2005 SUZUKI JIMNY bearing

Downloaded from www.Manualslib.com manuals search engine 0B-4 MAINTENANCE AND LUBRICATION
Maintenance Recommended Under Severe Driving Conditions
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as shown in the fol-
lowing table.
Severe condition code
A : Repeated short trips
B : Driving on rough and/or muddy roads
C : Driving on dusty roads
D : Driving in extremely cold weather and/or salted roads
E : Repeated short trips in extremely cold weather
F : Leaded fuel use
G : – – – – –
H : Trailer towing (if admitted)
Severe
Condition CodeMaintenanceMaintenance
OperationMaintenance Interval
– B C D – – – –Drive belt (V-rib belt)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
A – C D E F – H Engine oil and oil filter R Every 5,000 km (3,000 miles) or 4 months
– B – – – – – –Exhaust pipe mountings IEvery 15,000 km
(9,000 miles) or 12 months
– – C – – – – –Air cleaner filter ✱1I Every 2,500 km (1,500 miles)
REvery 30,000 km
(18,000 miles) or 24 months
A B C – E F – H Spark plugsNickel spark plug R Every 10,000 km (6,000 miles) or 8 months
Iridium spark plug
REvery 30,000 km
(18,000 miles) or 24 months
– B C D – – – H Wheel bearing IEvery 15,000 km
(9,000 miles) or 12 months
– B – – – – – –Suspension bolts and nuts TEvery 15,000 km
(9,000 miles) or 12 months
– B – D E – – H Propeller shafts IEvery 15,000 km
(9,000 miles) or 12 months
– B – – E – – HManual transmission,
transfer and differential oilRFirst time only:
15,000 km (9,000 miles) or 12 months
Second time and after: Every 30,000 km
(18,000 miles) or 24 months reckoning from
0 km (0 mile) or 0 month
– B – – E – – H Automatic transmission fluid REvery 30,000 km
(18,000 miles) or 24 months
– B C D – – – –Steering knuckle seal IEvery 15,000 km
(9,000 miles) or 12 months
NOTE:
 “I”: Inspect and correct, replace or lubricate if necessary
 “R”: Replace or change
 “T”: Tighten to the specified torque

✱
✱✱ ✱1: Inspect or replace more frequently if necessary

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3) Rotate tires.
For details, refer to “Tire Rotation” in Section 3F.
WHEEL DISCS INSPECTION
Inspect each wheel disc for dents, distortion and cracks. A disc in
badly damaged condition must be replaced.
WHEEL BEARING INSPECTION
1) Check front wheel bearing for wear, damage, abnormal
noise or rattles. For details, refer to “Wheel Disc, Nut and
Bearing Check” in Section 3D.
2) Check rear wheel bearing for wear, damage, abnormal noise
or rattles. For details, refer to “Wheel Disc, Nut and Bearing
Check” in Section 3E.
Suspension System
INSPECTION
Check suspension bolts and nuts for tightness and retighten them
as necessary.
Repair or replace defective parts, if any.
FRONT
1) Check stabilizer bar (6) for damage or deformation.
2) Check bushing (8) for damage, wear or deterioration.
3) Check coil spring (1), lateral rod (5) and leading arm (3) for
deformation and damage.
4) Check lateral rod (5) and leading arm bushings for wear,
damage and deterioration.
5) Inspect absorbers (2) for evidence of oil leakage, dents or
any other damage on sleeves; and inspect anchor ends for
deterioration.
6) Inspect for cracks or deformation in spring seat.
7) Inspect for deterioration of bump stopper.NOTE:
For details of check points, refer to tables of “Tightening
Torque Specification” in Section 3D and 3E.
4. Front axle housing
7. Ball joint

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-7
Abnormal Noise Diagnosis
There are various types of noise, ranging from those produced in the engine compartment to those from the
passenger compartment, also from rumbling noises to whistling noises.
Abnormal noise from compressor
Abnormal noise from magnetic clutch
Abnormal noise from tubing
Abnormal noise from condenser
Condition Possible Cause Correction
During compressor
operation, a rumbling
noise is heard propor-
tional to engine revo-
lutions.Inadequate clearance in piston area (piston or
swash-plate).Repair or replace compressor as
necessary
A loud noise is heard
at a certain rpm, dis-
proportionately to
engine revolution.Loose or faulty compressor drive belt. Adjust drive belt tension, or replace
belt.
Loose compressor mounting bolts. Retighten mounting bolts.
A loud rattle is heard
at low engine rpm.Loose compressor clutch plate bolt. Retighten clutch plate bolt.
Replace compressor if it was oper-
ated in this condition for a long
time.
Condition Possible Cause Correction
A rumbling noise is
heard when compres-
sor is not operating.Worn or damaged bearings. Replace magnet clutch assembly.
A chattering noise is
heard when compres-
sor is engaged.Faulty clutch clearance (excessive). Adjust clutch clearance.
Worn clutch friction surface. Replace magnet clutch assembly.
Compressor oil leaked from lip type seal. Replace lip type seal.
Contaminating the friction surface. Replace compressor body assem-
bly.
Condition Possible Cause Correction
A droning noise is
heard inside vehicle,
but not particularly
noticeable in engine
compartment.Faulty tubing clamps. Reposition clamps or increase the
number of clamps.
Resonance caused by pulsation from variations
in refrigerant pressure.Attach a silencer to tubing, or mod-
ify its position and length.
Condition Possible Cause Correction
Considerable vibra-
tion in condenser.Resonance from condenser bracket and body. Firmly insert a silencer between
condenser bracket and body.

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Abnormal noise from crankshaft pulley
Abnormal noise from tension pulley
Abnormal noise from A/C evaporator
Abnormal noise from blower fan motor
Condition Possible Cause Correction
A large rattling noise
is heard at idle or sud-
den acceleration.Loosen crankshaft pulley bolt. Retighten bolt.
Condition Possible Cause Correction
Clattering noise is
heard from pulley.Worn or damaged bearing. Replace tension pulley.
Pulley cranks upon
contact.Cracked or loose bracket. Replace or retighten bracket.
Condition Possible Cause Correction
Whistling sound is
heard from A/C evapo-
rator.Depending on the combination of the interior /
exterior temperatures, engine rpm and refriger-
ant pressure, the refrigerant flowing out of the
expansion valve may, under certain conditions,
make a whistling sound.At times, slightly decreasing refrig-
erant volume may stop this noise.
Inspect expansion valve and
replace if faulty.
Condition Possible Cause Correction
Blower fan motor
emits a chirping
sound in proportion to
its speed of rotation.Worn or damaged motor brushes or commuta-
tor.Repair or replace blower fan motor.
Fluttering noise or
large droning noise is
heard from blower fan
motor.Leaves or other debris introduced from fresh air
inlet to blower fan motor.Remove debris and make sure that
the screen at fresh air inlet is intact.

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INSPECTION
Check clutch plate and clutch pulley for leaks of compressor
oil.
Check clutch bearing of compressor pulley for noise, wear
and grease leakage.
Measure resistance of magnet clutch coil (1) between mag-
net clutch lead wire (2) and compressor body assembly.
If measured resistance is not within tolerance, replace mag-
net clutch coil.
Magnet Clutch coil resistance
: 3.4 – 4.1
Ω at 20 °C (68 °F)
Check thermal switch (1) for continuity using ohmmeter.
If it is no continuity, replace thermal switch.
REMOVAL
1) Remove compressor from vehicle referring to “Compressor”
in this section.
2) Fix clutch plate (1) with special tool, and remove clutch plate
bolt (2) and washer (3).
Special tool
(A) : 09991-06020
3) Remove clutch plate (1) using special tool.
Special tool
(A) : 09991-06030

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3) Install magnet clutch.
a) Set magnet clutch squarely over clutch installation boss.
b) Place special tool onto clutch bearing.
Ensure that edge rests only on inner race of bearing.
Special tool
(A) : 09991-06010
4) Install snap ring (1) using special tool.
Special tool
(A) : 09900-06107
5) Adjust clearance between clutch plate (1) and magnet clutch
coil (2) by putting shim on compressor shaft.
Standard clearance between clutch plate and magnet
clutch coil
“a” : 0.3 – 0.6 mm (0.012 – 0.024 in.)
6) Tighten new clutch plate bolt (1) as specified torque.
Tightening torque
Clutch plate bolt
(a) : 14 N·m (1.4 kg-m, 10.5 lb-ft)
Special tool
(A) : 09991-06020
CAUTION:
Be careful not to scratch bearing seal.

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Lip Type Seal
REMOVAL
1) Remove magnet clutch referring to “Magnet Clutch” in this
section.
2) Remove front head mounting bolts (10 pcs).
3) Remove front head (1) by pushing compressor shaft (2).
4) Remove O-ring (5).
5) Remove lip type seal from front head (1) using bearing
remover (2).
INSTALLATION
1) Press-fit lip type seal (1) into front head (2) using special
tool.
Special tool
(A) : 09991-06050
1. Front head
NOTE:
Be careful not to remove cylinder (3) from compressor
body assembly (4).
CAUTION:
Do not reuse lip seal (1) once removed from compressor.

Downloaded from www.Manualslib.com manuals search engine 3-2 STEERING, SUSPENSION, WHEELS AND TIRES
General Diagnosis
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be consid-
ered when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged
parts.
3) Spin front wheel. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and/or rough wheel
bearings.
Diagnosis Table
Condition Possible Cause Correction
Vehicle Pulls (Leads)
Mismatched or uneven tires Replace tire.
Tires not adequately inflated Adjust tire pressure.
Broken or sagging springs Replace spring.
Radial tire lateral force Replace tire.
Disturbed front wheel alignment Check and adjust wheel alignment.
Disturbed rear wheel alignment Check and adjust wheel alignment.
Brake dragging in one road wheel Repair front brake.
Loose, bent or broken front or rear suspension
partsTighten or replace suspension part.
Abnormal or
Excessive Tire WearSagging or broken springs Replace spring.
Tire out of balance Adjust balance or replace tire.
Disturbed front wheel alignment Check wheel alignment.
Faulty shock absorber Replace shock absorber.
Hard driving Replace tire.
Overloaded vehicle Replace tire.
Not rotating tire Replace or rotate tire.
Worn or loose road wheel bearings Replace wheel bearing.
Wobbly wheel or tires Replace wheel or tire.
Tires not adequately inflated Adjust the pressure.
Wheel Tramp
Blister or bump on tire Replace tire.
Improper shock absorber action Replace shock absorber.