2005 SUZUKI JIMNY service

Downloaded from www.Manualslib.com manuals search engine 3E-16 REAR SUSPENSION
7) Install rear axle shaft to rear axle housing (2) and tighten
brake back plate nuts (4) to specified torque.
Tightening torque
Brake back plate nuts
(a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
8) Connect brake pipe (3) to wheel cylinder and tighten brake
pipe flare nut to specified torque.
Tightening torque
Brake pipe flare nut
(b) : 16 N·m (1.6 kg-m, 11.5 lb-ft)
9) Tighten wheel speed sensor bolt to specified torque (if
equipped with ABS).
Tightening torque
Wheel speed sensor bolt
(c) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
10) Install parking brake cable (3) to brake back plate (1).
11) Install brake shoes, referring to “Brake Shoe” in Section 5.
12) Install brake drum. Refer to “Rear Brake Drum” in Section 5.
13) Refill differential housing with new specified gear oil. Refer to
“Maintenance Service” in Section 7E for refill.
14) Fill reservoir with brake fluid and bleed brake system. (For
bleeding operation, refer to “Bleeding Brakes” in Section 5.)
15) Install wheel and tighten wheel nuts to specified torque.
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.5 lb-ft) NOTE:
When installing rear axle shaft, be careful not to cause
damage to oil seal lip in axle housing (2).
1. Wheel speed sensor
2. Cable stopper ring

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 WHEELS AND TIRES 3F-1
6F1
6F2
6G
3F
8A
8B
8C
8B
8C
8D
8E
9
10
10A
10B
SECTION 3F
WHEELS AND TIRES
CONTENTS
General Description ........................................ 3F-2
Tires .............................................................. 3F-2
Wheels .......................................................... 3F-2
Replacement Tires ........................................ 3F-2
Replacement Wheels ................................ 3F-3
How To Measure Wheel Runout ............... 3F-3
Metric Lug Nuts and Wheel Studs ............. 3F-3
Diagnosis ......................................................... 3F-4
Diagnosis Table ............................................ 3F-4
Balancing Wheels ......................................... 3F-4
General Balance Procedure .......................... 3F-4
Off-vehicle balancing ................................. 3F-4
On-vehicle balancing ................................. 3F-4
Maintenance and Minor Adjustments ........... 3F-6Wheel and Tire.............................................. 3F-6
Studs ......................................................... 3F-6
Matched tires and wheels
(For vehicle equipped with steel
wheels) ...................................................... 3F-6
Inflation of Tires ............................................ 3F-6
Tire placard ............................................... 3F-7
Tire rotation ............................................... 3F-7
On-Vehicle Service ......................................... 3F-8
Wheel ............................................................ 3F-8
Tire ................................................................ 3F-9
Mounting and demounting......................... 3F-9
Repair........................................................ 3F-9

NOTE:
All wheel 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 replace-
ment part of lesser quality or substitute design. Torque values must be used as specified during reas-
sembly to assure proper retention of all parts.
There is to be no welding as it may result in extensive damage and weakening of the metal.

Downloaded from www.Manualslib.com manuals search engine 3F-8 WHEELS AND TIRES
On-Vehicle Service
Wheel
REMOVAL
1) Loosen wheel nuts by approximately 180° (half a rotation).
2) Hoist vehicle.
3) Remove wheel.
INSTALLATION
Wheel nuts must be tightened in sequence and to proper torque
to avoid bending wheel or brake drum or disc as shown.
Tightening order
: “A”–“B”–“C”–“D”–“E”
Tightening torque
Wheel nuts
(a) : 95 N·m (9.5 kg-m, 69.0 lb-ft) CAUTION:
Never use heat to loosen tight wheel because application
of heat to wheel can shorten life of wheel and damage
wheel bearings.
NOTE:
Before installing wheels, remove any build-up of corro-
sion on wheel mounting surface and brake drum or disc
mounting surface by scraping and wire brushing. Install-
ing wheels without good metal-to-metal contact at
mounting surfaces can cause wheel nuts to loosen,
which can later allow wheel to come off while vehicle is
moving.

Downloaded from www.Manualslib.com manuals search engine PROPELLER SHAFTS 4B-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
4B
8D
8E
9
8E
9
10
10A
10B
SECTION 4B
PROPELLER SHAFTS
CONTENTS
General Description ....................................... 4B-2
Components ................................................. 4B-2
Diagnosis ........................................................ 4B-2
Diagnosis Table ........................................... 4B-2
Propeller Shaft Joint Check .......................... 4B-2
On-Vehicle Service......................................... 4B-3Propeller Shafts ........................................... 4B-3
Universal Joint ............................................. 4B-5
Tightening Torque Specification .................. 4B-7
Required Service Material ............................. 4B-7
Special Tool .................................................... 4B-8

NOTE:
All propeller shaft fasteners are an important attaching part in that it 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 speci-
fied during reassembly to assure proper retention of this part.
Never attempt to heat, quench or straighten any propeller shaft part. Replace it with a new part, or
damage to the part may result.

Downloaded from www.Manualslib.com manuals search engine PROPELLER SHAFTS 4B-3
On-Vehicle Service
Propeller Shafts
REMOVAL
1) Hoist vehicle.
2) Drain transmission oil only when servicing propeller shaft
No. 1.
3) Before removing propeller shaft (2), give match marks (1) on
each joint flange (3) and propeller shaft (2) as shown.
4) Remove propeller shaft(s).
INSPECTION
Inspect propeller shaft and flange yoke for damage, and propeller
shaft for runout.
If damage is found or shaft runout exceeds its limit, replace.
Propeller shaft runout limit : 0.8 mm (0.031 in.)

Downloaded from www.Manualslib.com manuals search engine PROPELLER SHAFTS 4B-7
3) Insert bearing race into opposite side of shaft yoke until it is
flush with side face of shaft yoke, tapping it by a copper
hammer.
4) In the same way as Step 2) to Step 3), insert bearing races
into flange yoke.
5) Using round bar of 22 – 24 mm (0.87 in. – 0.94 in.) in diame-
ter and hammer, tap bearing races into shaft or flange yoke
until circlips can be installed in its groove on yoke bores.
6) Install 4 circlips in each groove on shaft and flange yoke
bores.
Tightening Torque Specification
Required Service Material
NOTE:
After reassembly, ensure that both shaft yoke and
flange yoke move smoothly.
Make sure that each circlip is fitted in groove securely.
Fastening portionTightening torque
Nm kg-m lb-ft
Propeller shaft bolt (propeller shaft No.1 No.2 and No.3 rear dif-
ferential side)50 5.0 36.5
Propeller shaft bolt (propeller shaft No.3 transfer case side) 33 3.3 24
MaterialRecommended SUZUKI product
(Part Number)Use
Lithium greaseSUPER GREASE C
(99000-25030)To apply to spider bearing race and propel-
ler shaft No.2 and No.3 splines.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
5
9
10
10A
10B
9
10
10A
10B
SECTION 5
BRAKES
CONTENTS
General Description ......................................... 5-3
Diagnosis .......................................................... 5-4
Road Testing Brakes ...................................... 5-4
Brake Fluid Leaks .......................................... 5-4
Substandard or Contaminated Brake Fluid .... 5-4
Diagnosis Table ............................................. 5-5
Brake Pedal Free Height Adjustment ............. 5-8
Brake Pedal Play Check ................................ 5-8
Stop Light Switch Adjustment ........................ 5-8
Excessive Pedal Travel Check ....................... 5-9
Front Brake Disc Check ................................. 5-9
Front Brake Pad Check .................................. 5-9
Rear Brake Shoe Check .............................. 5-10
Master Cylinder and Brake Fluid Level
Check ........................................................... 5-10
Rear Drum Brake Shoe Adjustment ............. 5-11
Parking Brake Inspection and Adjustment ... 5-11
Booster Operation Check ............................. 5-12Fluid Pressure Test
(If Equipped with LSPV) ............................... 5-15
On-Vehicle Service ........................................ 5-17
Air Bleeding of Brake System ...................... 5-17
Brake Hose and Pipe Inspection.................. 5-18
Front Disc Brake .......................................... 5-19
Brake pad ................................................. 5-20
Caliper assembly...................................... 5-22
Brake Disc.................................................... 5-26
Rear Brake ................................................... 5-29
Brake drum............................................... 5-29
Brake shoe ............................................... 5-32
Wheel Cylinder............................................. 5-33
Brake back plate ...................................... 5-34
Master Cylinder .............................................. 5-36
Master Cylinder Reservoir ........................... 5-36
Master Cylinder Assembly ........................... 5-37 WARNING:
For lifting point of vehicle, refer to Section 0A.
WARNING:
For vehicles equipped with Supplement 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 the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E first.
All brake 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
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
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.