2005 SUZUKI JIMNY front suspension

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-43
17) Tighten lateral rod (1) mounting 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)
18) Tighten right and left shock absorber lower mounting nuts
and leading arm mounting nuts to specified torque.
Tightening torque
Shock absorber lower nuts and leading arm nuts
(a) : 90 N·m (9.0 kg-m, 65.0 lb-ft)
19) Refill front axle (differential) housing with new specified gear
oil. Refer to “Maintenance Service” in Section 7E for refill.
20) Confirm front end (wheel) alignment referring to “Preliminary
Checks Prior to Adjusting Front Alignment” in Section 3A. NOTE:
When tightening bolt and nut, be sure that vehicle is off
hoist and in non loaded condition.
NOTE:
When tightening these nuts, be sure that vehicle is off
hoist and in non loaded condition.
1. Shock absorber
2. Leading arm

Downloaded from www.Manualslib.com manuals search engine 3D-44 FRONT SUSPENSION
Tightening Torque Specifications
Required Service Material
Fastening partTightening torque
Nm kg-m lb-ft
Stabilizer mount bracket bolt 20 2.0 14.5
Stabilizer ball joint nut 50 5.0 36.5
Shock absorber lock nut 29 2.9 21.0
Shock absorber lower nut 90 9.0 65.0
Brake caliper carrier bolt 85 8.5 61.5
Wheel bearing lock nut 220 22.0 160.0
Wheel bearing lock washer screw 1.5 0.15 1.0
Air locking hub bolt 48 4.8 35.0
Wheel spindle bolt 50 5.0 36.5
Kingpin bolt 25 2.5 18.0
Knuckle seal cover bolt 10 1.0 7.5
Tie-rod end nut
43 4.3 31.5
Drag-rod end nut (Knuckle side)
Lateral rod bolt and nut
90 9.0 65.0
Leading arm nut
Front differential carrier bolt 23 2.3 17.0
Front propeller shaft flange bolt 50 5.0 36.5
Wheel nut 95 9.5 69.0
Vacuum pipe clamp bolt 5.5 0.55 4.0
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium grease SUZUKI SUPER GREASE (A)
(99000-25010)Knuckle seal / axle shaft oil seal
Recess of wheel spindles
Wheel hub oil seal
Wheel bearing
Spindle thrust washer
Spindle bush (inside and flange
part)
Spindle oil seal
SUZUKI SUPER GREASE (C)
(99000-25030)Kingpin bearing
Axle shaft joint (for 4WD)
Sealant SUZUKI BOND NO. 1215
(99000-31110)Mating surfaces of wheel spindle
and knuckle
Mating surface of differential carrier
and axle housing
Sealing compound SUZUKI SEALING COMPOUND
366E
(99000-31090)Mating surface of wheel spindle and
knuckle
Kingpin
Mating surfaces of hub cap and
wheel hub

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-45
Special Tool
09917-47910 09913-50121 09913-65210 09913-75520
Vacuum pump gauge Oil seal remover Tie rod end remover Bearing installer
09951-76010 09924-74510 09942-15510 09943-35511 or 09943-
35512
Bearing installer Bearing installer handle Sliding hammer Brake drum remover
09944-66010 09944-68510 09951-16050 09944-77020
Wheel hub / knuckle oil
seal installerBearing installer attach-
mentWheel bearing tightening
toolRing nut wrench
09944-78210 09917-88210 09916-58210 09922-55131
Bearing installer support Valve guide installer
attachmentValve guide installer han-
dleBearing installer

Downloaded from www.Manualslib.com manuals search engine 3D-46 FRONT SUSPENSION
09944-66020 09913-85210 09951-16030 09951-26010
Bearing installer Oil seal installer Bush remover Bush remover plate

Downloaded from www.Manualslib.com manuals search engine 3E-22 REAR SUSPENSION
Tightening Torque Specifications
Required Service Materials
Fastening portionTightening torque
Nm kg-m lb-ft
Shock absorber upper and lower bolt 85 8.5 61.5
Bump stopper 50 5.0 36.5
Lateral rod bolt and nut
90 9.0 65.0
Trailing arm nut (Front and Rear)
Brake back plate nut 23 2.3 17.0
Brake pipe flare nut 16 1.6 11.5
Rear differential carrier bolt 23 2.3 17.0
Rear propeller shaft bolt (Differential case side) 50 5.0 36.5
Rear propeller shaft bolt (Shaft No.3 transfer case side) 33 3.3 24.0
Wheel nut 95 9.5 69.0
Wheel speed sensor bolt and harness clamp bolt 10 1.0 7.5
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium greaseSUZUKI SUPER GREASE A
(99000-25010)Oil seal lip
SealantSUZUKI BOND NO. 1215
(99000-31110)Joint seam of differential carrier and
axle housing
Water tight sealantSEALING COMPOUND 366E
(99000-31090)To apply to mating surfaces of brake
back plate and rear axle.
Gear oilFor gear oil information, refer to “Mainte-
nance Service” in Section 7E of this manual.Differential gear
(Rear axle housing)

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 5E-36 ANTILOCK BRAKE SYSTEM (ABS)
Rear Wheel Speed Sensor
OUTPUT VOLTAGE INSPECTION
Check in the same procedure as that used of front wheel speed
sensor check.
Output AC voltage at 1 to 1 1/3 rotation per second
: 100 mV or more at 38 – 49 Hz
Reference
When using oscilloscope, peak-to-peak voltage at 1 to
1 1/3 rotation per second
: 280 mV or more at 38 – 49 Hz
REMOVAL
1) Disconnect negative cable from battery.
2) Hoist vehicle.
3) Disconnect rear wheel speed sensor coupler (1).
4) Detach ABS wheel sensor wire harness from suspension
frame.
1. Left rear wheel sensor 3. Sensor ring Tightening torque
2. Trailing arm 4. Clamp bolt
2. Rear wheel sensor