ESP SUZUKI JIMNY 2005 3.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-9
4) From the position where contact coil became unable to turn
any further (it stopped), turn it back clockwise about two and
a half rotations and align center mark with alignment mark
(1).
Combination Switch (For Vehicle without Air
Bag System)/Contact Coil and Combination
Switch Assembly (For Vehicle with Air Bag
System)
REMOVAL
1) Remove steering wheel from steering column referring to
“Steering Wheel” in this section.
2) Remove steering column hole cover (1).
3) Remove steering column cover standard screw (1) and tap-
ping screws (2).
4) Loosen steering column mounting bolts and nuts referring to
“Steering Column” in this section.
5) Separate upper cover (3) and lower cover (4), then remove
them.
6) Disconnect all connectors for combination switch/contact coil
and combination switch assembly.
CAUTION:
For vehicle with air bag system
Do not turn contact coil (on combination switch) more
than allowable number of turns (about two and a half
turns from the center position clockwise or counter-
clockwise respectively), or coil will break.

Downloaded from www.Manualslib.com manuals search engine WHEELS AND TIRES 3F-7
Lower than Recommended Pressure Can Cause:
1) Tire squeal on turns
2) Hard steering
3) Rapid and uneven wear on the edges of the tread
4) Tire rim bruises and rupture
5) Tire cord breakage
6) High tire temperatures
7) Reduced handling
8) High fuel consumption
Tire placard
The tire placard is located on the driver’s side door lock pillar and should be referred to for tire information. The
placard lists the maximum load, tire size and cold tire pressure where applicable.
Tire rotation
To equalize wear, rotate tires according to left figure. Radial tires
should be rotated periodically. Set tire pressure. NOTE:
Whether rim size and/or maximum load are listed or not depends on regulations of each country.
NOTE:
Due to their design, radial tires tend to wear faster in the
shoulder area, particularly in front positions. This makes
regular rotation especially necessary.
[A] : RH steering vehicle
[B] : LH steering vehicle
F : Front

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-11
Rear Drum Brake Shoe Adjustment
Rear brake has self-adjusting mechanism but it does require
adjustment for proper drum to shoe clearance when brake shoe
has been replaced or brake drum has been removed for some
other service.
Adjustment is automatically accomplished by depressing brake
pedal about 30 times with approximately 30 kg (66 Ibs) load after
all parts are installed.
Then check brake drum for dragging and brake system for proper
performance. After lowering vehicle from hoist, brake test should
be performed.
Parking Brake Inspection and Adjustment
INSPECTION
Hold center of parking brake lever grip and pull it up with 20 kg
(44 Ibs) force.
With parking brake lever pulled up as above, count ratchet
notches.
There should be 6 to 8 notches.
Also, check if both right and left rear wheels are locked firmly. To
count number of notches easily, listen to click sounds that ratchet
makes while pulling parking brake lever without pressing its but-
ton.
One click sound corresponds to one notch.NOTE:
Be sure to use particular brake fluid either as indicated
on reservoir cap of that vehicle or recommended in
owner’s manual which comes along with that vehicle.
Use of any other fluid is strictly prohibited.
Fluid level should be between MIN and MAX lines marked
on reservoir.
When brake warning lamp lights sometimes during driv-
ing, replenish fluid to MAX level.
When fluid decreases quickly, inspect brake system for
leakage.
Correct leaky points and then refill to specified level.
CAUTION:
Do not use shock absorber fluid or any other fluid which
contains mineral oil. Do not use a container which has
been used for mineral oil or a container which is wet from
water. Mineral oil will cause swelling and distortion of
rubber parts in hydraulic brake system and water mixed
into brake fluid will lower fluid boiling point. Keep all fluid
containers capped to prevent contamination.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-15
Fluid Pressure Test (If Equipped with LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.
Fuel tank is filled with fuel fully.
Vehicle is equipped with spare tire, tools, jack and jack han-
dle.
1) Stop vehicle on level floor and place approximately about
140 kg (309 Ibs) weight on rear housing so that rear axle
weights 600 kg (1323 Ib).
Rear axle weight
“L” : 600 kg (1323 lb)
2) Install special tool to front and rear brake.
Special tool
Front brake
(A) : 09956-02310
(B) : 55473-82030 (Use the air bleeder plug supplied as a
spare part)
Rear brake
(A) : 09956-02310
(B) : 55473-82030 (Use the air bleeder plug supplied as a
spare part)
3) Depress brake pedal gradually till fluid pressure of front
brake becomes as specified below and check corresponding
pressure of rear brake. It should be within specification given
below.
As done above, apply 100 kg/cm
2 pressure to front brake and
check that rear brake pressure is within specification as given
below.NOTE:
Special tool should be connected to bleeder plug hole of
front (driver’s side brake) and rear brakes.
1. Air bleeder plug
2. Weight
3. Attachment
Front brake Rear brake
5000 kPa
50 kg/cm
2
711 psi3800 – 5100 kPa
38 – 51 kg/cm
2
540 – 725 psi
Front brake Rear brake
10000 kPa
100 kg/cm
2
1422 psi5100 – 6500 kPa
51 – 65 kg/cm
2
725 – 924 psi

Downloaded from www.Manualslib.com manuals search engine 5-42 BRAKES
LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped)
REMOVAL
1) Clean around reservoir cap and take out fluid with syringe or
such.
2) Hoist vehicle.
3) Disconnect brake pipes from LSPV.
4) Remove LSPV assembly from vehicle.
5) Remove spring and stay from LSPV.
INSTALLATION
Install by reversing removal procedure, noting the following.
1) Torque each bolt and nut to specification as indicated
respectively.
Tightening torque
LSPV bolts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Brake pipe flare nuts
(b) : 16 N·m (1.6 kg-m, 12.0 lb-ft)
2) Upon completion of installation, fill reservoir tank with speci-
fied fluid and bleed air from brake system.
Tightening torque
LSPV bleeder plug
(a) : 8 N·m (8.0 kg-m, 6.0 lb-ft)
3) After bleeding air, check that LSPV is installed properly,
referring to following INSPECTION & ADJUSTMENT. CAUTION:
Brake fluid is extremely damaging to paint.
Do not allow brake fluid to get on painted surface.
LSPV assembly must not be disassembled.
Replace with new one if defective.
NOTE:
As shown in figure, LSPV assembly should be removed
together with its spring and stay installed as they are.
NOTE:
Make sure to bleed air from LSPV bleeder without fail.

Downloaded from www.Manualslib.com manuals search engine 6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Diagnostic trouble code (DTC) table ......... 6-16
Fail-safe table............................................ 6-19
Visual inspection ....................................... 6-20
Engine basic inspection ............................ 6-21
Engine diagnosis table .............................. 6-23
Scan Tool Data ............................................. 6-28
Scan tool data definitions .......................... 6-30
Inspection of ECM and Its Circuits ................ 6-33
Component Location ..................................... 6-42
Table A-1 Malfunction Indicator Lamp Circuit
Check - Lamp Does Not Come “ON” at Ignition
Switch ON (But Engine at Stop).................... 6-43
Table A-2 Malfunction Indicator Lamp Circuit
Check - Lamp Remains “ON” after Engine
Starts............................................................. 6-44
Table A-3 Malfunction Indicator Lamp Circuit
Check - Mil Flashes at Ignition Switch ON .... 6-45
Table A-4 Malfunction Indicator Lamp Circuit
Check - MIL Does Not Flash, Just Remains
ON or Just Remains OFF Even with Grounding
Diagnosis Switch Terminal............................ 6-45
Table A-5 ECM Power and Ground Circuit
Check - MIL Doesn’t Light at Ignition Switch
ON and Engine Doesn’t Start Though It Is
Cranked Up ................................................... 6-46
DTC P0105 (DTC No.11) Manifold Absolute
Pressure (MAP) Circuit Malfunction .............. 6-48
DTC P0110 (DTC No.18) Intake Air Temp.
(IAT) Circuit Malfunction ............................... 6-51
DTC P0115 (DTC No.19) Engine Coolant
Temperature (ECT) Circuit Malfunction ........ 6-53
DTC P0120 (DTC No.13) Throttle Position
Circuit Malfunction ........................................ 6-55
DTC P0121 Throttle Position Circuit Range /
Performance Problem ................................... 6-57
DTC P0130 (DTC No.14) Heated Oxygen
Sensor (HO2S) Circuit Malfunction
(Sensor-1) ..................................................... 6-59
DTC P0133 Heated Oxygen Sensor (HO2S)
Circuit Slow Response (Sensor-1) ................ 6-61
DTC P0135 (DTC No.14) Heated Oxygen
Sensor (HO2S) Heater Circuit Malfunction
(Sensor-1) ..................................................... 6-62
DTC P0136 Heated Oxygen Sensor (HO2S)
Circuit Malfunction (Sensor-2) ...................... 6-64
DTC P0141 Heated Oxygen Sensor (HO2S)
Heater Circuit Malfunction (Sensor-2)........... 6-66
DTC P0171 Fuel System Too Lean .............. 6-68
DTC P0172 Fuel System Too Rich ............... 6-68
DTC P0300 Random Misfire Detected
(Misfire Detected at 2 or More Cylinders) ..... 6-72DTC P0301 Cylinder 1 Misfire Detected ........ 6-72
DTC P0302 Cylinder 2 Misfire Detected ........ 6-72
DTC P0303 Cylinder 3 Misfire Detected ........ 6-72
DTC P0304 Cylinder 4 Misfire Detected ........ 6-72
DTC P0325 (DTC No.17) Knock Sensor Circuit
Malfunction .................................................... 6-77
DTC P0335 (DTC No.23) Crankshaft Position
(CKP) Sensor Circuit Malfunction .................. 6-79
DTC P0340 (DTC No.15) Camshaft Position
(CMP) Sensor Circuit Malfunction ................. 6-82
DTC P0400 Exhaust Gas Recirculation Flow
Malfunction .................................................... 6-85
DTC P0420 Catalyst System Efficiency below
Threshold ....................................................... 6-88
DTC P0443 Purge Control Valve Circuit
Malfunction .................................................... 6-91
DTC P0481 A/C Condenser Fan Control
Circuit Malfunction ......................................... 6-92
DTC P0500 (DTC No.16) Vehicle Speed
Sensor (VSS) Malfunction ............................. 6-94
DTC P0505 Idle Control System
Malfunction .................................................... 6-96
DTC P0601 Internal Control Module Memory
Check Sum Error (DTC No.71) ...................... 6-98
DTC P1450 Barometric Pressure Sensor
Low / High Input ............................................. 6-99
DTC P1451 Barometric Pressure Sensor
Performance Problem .................................... 6-99
DTC P1500 Engine Starter Signal Circuit
Malfunction .................................................. 6-101
DTC P1510 ECM Back-up Power Supply
Malfunction .................................................. 6-103
DTC P1570 (DTC No.21) ABS Signal Circuit
Malfunction .................................................. 6-104
DTC P1600 Serial Communication Problem
Between ECM and TCM .............................. 6-105
DTC P1717 A/T Drive Range (Park / Neutral
Position) Signal Circuit Malfunction ............. 6-107
Table B-1 Fuel Injector Circuit Check ..........6-109
Table B-2 Fuel Pump and Its Circuit
Check........................................................... 6-110
Table B-3 Fuel Pressure Check................... 6-112
Table B-4 Idle Air Control System Check ....6-114
Table B-5 A/C Signal Circuits Check
(Vehicle with A/C) ........................................ 6-117
Table B-6 Electric Load Signal Circuit
Check........................................................... 6-119
TAble B-7 A/C Condenser Fan Control
System Check.............................................. 6-121
Special Tool ................................................... 6-123

Downloaded from www.Manualslib.com manuals search engine 6-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Precaution in Diagnosing Trouble
Don’t disconnect couplers from ECM, battery cable at battery, ECM ground wire harness from engine or
main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in ECM memory.
Such disconnection will erase memorized information in ECM memory.
Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have
good understanding as to what functions are available and how to use it.
Priorities for diagnosing troubles (Vehicle with Immobilizer indicator lamp).
If multiple diagnostic trouble codes (DTCs) are stored, proceed to the flow table of the DTC which has
detected earliest in the order and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
–Diagnostic trouble codes (DTCs) other than DTC P0171/P0172 (Fuel system too lean / too rich), DTC
P0300/P0301/P0302/P0303/P0304 (Misfire detected) and DTC P0400 (EGR flow malfunction)
–DTC P0171/P0172 (Fuel system too lean / too rich) and DTC P0400 (EGR flow malfunction)
–DTC P0300/P0301/P0302/P0303/P0304 (Misfire detected)
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before inspection and observe what
is written there.
ECM Replacement
When substituting a known-good ECM, check for following conditions. Neglecting this check may cause
damage to a known-good ECM.
–Resistance value of all relays, actuators is as specified respectively.
–MAP sensor and TP sensor are in good condition and none of power circuits of these sensors is shorted
to ground.AMBIENT TEMPERATURE TIME TO CUT POWER TO
ECM
Over 0 °C (32 °F) 60 sec. or longer
Under 0 °C (32 °F)Not specifiable.
Select a place with higher than
0 °C (32 °F) temperature.

Downloaded from www.Manualslib.com manuals search engine 6-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Diagnostic trouble code (DTC) table
DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)
P0105
(No.11)Manifold absolute pressure
circuit malfunctionLow pressure-high vacuum-low voltage
(or MAP sensor circuit shorted to ground)
High pressure-low vacuum-high voltage
(or MAP sensor circuit open)1 driving
cycle1 driving
cycle
P0110
(No.18)Intake air temp. circuit mal-
functionIntake air temp. circuit low input
Intake air temp. circuit high input1 driving
cycle1 driving
cycle
P0115
(No.19)Engine coolant temp. cir-
cuit malfunctionEngine coolant temp. circuit low input
Engine coolant temp. circuit high input1 driving
cycle1 driving
cycle
P0120
(No.13)Throttle position circuit mal-
functionThrottle position circuit low input
Throttle position circuit high input1 driving
cycle1 driving
cycle
P0121Throttle position circuit per-
formance problemPoor performance of TP sensor 2 driving
cyclesNot
applicable
P0130
(No.14)HO2S circuit malfunction
(Sensor-1)Min. output voltage of HO2S-higher than
specification
Max. output voltage of HO2S-lower than
specification2 driving
cycles1 driving
cycle
P0133HO2S circuit slow response
(Sensor-1)Response time of HO2S-1 output voltage
between rich and lean is longer than spec-
ification.2 driving
cyclesNot
applicable
P0135
(No.14)HO2S heater circuit mal-
function (Sensor-1)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.2 driving
cycles1 driving
cycle
P0136HO2S circuit malfunction
(Sensor-2)HO2S-2 voltage is higher than specifica-
tion2 driving
cyclesNot
applicable
P0141HO2S heater circuit mal-
function (Sensor-2)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.
(or heater circuit or short)2 driving
cyclesNot
applicable
P0171 Fuel system too leanShort term fuel trim or total fuel trim (short
and long terms added) is larger than spec-
ification for specified time or longer.
(fuel trim toward rich side is large.)2 driving
cyclesNot
applicable
P0172 Fuel system too richShort term fuel trim or total fuel trim (short
and long term added) is smaller than spec-
ification for specified time or longer.
(fuel trim toward lean side is large.)2 driving
cyclesNot
applicable
P0300
P0301
P0302
P0303
P0304Random misfire detected
Cylinder 1 misfire detected
Cylinder 2 misfire detected
Cylinder 3 misfire detected
Cylinder 4 misfire detectedMisfire of such level as to cause damage
to three way catalystMIL flashing
during mis-
fire detec-
tionNot
applicable
Misfire of such level as to deteriorate emis-
sion but not to cause damage to three way
catalyst2 driving
cyclesNot
applicable
P0325
(No.17)Knock sensor circuit mal-
functionKnock sensor circuit low input
Knock sensor circuit high input1 driving
cycle1 driving
cycle

Downloaded from www.Manualslib.com manuals search engine 6-24 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Engine has no power
Engine overheating Refer to “Overheating” of this table.
Faulty ignition coil Ignition coil assembly in Section 6F.
Faulty knock sensor Knock sensor malfunction in this sec-
tion.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty injector Diagnostic Flow Table B-1
Faulty TP sensor, ECT sensor or MAP
sensorTP sensor, ECT sensor or MAP sen-
sor in Section 6E.
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
Maladjusted accelerator cable play Accelerator cable adjustment in Sec-
tion 6E.
Low compression Previously outlined.
Dragging brakes Diagnosis table in Section 5.
Slipping clutch Diagnosis table in Section 7C.
Improper engine idling
or engine fails to idleFaulty ignition coil Ignition coil assembly in Section 6F.
Engine overheating Refer to “Overheating” of this table.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty idle air control system Diagnostic Flow Table B-4
Faulty evaporative emission control sys-
temEVAP control system in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECT sensor, TP sensor or MAP
sensorECT sensor, TP sensor or MAP sen-
sor in Section 6E.
Malfunctioning PCV system PCV system in Section 6F.
Faulty ECM Inspection of ECM and its circuit in
this section.
Faulty EGR system (if equipped) EGR system in Section 6E.
Low compression Previously outlined.
Engine hesitates
(Momentary lack of
response as the accel-
erator is depressed.
Can occur at all vehicle
speeds.
Usually most severe
when first trying to
make the vehicle move,
as from a stop sign.)Faulty ignition coil Ignition coil assembly in Section 6F.
Engine overheating Refer to “Overheating” of this table.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty injector Diagnostic Flow Table B-1
Faulty TP sensor, ECT sensor or MAP
sensorTP sensor, ECT sensor or MAP sen-
sor in Section 6E.
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
Low compression Previously outlined.
Surges
(Engine power variation
under steady throttle or
cruise.
Feels like the vehicle
speeds up and down
with no change in the
accelerator pedal.)Faulty ignition coil or high-tension cord Ignition coil assembly or high-tension
cords in Section 6F.
Variable fuel pressure Diagnostic Flow Table B-3
Faulty MAP sensor MAP sensor in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E. Condition Possible Cause Reference Item

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-61
DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1)
WIRING DIAGRAM
Refer to DTC P0130 section.
CIRCUIT DESCRIPTION
Fig. 1
DTC CONFIRMATION PROCEDURE
Refer to DTC P0130 section.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
When running at specified idle speed after engine warmed up and
running at specified vehicle speed, response time (time to change
from lean to rich or from rich to lean) of HO2S-1 output voltage is
about 1 sec. at minimum or average time of 1 cycle is 5 sec. at
minimum. See. Fig. 1
✱
✱✱ ✱2 driving cycle detection logic, Monitoring once / 1 driving.Heated oxygen sensor-1 malfunction
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Is there DTC(s) other than HO2S-1 (DTC
P0133)?Go to applicable DTC
Diag. Flow Table.Replace HO2S-1.