system 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.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM)
NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified dur-
ing reassembly to assure proper retention of these parts.

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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 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-9
2) Adjust tie rod (and/or drag rod) length to the measurement
shown in figure; then tighten tie rod end lock nuts temporarily
by finger.
Tie rod and drag rod length
Tie rod length “a” : 1132 mm (44.6 in.)
Drag rod length “a” : 864.5 mm (34.0 in.)
3) Align lock nut (3) with mark on tie rod thread and connect tie
rod end to knuckle and/or pitman arm. Tighten new nut (1) to
specified torque.
Tightening torque
Tie rod end nut
(a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)
4) Inspect for proper toe and steering angle (inside & outside).
(Refer to “Preliminary Checks Prior To Adjusting Front Align-
ment” in Section 3A).
Adjust tie rod (2) and drag rod length as required, if neces-
sary.
5) After confirming proper toe, tighten tie rod end lock nut (3) to
specified torque.
Tightening torque
Tie rod end lock nut
(b) : 65 N·m (6.5 kg-m, 47.0 lb-ft)
6) Tighten wheel nuts to specified torque and lower hoist.NOTE:
Make the length “b” of right and left tie rod end the same.
NOTE:
To prevent ball stud from being rotated while tightening
tie rod end nut (1), 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 (1) to specified torque.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-1
6F1
6F2
6G
6H
6K
3B1
7D
7E
7F
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B1
POWER STEERING (P/S) SYSTEM
(If equipped)
CONTENTS
General Description ......................................3B1-2
Diagnosis .......................................................3B1-3
Diagnosis Table .......................................... 3B1-3
Steering Wheel Play Check ........................ 3B1-5
Steering Force Check ................................. 3B1-5
Power Steering Belt Check ......................... 3B1-6
Power Steering Belt Tension Adjustment .... 3B1-6
Power Steering Fluid Level Check .............. 3B1-6
Idle-Up System Check ................................ 3B1-7
Power Steering Fluid Leakage Check ......... 3B1-7Air Bleeding Procedure ............................... 3B1-8
Hydraulic Pressure In P/S Circuit Check .. 3B1-10
On-Vehicle Service ..................................... 3B1-12
Power Steering Belt .................................. 3B1-12
Power Steering (P/S) Pump ...................... 3B1-12
Power Steering (P/S) Gear Box ................ 3B1-18
Tightening Torque Specifications ............. 3B1-21
Required Service Materials ........................ 3B1-21
Special Tools ............................................... 3B1-21 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. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system 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.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified dur-
ing reassembly to assure proper retention of these parts.

Downloaded from www.Manualslib.com manuals search engine 3B1-2 POWER STEERING (P/S) SYSTEM (If equipped)
General Description
The power steering system in this vehicle reduces the driver’s effort needed in turning the steering wheel by uti-
lizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an
integral type with the mechanical gear unit, hydraulic pressure cylinder unit and control valve unit all housed in
the gear box.
1. Steering gear box 2. Power steering (P/S) pump 3. P/S fluid reservoir
1. Power steering gear box 3. Spool valve 5. P/S fluid reservoir
2. Control valve section 4. Power steering (P/S) pump

Downloaded from www.Manualslib.com manuals search engine 3B1-8 POWER STEERING (P/S) SYSTEM (If equipped)
Air Bleeding Procedure
AIR BLEEDING FROM SYSTEM
1) Jack up the front end of vehicle and apply rigid rack.
2) Fill P/S fluid reservoir with fluid up to specified level.
3) With engine running at idling speed, add fluid up to specified
level.
4) When fluid stops reducing, stop engine and leave P/S sys-
tem as it is for about 10 minutes.
5) After running engine at idling speed for 1 minute, stop it.
6) As a final step, check to make sure that fluid is up to speci-
fied level.
7) Check steering condition and P/S system for fluid leakage.
AIR BLEEDING FROM GEAR BOX
1) Remove steering gear box from vehicle referring to “Power
Steering (P/S) Gear Box” in this section.
2) Install special tool as shown.
Special tool
(A) : 09945-35010 CAUTION:
When air bleeding is not complete, it is indicated by
foaming fluid on level gauge or humming noise from P/S
pump.
NOTE:
Bleed air from system when P/S system has been ser-
viced in any way other than replacement of steering gear
box (e.g., disconnection of piping, replacement of P/S
pump). Never operate steering system while servicing.
Or Air Bleeding from gear box must be performed.
NOTE:
Bleed air from gear box:
When steering gear box has been replaced with a new
one.
When entry of air into hydraulic circuit of steering gear
box is suspected.
1. Steering gear box 3. High pressure hose / pipe
2. Low pressure hose / pipe

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-9
3) After running engine at idling speed for 3 to 5 seconds, stop
it and add fluid up to specified level. Repeat this step a few
times.
4) Set steering gear box (1) to state [A] as shown.
5) With engine running at idling speed, turn input shaft by using
special tool in both directions as far as it locks till all foams
are gone.
Special tool
(B) : 09944-18211
6) Perform Step 5) but with steering gear box in state [B] this
time and then in state [C].
7) Set input shaft at neutral position (straight position).
8) Remove (special) tools and install steering gear box to vehi-
cle and P/S pipe / hose to steering gear box referring to
“Power Steering (P/S) Gear Box” in this section.
9) Bleed air in P/S system referring to “Air Bleeding Procedure”
in this section.
10) Install pitman arm and steering lower shaft to steering gear
box. NOTE:
Don’t operate steering system for this step.
NOTE:
Add fluid into P/S fluid reservoir whenever its level
lowers while servicing.
Turn input shaft till it locks, return it a little and turn it
again in the same direction till it locks. Repeat this
some times.
NOTE:
To change of state of gear box from [A] to [B] and from
[B] to [C], turn gear box in arrow direction in figures [A]
and [B].
NOTE:
As input shaft makes 4 full turns from lock to lock, neu-
tral position is obtained by turning it till it locks and turn-
ing it back by 2 full turns.
2. Vinyl tube (See-through tube)
NOTE:
Don’t install pitman arm and steering lower shaft to
steering gear box.
Installation of these parts will cause input shaft and/or
sector shaft to turn, allowing air to enter gear box.
Plug up opening after pipe or hose disconnection.

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.