2005 SUZUKI JIMNY All

Downloaded from www.Manualslib.com manuals search engine 3A-2 FRONT WHEEL ALIGNMENT
General Description
Front alignment refers to the angular relationship between the
front wheels, the front suspension attaching parts and the ground.
Generally, the only adjustment required for front wheel alignment
is toe setting.
Camber and caster can’t be adjusted. Therefore, should camber
or caster be out of specification due to the damage caused by
hazardous road conditions or collision, whether the damage is in
body or in suspension should be determined. If the body is dam-
aged, it should be repaired and if suspension is damaged, it
should be replaced.
Toe Setting
Toe is the turning in or out of the front wheels. The purpose of a
toe specification is to ensure parallel rolling of the front wheels
(Excessive toe-in or toe-out may increase tire wear).
Toe-in
“B” – “A” : 2 – 6 mm (0.08 – 0.24 in.)
For adjusting toe setting, refer to “Toe Adjustment” in this section.
Camber
Camber is the tilting of the front wheels from the vertical, as
viewed from the front of the vehicle. When the wheels tilt outward
at the top, the camber is positive. When the wheels tilt inward at
the top, the camber is negative. The amount of tilt is measured in
degrees.
Camber
“C” : 0° 30’ ± 1°
Alignment Service Data (Reference)
Caster
: 1° 55’ ± 1° NOTE:
Toe-in value was measured by using a toe-in gauge.
[A]: Wheel top view
1. Forward
“A”
“B”1 [A]
1. Body center [A]: Front view
2. Center line of wheel
2
1
90
o
C [A]

Downloaded from www.Manualslib.com manuals search engine FRONT WHEEL ALIGNMENT 3A-3
Diagnosis
Diagnosis Table
For the details, refer to “Diagnosis Table” in Section 3.
Preliminary Checks Prior To Adjusting Front Wheel Alignment
Steering and vibration complaints are not always the result of improper alignment. An additional item to be
checked is the possibility of tire lead due to worn or improperly manufactured tires. “Lead” is the deviation of the
vehicle from a straight path on a level road without hand pressure on the steering wheel. Section 3 of this man-
ual contains a procedure for determining the presence of a tire lead problem. Before making any adjustment
affecting toe setting, the following checks and inspections should be made to ensure correctness of alignment
readings and alignment adjustments:
1) Check all tires for proper inflation pressures and approximately the same tread wear.
2) Check for loose of king pin bearings. Check tie rod ends; if excessive looseness is noted, it must be cor-
rected before adjusting.
3) Check for run-out of wheels and tires.
4) Check vehicle trim heights; if out of limits and a correction is to be made, it must be made before adjusting
toe.
5) Check for loose of suspension arms.
6) Check for loose or missing stabilizer bar attachments.
7) Consideration must be given to excess loads, such as tool boxes. If this excess load is normally carried in
vehicle, it should remain in vehicle during alignment checks.
8) Consider condition of equipment being used to check alignment and follow manufacturer's instructions.
9) Regardless of equipment used to check alignment, vehicle must be on a level surface both fore and aft and
transversely.
Toe Adjustment
Toe is adjusted by changing tie rod length. Loosen right and left
tie rod end lock nuts first and then rotate tie rod to align toe-in to
specification.
In this adjustment, right and left tie rod should become equal in
length (“A”).
After adjustment, tighten lock nuts to specified torque.
Tightening torque
Tie rod end lock nuts
(a) : 65 N·m (6.5 kg-m, 47.0 lb-ft)

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.

Downloaded from www.Manualslib.com manuals search engine 3B-2 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
General Description
1. Steering gear box 5. Tie rod 9. Worm shaft 13. Sector shaft
2. Pitman arm 6. Steering lower shaft 10. Ball 14. Rack gear
3. Drag rod 7. Steering wheel 11. Ball nut
4. Knuckle arm 8. Steering upper shaft 12. Gear case

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-3
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 3B-4 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
Steering Gear Box Oil Level Check
Oil surface should be up to the level as shown in figure. If not, add
prescribed gear oil, SAE 90.
Steering gear box oil level
“a” : 23 mm (0.91 in.)
Apply sealant to thread parts of breathing plug and tighten breath-
ing plug to specified torque.
(A) : Sealant 99000-31110
Tightening torque
Breathing plug
(a) : 4 N·m (0.4 kg-m, 3.0 lb-ft)
Adjustment of Worm Shaft Starting Torque
Steering gear box has adjusting bolt (1) which gives preload to
sector shaft.
Special tool
(A) : 09944-18211
MAKE ADJUSTMENT ACCORDING TO FOLLOWING PRO-
CEDURE.
1) Check worm shaft (1) to ensure that it is free from thrust
play.
2) Position pitman arm (2) in nearly parallel with worm shaft (1)
as shown. (With pitman arm (2) in this position, front wheels
are in straightforward state.)

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3) Measure worm shaft starting torque from its position in
straight forward state as described in Step 2).
Starting Torque for Worm shaft
(a) : 50 – 100 N·cm (5.0-10.0 kg-cm, 0.4-0.7 lb-ft)
Special tool
(A) : 09944-18211

If measured torque is not within specification, carry out adjust-
ment with adjusting bolt (1) to meet specification and check to
confirm it again.
Tightening torque
Steering gear box adjusting bolt lock nut
(a) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
4) If worm shaft starting torque is checked all right, another
check should be carried out on worm shaft operating torque
in its entire operating range (by turning worm shaft all the
way to the right and left).
Worm Shaft (Including sector shaft) Operating Torque
(a) : Under 120 N·cm (12.0 kg-cm, 10.9 lb-ft)
Special tool
(A) : 09944-18211
If measured torque does not conform to specification, readjust
worm shaft starting torque in straightforward state by means of
adjusting bolt (1), and then recheck worm shaft operating torque.
Tightening torque
Steering gear box adjusting bolt lock nut
(b) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
If specified value is not attained even after readjustment, it is
advisable to replace gear box with new gear box assembly.
1. Adjusting bolt
2. Lock nut

Downloaded from www.Manualslib.com manuals search engine 3B-6 STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE
On-Vehicle Service
Steering Gear Box
REMOVAL
1) Remove steering lower shaft joint bolt (2).
2) Remove drag rod end nut from pitman arm (1).
3) Disconnect drag rod end (2) from pitman arm (1), using spe-
cial tool.
Special tool
(A) : 09913-65210
4) Remove radiator support member.
5) Remove steering gear box bolts, and remove steering gear
box (1).
6) Remove pitman arm mounting nut (4).
7) Make match marks (3) on pitman arm (1) and sector shaft
(2), for a guide during reinstallation.
8) Remove pitman arm (1) by using puller.