2005 SUZUKI JIMNY steering wheel

Downloaded from www.Manualslib.com manuals search engine 3C-18 STEERING WHEEL AND COLUMN
Checking Steering Column for Accident Damage
CHECKING PROCEDURE
1) Check that two capsules (1) are attached to steering column
bracket (2) securely. Check clearance between capsules (1)
and steering column bracket (2). Clearance should be 0.0
mm (0.0 in.) on both sides.
If found loose or clearance, replace steering column assem-
bly.
2) Check two plates (3) for any damages such as crack or
breakage.
If anything is found faulty, replace as steering column assem-
bly.
3) Take measurement “a” as shown.
If it is shorter than specified length, replace column assem-
bly (1) with new one.
Steering column assembly length
“a” : 733.2 – 734.8 mm (28.87 – 28.93 in.)
4) Check if steering lower shaft (1) is with in specified length.
If it is out of specified length, replace it with new one.
Steering lower shaft length
“b” : 478.3 – 480.3 mm (18.83 – 18.91 in.)
(For LH steering vehicle without P/S system)
438.3 – 440.3 mm (17.26 – 17.33 in.)
(For RH steering vehicle without P/S system)
393.6 – 395.6 mm (15.50 – 15.57 in.)
(For LH steering vehicle with P/S system)
434.2 – 436.2 mm (17.09 – 17.17 in.)
(For RH steering vehicle with P/S system)
5) Check steering column lower seal (1) for breakage or defor-
mation.
If found defective, replace. NOTE:
Vehicles involved in accidents resulting in body damage, where steering column has been impacted
(or air bag deployed) may have a damaged or misaligned steering column.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-19
6) Check steering shaft joints and shaft for any damages such
as crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as lower joint assembly or
column assembly.
7) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
8) Check steering shaft and column for bend, cracks or defor-
mation.
If found defective, replace.
Tightening Torque Specifications
Required Service Material
Special Tool
Fastening partTightening torque
Nm kg-m lb-ft
Driver air bag (inflator) module bolts 9 0.9 6.5
Steering shaft nut 33 3.3 23.5
Steering column mounting bolts and nuts 14 1.4 10.5
Steering shaft joint bolts 25 2.5 18.0
Material Recommended SUZUKI product Use
Water tight sealant SEALING COMPOUND 366E
(99000-31090)To apply to steering column seal.
Lithium grease SUZUKI GREASE CE-T
(99000-25290)Contact plate
09944-36011
Steering wheel remover

Downloaded from www.Manualslib.com manuals search engine 3C-20 STEERING WHEEL AND COLUMN

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-1
6F1
6F2
6G
1A
6K
7A
7A1
3D
7F
8A
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3D
FRONT SUSPENSION
CONTENTS
General Description ....................................... 3D-2
4WD Control System .................................... 3D-2
Diagnosis ........................................................ 3D-8
Diagnosis Table ........................................... 3D-8
4WD Controller and ITS Circuit Check ....... 3D-10
4WD Control System Check ...................... 3D-11
Stabilizer bar / bushing check ................ 3D-13
Shock Absorber and/or Coil Spring
Check ......................................................... 3D-14
Leading Arm / Lateral Rod / Steering
Knuckle Check ........................................... 3D-14
Leading Arm Bushing / Lateral Rod
Bushing Check ........................................... 3D-15
Kingpin / Kingpin Bearing Check ................ 3D-15
Barfield Joint Check ................................... 3D-15
Steering Knuckle Seal Check ..................... 3D-15
Wheel Disc, Nut and Bearing Check .......... 3D-16On-Vehicle Service ...................................... 3D-17
Stabilizer Bar / Bushings ............................ 3D-17
Front Shock Absorber ................................ 3D-19
Coil Spring ................................................. 3D-19
Bump Stopper and Spring Upper Seat ...... 3D-21
Wheel Hub / Bearing / Oil Seal .................. 3D-21
Steering Knuckle / Wheel Spindle.............. 3D-28
Front Axle Shaft / Oil Seal / Kingpin
Bearing Outer Race ................................... 3D-32
Steering Knuckle Seal................................ 3D-34
Lateral Rod ................................................ 3D-35
Leading Arm / Bushing............................... 3D-36
Front Axle Housing .................................... 3D-38
Tightening Torque Specifications .............. 3D-44
Required Service Material ........................... 3D-44
Special Tool .................................................. 3D-45

WARNING:
When hoisting vehicle, be sure to select the lifting point suitable for the service work referring to Sec-
tion 0A.
NOTE:
All front suspension 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 front suspension part. Replace it with a new part or
damage to the part may result.

Downloaded from www.Manualslib.com manuals search engine 3D-2 FRONT SUSPENSION
General Description
4WD Control System
The 4WD control system consists of a 4WD switch, a vacuum switch, a vacuum tank, two vacuum switching
valves (VSV1 and VSV2) and air locking hub assemblies.
The 4WD controller controls locking or unlocking of the air locking hub according to operation of the transfer shift
control lever.
Vacuum generated in the intake manifold passes through the check valve and stored in the vacuum tank.
According to signals from the 4WD switch, the 4WD controller activates VSV1 (for unlocking) or VSV2 (for lock-
ing) to apply vacuum from the vacuum tank so that the front axle and the wheel hub are disengaged or engaged.
1. Front axle housing 3. Steering knuckle 5. Wheel spindle 7. Wheel bearing
2. Shock absorber 4. Kingpin 6. Wheel hub 8. Front axle shaft (4WD)

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-15
Leading Arm Bushing / Lateral Rod Bushing
Check
Inspect for damage, wear or deterioration.
If defective, replace.
Kingpin / Kingpin Bearing Check
1) Inspect for wear or deterioration.
2) Inspect for crack, damage or deformation of kingpin.
If defective, replace.
Barfield Joint Check
To be checked on this joint is its axial play, which shows up when
a push-and-pull motion is given to live axle shaft and wheel spin-
dle held in both hands, as shown in figure. There should be no
play at all but a play of up to 1.5 mm (0.06 in.) is permissible. If
play exceeds service limit, replace it.
Axial play in barfield joint
Steering Knuckle Seal Check
The knuckle seal used at the spherical sliding joint between the
knuckle and the inner case accomplishes the additional purposes
of keeping out road dust and of acting as the damper for the
steering handwheel. As the wear of this seal advances, its damp-
ing effect decreases and thus make the front wheel develop a ten-
dency to “shimmy” not only that road dust begins to creep into the
sliding clearance to promote the wear of the spherical sliding sur-
faces.
Check the knuckle seal for wear or damage. If defective, replace
with new one.
Standard Service Limit
0 mm (no play) 1.5 mm (0.06 in.)

Downloaded from www.Manualslib.com manuals search engine 3D-28 FRONT SUSPENSION
Steering Knuckle / Wheel Spindle
REMOVAL
1) Hoist vehicle and remove wheel.
2) Remove wheel hub assembly, refer to “Wheel Hub / Bearing /
Oil Seal” in this section.
3) Disconnect spindle vacuum hoses (1) from wheel spindle (for
4WD).
4) Remove disc dust cover (1) and wheel spindle (2).
5) Remove tie rod end (and drag rod end) nut(s) and discon-
nect tie rod end (and drag rod end) (2) from steering knuckle
(1) with special tool.
Special tool
(A) : 09913-65210
6) Remove knuckle seal cover bolts. Then remove knuckle seal
cover (1), knuckle seal and knuckle seal retainer from
knuckle. CAUTION:
Give match mark to each spindle vacuum hoses before
removing hose.

Downloaded from www.Manualslib.com manuals search engine FRONT SUSPENSION 3D-29
7) Remove lower and upper kingpins (1).
8) Remove steering knuckle (1).
9) Remove knuckle seal cover (1), knuckle seal (2) and knuckle
seal retainer (3) from front axle housing (4).
10) Remove spindle oil seal by using special tool.
Special tool
(A) : 09913-50121
11) Remove spindle bushing by using special tools.
Special tool
(A) : 09917-88210
(B) : 09916-58210 NOTE:
Upper and lower kingpins (1), when removed, must be
marked off one from the other.
NOTE:
When steering knuckle (1) is pulled, lower kingpin
bearing sometimes falls off. So remove bearing while
pulling off the knuckle gradually.
Upper and lower kingpin bearings must be also
marked off one from the other.
1. Wheel spindle