2005 SUZUKI JIMNY bolts

Downloaded from www.Manualslib.com manuals search engine 3D-40 FRONT SUSPENSION
19) Lower floor jack until tension of suspension coil spring
becomes a little loose and remove right and left sides lower
mounting bolt of shock absorber (1).
20) Remove front mounting bolts of leading arm.
21) Lower front axle housing gradually.
22) Remove axle housing.
INSTALLATION
1) Place rear axle housing on floor jack. Then install leading
arm front mounting bolts (right & left) in proper direction as
shown. At this time, mount nuts but don’t tighten them.
2) Install lower part of shock absorber (1) to right and left sides
of axle housing and install bolts (2) in proper direction as
shown in figure. At this time, mount nuts (3) but don’t tighten
them.
A : Body outside

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-41
3) Install air locking hub vacuum pipe and tighten clamp bolts to
specified torque (for 4WD).
Tightening torque
Vacuum pipe clamp bolts
(a) : 5.5 N·m (0.55 kg-m, 4.0 lb-ft)
4) Install stabilizer bar, refer to “Stabilizer Bar / Bushings” in
this section.
5) Install lateral rod (1) to vehicle body and axle housing.
Install bolts in proper direction as shown in figure.
At this time, mount bolt and nut but don't tighten them.
6) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side (for 4WD).
“A” : Sealant 99000-31110
7) Install differential carrier assembly (2) to axle housing and
tighten carrier bolts to specified torque (for 4WD).
Tightening torque
Front differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Install front propeller shaft (1) to joint flange aligning match
marks (3) and torque flange bolts to specification (for 4WD).
Tightening torque
Front propeller shaft flange bolts
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
NOTE:
For left hand steering vehicle, install lateral rod with its
bending point (2) placed to right side of vehicle.
[A] : Right hand steering vehicle
[B] : Left hand steering vehicle

Downloaded from www.Manualslib.com manuals search engine 3D-42 FRONT SUSPENSION
9) Install right and left axle shafts to axle housing (for 4WD).
Install knuckle to axle housing (for 2WD).
10) Install kingpins (2) and knuckle seal cover (1) to steering
knuckle (R&L), refer to “Steering Knuckle / Wheel Spindle” in
this section.
11) Install right and left brake disc and caliper assembly.
Tighten carrier bolts to specified torque.
Tightening torque
Brake caliper carrier bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
12) Connect spindle vacuum hoses to wheel spindle (for 4WD),
while aligning the match mark.
13) Install ABS wheel sensor to steering knuckle (if equipped
with ABS).
14) Install tie rod ends and drag rod end to knuckle arm (1)
(R&L). Tighten new nuts to specified torque.
Tightening torque
Tie rod end nuts and drag rod end nut (Knuckle side)
(a) : 43 N·m (4.3 kg-m, 31.5 lb-ft)
15) Install wheels and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
: 95 N·m (9.5 kg-m, 69.0 lb-ft)
16) Lower hoist.NOTE:
Place knuckle seal and retainer in axle housing before
installing axle shaft (knuckle), using care for installation
direction of knuckle seal.
NOTE:
To prevent ball stud from being rotated while tightening
tie rod end nut, tighten Nut (M12 x 1.25) to about 20 N·m
(2.0 kg-m, 14.5 Ib-ft) and remove it. Then tighten new nut
to specified torque.

Downloaded from www.Manualslib.com manuals search engine 3E-6 REAR SUSPENSION
3) Remove upper mounting bolt (2).
4) Remove lower mounting bolt (3).
5) Remove shock absorber (1).
INSTALLATION
1) Install shock absorber (1), refer to figure for proper installing
direction of bush and washer (2).
Tighten bolts (3) temporarily by hand.
2) Remove floor jack.
3) Lower hoist.
4) Tighten shock absorber bolts (3) to specified torque.
Tightening torque
Shock absorber upper and lower bolts
(a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
Coil Spring
REMOVAL
1) Hoist vehicle and remove wheel.
2) Support rear axle housing (1) by using floor jack (2).
3) Remove brake flexible hose E-ring (2).
NOTE:
Tighten lower bolt with vehicle off hoist and in non-
loaded condition.
1. Brake flexible hose

Downloaded from www.Manualslib.com manuals search engine 3E-10 REAR SUSPENSION
INSTALLATION
1) Install lateral rod to vehicle body and rear axle housing.
Tighten bolt and nut temporarily by hand.
2) Lower hoist and with vehicle in non-loaded condition, tighten
lateral rod bolt and nut to specified torque.
Tightening torque
Lateral rod bolt and nut
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Trailing Arm / Bushing
REMOVAL
1) Hoist vehicle.
2) Support rear axle housing (1) by using floor jack (2).
3) Disconnect parking brake cable clamp (1) from trailing arm.
4) Disconnect wheel speed sensor harness clamps (2) from
trailing arm (if equipped with ABS).
5) Remove trailing arm mounting bolts.
6) Remove trailing arm (1).

Downloaded from www.Manualslib.com manuals search engine 3E-12 REAR SUSPENSION
Install bushings so that either face of bushing are aligned
with housing edge of leading arm, also the length between
the aligned side end of bushing and trailing arm (1) are
within specification below.
Specification for trailing arm bushing protrusion
“a” : 8.5 – 10.5 mm (0.33 – 0.41 in.)
“b” : 6.0 – 9.0 mm (0.24 – 0.35 in.)
2) Install trailing arm (1) to vehicle body and rear axle housing,
referring to figure for proper installing direction of bolts.
3) Remove floor jack.
4) Connect wheel speed sensor harness clamps to trailing arm
(if equipped with ABS).
5) Connect parking brake cable clamp to trailing arm.
6) Lower hoist and with vehicle in non-loaded condition, tighten
trailing arm nuts to specified torque.
Tightening torque
Trailing arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
Rear Axle Shaft and Wheel Bearing
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove rear brake drum and disconnect parking brake
cable from brake back plate. For details, refer to “Brake back
plate” in Section 5.
3) Drain gear oil from rear axle housing by loosening drain plug.

Downloaded from www.Manualslib.com manuals search engine REAR SUSPENSION 3E-19
10) Loosen rear mounting nuts of trailing arm (2) but don’t
remove bolt.
11) Remove shock absorber (1) lower mounting bolt.
12) Lower floor jack until tension of suspension coil spring
becomes a little loose and remove rear mount bolts of trailing
arm.
13) Lower rear axle housing gradually.
14) Remove axle housing.
INSTALLATION
Install removed parts in reverse order of removal, noting the fol-
lowing.
1) Place rear axle housing (1) on floor jack. Then install trailing
arm (2) rear mounting bolts (right & left) in proper direction
as shown. At this time, mount nuts but don’t tighten them.
2) Install coil spring (2) (right & left) on spring seat (1) of axle
housing and raise axle housing.
3. Out side
4. Body center
NOTE:
Upper and lower diameters of coil spring (2) are differ-
ent. Bring larger diameter end at bottom and set its
open end in place on spring seat (1).
When seating coil spring (2), mate spring end with
stepped part (3) of rear axle spring seat (1) as shown.
A: Upper side (small dia.)
B: Lower side (large dia.)

Downloaded from www.Manualslib.com manuals search engine 3E-20 REAR SUSPENSION
3) Install lower part of shock absorber (1) to right and left sides
of axle housing and tighten bolts (2) temporarily by hand.
4) Install lateral rod (1) and install bolts in proper direction as
shown.
At this time, mount bolt and nut but don’t tighten them.
5) Clean mating surfaces of axle housing (1) and differential
carrier and apply sealant to housing side.
“A” : Sealant 99000-31110
6) Install differential carrier assembly (3) to axle housing and
tighten carrier bolts to specified torque.
Tightening torque
Rear differential carrier bolts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
7) Install propeller shaft (2) to joint flange aligning match marks
(1) and tighten flange bolts to specified torque.
Tightening torque
Rear propeller shaft bolts
(b) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
8) Install LSPV stay to axle housing and adjust LSPV stay posi-
tion, referring to “LSPV Assembly Inspection and Adjust-
ment” in Section 5 (if equipped with LSPV).
9) Remove floor jack from axle housing.
10) Connect brake pipes and parking brake cable onto axle
housing and clamp them securely.
For clamping positions, refer to “Rear Brake Hose / Pipe”
and “Parking Brake Cable” in Section 5.