2020 SUZUKI JIMNY maintenance

INSPECTION AND MAINTENANCE
NOTE: SUZUKI highly recommends the use of ECSTAR brand coolant. ECSTAR has been specially formulated for your SUZUKI product and contributes to the desired vehicle performance and ideal driving experience.
Coolant level check
Check the coolant level at the reservoir tank, not at the radiator. With the engine cool, the coolant level should be between "FULL" and "LOW" marks.
Adding coolant
,A WARNING
Swallowing engine coolant can cause severe injury or death. Inhaling cool­ant mist or vapors or getting coolant in your eyes could result in severe injury. • Do not drink antifreeze or coolant solution. If swallowed, do not induce vomiting. Immediately con­tact a poison control center or a physician. • Avoid inhaling coolant mist or hot vapors. If inhaled, remove to a fresh air area. (Continued)
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,A WARNING
(Continued) • If coolant gets in the eyes, flush with water and seek medical atten­tion. Wash thoroughly after handling coolant. Keep engine coolant out of the reach of children and pets.
NOTICE
SUZUKI LLC: Super (Blue) coolant; This coolant is already diluted to the proper percentage. Do not dilute with distilled water additionally. Doing so may result in the possibility of freez­ing and/or overheating coolant.
NOTICE
SUZUKI LLC: Standard (Green) cool­ant; • The mixture you use should con­tain 50% concentration of anti­freeze. If the lowest ambient temperature in your area is expected lo be -35°C (-31'F) or below, use higher con­centrations up to 60% following the instructions on the antifreeze con­tainer.
78RB07005
If the coolant level is below "LOW" mark, coolant should be added. While the engine is cool, remove the reservoir tank cap and add coolant until the reservoir tank level reaches "FULL" mark. Never fill the reser­voir tank above "FULL" mark.
NOTICE
When putting the cap on the reser­voir tank, line up the mark on the cap and the mark on the tank. Failure to follow this can result in coolant leak­age.
Coolant replacement
Since special procedures are required, ask a SUZUKI dealer for this job.

Air cleaner
If the air cleaner is clogged with dust, there will be greater intake resistance, resulting in decreased power output and increased fuel consumption.
(1)
78RB07044
1) Unclampthe clamps (1). 2) Hold up the air cleaner upper case. 3) Remove the element from the air cleaner case. If it appears to be dirty, clean or replace it with a new one. 4) If the element is installed on the air cleaner case, confirm the mark of "FRONT" on the element and fit the boss of the element in the groove of the front on the air cleaner case. 5) Clamp the clamps securely.
Spark plugs
Spark plug replacement and
inspection
(3)~
(1) 0
(2)
78RB07006
To access the spark plug: 1) Disconnect the coupler (1) while push­ing the release lever. 2) Remove the bolt (2). 3) Pull out the ignition coil (3) straight.
INSPECTION AND MAINTENANCE
NOTE: During installation, check that the wires, couplers, sealing rubber of air cleaner chassis and washers, are correctly returned in place.
Correct Wrong
§7® ~
~~
78K179
NOTICE
When pulling out the ignition coils, do not pull on the cable. Pulling on the cable can damage it. • When servicing the iridium/plati­num spark plugs (slender center electrode type plugs), do not touch the center electrode, as it is easy to be damaged.
6-30

INSPECTION AND MAINTENANCE
60G160
NOTICE
When installing the spark plugs, screw them in with your fingers to avoid stripping the threads. Tighten the spark plugs with a torque wrench to 17.5 Nm (1.7 kg­m, 12.9 lb-ft). Do not allow contami­nants to enter the engine through the spark plug holes when the plugs are removed. Never use spark plugs with the wrong thread size.
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Spark plug gap "a":
ZXU20PR11 1.0-1.1 mm (0.039-0.043 in.) KR6A-10 0.95-1.0Smm (0.037-0.041 in.)
NOTICE
54G106
When replacing spark plugs, you ".hould use the ~rand and type speci­fied for your vehicle. For the specified plugs, refer to "SPECIFICATIONS" section in the end of this book. If you wish to use a brand of spark plug other than the specified plugs, con­sult a SUZUKI dealer.
Gear oil
Manual transmission oil / transfer
oil/ rear differential oil
When adding gear oil, use gear oil with the appropriate viscosity and grade as shown in the chart below.
We highly recommend you use "SUZUKI GEAR OIL 75W" for manual transmission oil and transfer oil.
Manual transmission oil Transfer oil
<: ==:llil:::======> 75W
°C-30 -20 -10 0 10 20 30 40 °F-22 -4 14 32 50 68 86 104
54P120706
We highly recommend you use "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC" for front/rear differential oil.
Front/rear differential oil
<~==~7[fil5Wtfi-B~5====>
'C-30 -~0 -10 Of.22 4 14 0 ' 32
20 ' 68 83,60 4p 104
78RB07007

Gear oil level check
Manual transmission
(2)
(1) Oil filler and level plug (2) Oil drain plug
78RB07008
Transfer
4)
(3) Oil filter and level plug (4) Oil drain plug
Front/rear differential
(5) Oil filter and level plug (6) Oil drain plug
INSPECTION AND MAINTENANCE
To check the gear oil level, use the fol­lowing procedure:
1) Park the vehicle on a level surface with the parking brake applied. Then, stop the engine. 2) Remove the oil filler and level plug.
For the manual transmission;
3) If gear oil fiows from the plug hole, the oil level is correct. Reinstall the plug. If gear oil does not fiow from the plug hole, add oil through the filler plug hole until oil fiows a little from the plug hole.
78Rs0100, For the transfer and front/rear differential;
78RB07010
3) Check the inside of the hole with your finger. If the oil level comes up to the bottom of the plug hole, the oil level is correct. If so, reinstall the plug. 4) If the oil level is low, add gear oil through the oil filler and level plug hole until the oil level reaches the bottom of the filler hole, and then reinstall the plug.
Tightening torque for oil filler and level plug
Manual transmission (1 )(2): 23 Nm (2.3 kg-m, 16.6 lb-ft)
Transfer (3)(4): 23 Nm (2.3 kg-m, 16.6 lb-ft)
Front/rear differential (5)(6): (5)50 Nm (5.0 kg-m, 36.2 lb-ft) (6)55 Nm (5.6 kg-m, 40.5 lb-ft)
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· INSPECTION AND MAINTENANCE
A CAUTION
After driving the vehicle, the gear oil temperature may be high enough to burn you. Wait until the oil filler and level plug are cool enough to touch with your bare hands before inspect­ing gear oil level.
NOTICE
Be sure to use new plug with new gas­ket to avoid loose·ness of the plug and oil leakage.
Gear oil change
Since special procedures, materials and tools are required, ask a SUZUKI dealer for this job.
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Clutch pedal
Fluid control clutch
78RB07011
Check the clutch pedal for smooth opera­tion and clutch fiuid level from time to time. If clutch dragging is felt with the pedal fully depressed, have the clutch inspected by a SUZUKI dealer. If the clutch fiuid level is near "MIN" line, fill it up to "MAX" line with DOT3 or SAE J1703 brake fiuid.
Brakes
Brake fluid
MAX
MIN
78RB07011
Check the brake fluid level by looking at the reservoir in the engine compartment. Check that the fiuid level is between "MAX" and "MIN" lines.
NOTICE
If your brake fluid level is near the 11MIN" line, there is a possibility of brake pad and/or shoe wear and brake fluid leakage. Consult with a SUZUKI dealer regarding this possi­bility before filling the reservoir.

NOTE: SUZUKI highly recommends the use of ECSTAR brend brake fluid. ECSTAR has been specially formulated for your SUZUKI product and contributes to the desired vehicle performance and ideal driving experience.
A WARNING
Failure to follow the guidelines below can result in personal injury or seri­ous damage to the brake system. . If the brake fluid in the reservoir drops below a certain level, the brake warning light on the instru­ment cluster will come on (the engine must be running with the parking brake fully dise~gaged). Should the light come on, 1mmed1-ately ask a SUZUKI dealer to inspect the brake system. A rapid fluid loss indicates leakage in the brake system which should be inspected by a SUZUKI dealer immediately. Do not use any fluid other than DOT3 or SAE J1703 brake fluid. Do not use reclaimed fluid or fluid that has been stored in old or open con­tainers. It is essential that foreign particles and other liquids are kept out of the brake fluid reservoir.
A CAUTION
Brake fluid can harm your eyes and damage painted surfaces. Be careful when refilling the reservoir.
A WARNING
Brake fluid is harmful or fatal if swal­lowed, and harmful if it comes in con­tact with skin or eyes. If swallowed, do not induce vomiting. Immediately contact a poison control center or a physician. If brake fluid gets in eye~, flush eyes with water and seek medi­cal attention. Wash thoroughly after handling. Solution can be poisonous to animals. Keep out of reach of chil­dren and animals.
NOTE: • The fluid /eve/ can be expected to gredu­ally fall as the brake pad and/or shoe wear. Brake fluid absorbs water over time and brake fluid with high water content may cause vapor lock or breke system mal­function. Replace your breke fluid in accordance with the maintenance schedule m your Owner's Manual.
INSPECTION AND MAINTENANCE
Brake pedal
Check brake pedal stroke. If the stroke is so large, have the brake system inspected by a SUZUKI dealer. If you doubt th_e brake pedal is at its normal height, check 1t as fol­lows:
54G108
Minimum distance between brake pedal and floor carpet "a"
LHD 101 mm (4.0 in)
RHD 89 mm (3.5 in)
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INSPECTION AND MAINTENANCE
With the engine running, measure the dis­tance between the brake pedal and floor carpet when the pedal is depressed with approximately 30 kg (66 lbs) of force. The minimum distance required is as specified. Since your vehicle's brake system is self­adjusting, there is no need for pedal adjustment. If the pedal to floor carpet distance as measured above is less than the minimum distance required, have your vehicle inspected by a SUZUKI dealer.
NOTE: • When measuring the distance between the brake pedal and floor wall, be sure not to include the floor mat or rubber on the floor carpet in your measurement. Measure the distance at the brake pedal's side facing toward the passen­ger's door.
6-35
52RM70500
A WARNING
If you experience any of the following problems with your vehicle's brake system, have the vehicle inspected immediately by a SUZUKI dealer. Poor braking performance Uneven braking (brakes not work­ing uniformly on all wheels.) Excessive pedal travel Brake dragging Excessive noise
Parking brake
~
54G109
Ratchet tooth specification 11b": 4th-9th Lever pull force (1 ): 200 N (20 kg, 45 lbs)
Check the parking brake for proper adjust­ment by counting the number of clicks made by the ratchet teeth as you slowly pull up on the parking brake lever to the point of full engagement. The parking brake lever should stop between the speci­fied ratchet teeth and the rear wheels should be securely locked. If the parking brake is not properly adjusted or the brakes drag is suspected even after the lever has been fully released, have the parking brake inspected and/or adjusted by a SUZUKI dealer.

Brake discs and brake drums
Brake disc
Brake location Minimum thickness
Front wheels 8.0 mm (0.3 in.)
Brake drum
Brake location Maximum inner diameter
Rear wheels 222 mm (8.74 in.)
If the measured thickness or inner diame­ter of the most worn part falls below or exceeds the value indicated above, the parts should be replaced with a new one. The measurement involves disassembling each brake and requires the use of a micrometer or caliper, which must be done according to the instructions described in the relevant service manual or available from the relevant repair information site.
Steering wheel
78RB07012
Steering wheel play 11c": 0-30 mm (0.0 -1.2 in.)
Check the free play of the steering wheel by gently turning it from left to right and measuring the distance that it moves before you feel slight resistance. The play should be between the specified values.
Check that the steering wheel turns easily and smoothly without rattling by turning it all the way to the right and to the left while driving very slowly in an open area. If the amount of free play is not as specified or you find anything else to be wrong, an inspection must be performed by a SUZUKI dealer.
INSPECTION AND MAINTENANCE
Tyres
78RB07013
The front and rear tyre pressure specifica­tions are listed in the tyre information label. Both front and rear tyres should have the specified tyre pressure.
NOTE: The tyre pressure will change due to changes in atmospheric pressure, tem­perature or tyre temperature when driving. To reduce the chance that the low tyre pressure warning light (if equipped) will come on due to normal changes in tem­perature and atmospheric pressure, it is important to check and adjust the tyre pressures when the tyres are cold. If you check tyres after driving, they are warm. Even if the tyre pressure seems to be good in this condition, it could fall below the
6-36