2005 SUZUKI JIMNY Steering pump

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-5
Maintenance Service
Engine
Drive Belt
WATER PUMP AND GENERATOR DRIVE BELT INSPEC-
TION
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace.
Check belt for tension.
Water pump and generator belt tension
“a”: 4.5 – 5.5 mm (0.18 – 0.22 in.) deflection under 100 N
(10 kg, 22 lb) pressure
3) If belt is too tight or too loose, adjust it to specification by
adjusting alternator position.
4) Tighten alternator adjusting bolts and pivot bolt.
5) Connect negative cable to battery.
REPLACEMENT
Replace belt. Refer to “Water Pump Belt and Cooling Fan” in Sec-
tion 6B for replacement procedure of pump belt.
POWER STEERING PUMP AND/OR A/C COMPRESSOR
DRIVE BELTS INSPECTION (IF EQUIPPED)
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace. WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
NOTE:
When replacing belt with a new one, adjust belt tension
to 3 – 4 mm (0.12 – 0.16 in.).

Downloaded from www.Manualslib.com manuals search engine 0B-6 MAINTENANCE AND LUBRICATION
3) Check belt for tension.
Power steering pump and/or A/C compressor drive belt
tension
“a”: 6 – 9 mm (0.24 – 0.35 in.) deflection under 100 N
(10 kg, 22 lb) pressure.
4) If belt tension is out of above specification, adjust it referring
to “Compressor Drive Belt” in Section 1B or “Power Steering
Belt Check” in Section 3B1.
5) Connect negative cable to battery.
REPLACEMENT
Replace belt with new one referring to “Compressor Drive Belt” in
Section 1B or “Power Steering Belt Check” in Section 3B1.
Valve Lash
INSPECTION
1) Inspect intake and exhaust valve lash and adjust as neces-
sary.
Refer to “Valve Lash (Clearance)” in Section 6A1 for valve
lash inspection and adjustment procedure.
Engine Oil and Filter
CHANGE
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.
1. P/S pump pulley
2. Camshaft pulley
3. A/C compressor pulley (if equipped)
4. Belt tension pulley
1. Camshaft
2. Thickness gauge
WARNING:
 New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
 Step 1) – 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

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Power Steering (P/S) System (if equipped)
INSPECTION
1) Visually check power steering system for fluid leakage and
hose for damage and deterioration.
Repair or replace defective parts, if any.
2) With engine stopped, check fluid level indicated on fluid tank
or level gauge of tank cap, which should be between MAX
and MIN marks. If it is lower than MIN, fill fluid up to MAX
mark.
3) Visually check pump drive belt for cracks and wear.
4) Check belt for tension, referring to “Drive Belt” in this section.
If necessary, have belt adjusted or replaced.
All Hinges, Latches and Locks
DOORS INSPECTION
Check that each door of front and back doors opens and closes
smoothly and locks securely when closed.
If any malfunction is found, lubricate hinge and latch or repair
door lock system.
ENGINE HOOD INSPECTION
Check that secondary latch operates properly (check that sec-
ondary latch keeps hood from opening all the way even when pull-
ing hood release handle inside vehicle.) Also check that hood
opens and closes smoothly and properly and hood locks securely
when closed.
If any malfunction is found, lubricate hinge and latch, or repair
hood lock system. Check hood latch bolt for tightness.
Tightening torque
Hood latch bolts
10 N·m (1.0 kg-m, 7.5 lb-ft)
NOTE:
 Be sure to use an equivalent of DEXRON
®-II,
DEXRON
®-IIE or DEXRON®-III for P/S fluid.
 Fluid level should be checked when fluid is cool.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-1
6F1
6F2
6G
6H
6K
3B1
7D
7E
7F
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B1
POWER STEERING (P/S) SYSTEM
(If equipped)
CONTENTS
General Description ......................................3B1-2
Diagnosis .......................................................3B1-3
Diagnosis Table .......................................... 3B1-3
Steering Wheel Play Check ........................ 3B1-5
Steering Force Check ................................. 3B1-5
Power Steering Belt Check ......................... 3B1-6
Power Steering Belt Tension Adjustment .... 3B1-6
Power Steering Fluid Level Check .............. 3B1-6
Idle-Up System Check ................................ 3B1-7
Power Steering Fluid Leakage Check ......... 3B1-7Air Bleeding Procedure ............................... 3B1-8
Hydraulic Pressure In P/S Circuit Check .. 3B1-10
On-Vehicle Service ..................................... 3B1-12
Power Steering Belt .................................. 3B1-12
Power Steering (P/S) Pump ...................... 3B1-12
Power Steering (P/S) Gear Box ................ 3B1-18
Tightening Torque Specifications ............. 3B1-21
Required Service Materials ........................ 3B1-21
Special Tools ............................................... 3B1-21 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 3B1-2 POWER STEERING (P/S) SYSTEM (If equipped)
General Description
The power steering system in this vehicle reduces the driver’s effort needed in turning the steering wheel by uti-
lizing the hydraulic pressure generated by the power steering (P/S) pump which is driven by the engine. It is an
integral type with the mechanical gear unit, hydraulic pressure cylinder unit and control valve unit all housed in
the gear box.
1. Steering gear box 2. Power steering (P/S) pump 3. P/S fluid reservoir
1. Power steering gear box 3. Spool valve 5. P/S fluid reservoir
2. Control valve section 4. Power steering (P/S) pump

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-3
Diagnosis
Diagnosis Table
Condition Possible Cause Correction
Steering wheel feels
heavy
(at low speed)Fluid deteriorated, low viscosity, different type of
fluid mixedChange fluid.
Pipes or hoses deformed, air entering through
jointCorrect or replace.
Insufficient air bleeding from piping Bleed air.
Belt worn, lacking in tension Adjust belt tension or replace belt
as necessary.
Tire inflation pressure too low Inflate tire.
Wheel alignment out of adjustment Adjust front wheel alignment.
Steering wheel installed improperly (twisted) Install steering wheel correctly.
Hydraulic pressure failing to rise (See NOTE
“A”.)Replace P/S pump.
Slow hydraulic pressure rise (See NOTE “A”.)
Steering wheel feels
heavy momentarily
when turning it to the
left or right.Air drawn in due to insufficient amount of fluid Add fluid and bleed air.
Slipping belt Adjust belt tension or replace belt
as necessary.
No idle-up (See NOTE
“B”.)Defective pressure switch Replace pressure switch
(terminal set).
NOTE:
“A” : Be sure to warm up engine fully before performing this check. Pump vanes are sometimes
hard to come out where temperature is low.
“B” : Acceptable if idling speed does not drop.
Condition Possible Cause Correction
Steering wheel returns
slowly from turns.
(See NOTE “C”.)Dust or foreign object mixed in fluid Change fluid.
Deformed pipes or hoses Correct or replace.
Steering column installed improperly Install correctly.
Wheel alignment maladjusted Adjust.
Linkage or joints not operating smoothly Correct.
Vehicle pulls to one
side during straight
driving.Low or uneven tire inflation pressure Inflate tire (s) as necessary.
Wheel alignment maladjusted Adjust.
Defective spool valve Replace gear box assembly.
Steering wheel play is
large and vehicle wan-
ders.Loose steering shaft nut Retighten.
Loose linkage or joint Retighten.
Loose gear box fixing bolt Retighten.
Front wheel bearing worn Replace.
Fluid leakage
Loose joints of hydraulic pressure pipes and
hosesRetighten.
Deformed or damaged pipes or hoses Correct or replace.
Gear box Replace gear box assembly.

Downloaded from www.Manualslib.com manuals search engine 3B1-4 POWER STEERING (P/S) SYSTEM (If equipped)
Abnormal noise
(See NOTE “D”.)Air drawn in due to insufficient fluid Replenish fluid.
Air drawn in through pipe or hose joints Retighten or replace.
Belt slipping (loose) Adjust.
Worn belt Replace.
Loose steering linkage Retighten.
Loose gear box fixing bolt Retighten.
Loose pitman arm Retighten.
Pipes or hoses in contact with chassis Correct.
Defective pump vane Replace pump assembly.
Malfunction of flow control valve Replace gear box assembly.
Defective pump shaft bearing Replace pump assembly. Condition Possible Cause Correction
NOTE:
“C” : Turn steering wheel 90° at 35 km/h (22 mile/h) and let it free. If it returns more than 60° then, it
is normal.
“D” : Some hissing noise may be heard through steering column when turning steering wheel with
vehicle halted. It is from operation of the valve in the gear box and indicates nothing abnormal.

Downloaded from www.Manualslib.com manuals search engine 3B1-6 POWER STEERING (P/S) SYSTEM (If equipped)
Power Steering Belt Check
INSPECTION
Check that belt is free from any damage and properly fitted
in pulley groove.
Check belt tension by measuring how much it deflects when
pushed at mid-point between pulley with about 10 kg (22 lb)
force.
Deflection of oil pump belt
“a” : 6 – 9 mm (0.25 – 0.35 in.)
Power Steering Belt Tension Adjustment
1) Loosen tension pulley bolts (3) and set hexagon wrench to
hexagon hole (5).
2) Turn tension pulley counterclockwise by hexagon wrench in
order to obtain above specification.
3) Tighten tension pulley bolts to specified torque.
Tightening torque
Tension pulley bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Power Steering Fluid Level Check
With engine stopped check fluid level indicated on P/S fluid reser-
voir (1) or level gauge (3), which should be between MAX and
MIN marks. If it is lower than lower limit (MIN), replenish fluid up
to upper limit (MAX) mark.
1. P/S pump pulley 4. A/C compressor pulley (if equipped)
2. Crank pulley
CAUTION:
Make sure to use an equivalent of DEXRON
®-II,
DEXRON
®-IIE or DEXRON®-III for P/S fluid.
Fluid level should be checked when fluid is cool before
starting engine.
2. Cap