Manual Transmission SUZUKI JIMNY 2005 3.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine 0B-16 MAINTENANCE AND LUBRICATION
Manual Transmission Oil
INSPECTION
1) Inspect transmission case for evidence of oil leakage.
Repair leaky point if any.
2) Make sure that vehicle is placed level for oil level check.
3) Remove level plug (2) of transmission.
4) Check oil level.
Oil level can be checked roughly by means of level plug hole.
That is, if oil flows out of level plug hole or if oil level is found
up to hole when level plug is removed, oil is properly filled.
If oil is found insufficient, pour specified amount of specified
oil.
5) Tighten level plug to specified torque.
Refer to “Maintenance Service” in Section 7A for installation
and tightening torque.
CHANGE
Change transmission oil with new specified oil referring to “Main-
tenance Service” in Section 7A.
Automatic Transmission Fluid
INSPECTION
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Check fluid level.
For fluid level checking procedure, refer to “Fluid Level
Check” in Section 7B and be sure to perform it under speci-
fied conditions. If fluid level is low, replenish specified fluid.
CHANGE
1) Inspect transmission case for evidence of fluid leakage.
Repair leaky point, if any.
2) Make sure that vehicle is placed level for fluid level check.
3) Change fluid. For its procedure, refer to “Changing Fluid” in
Section 7B.
1. Dipstick
2.“FULL HOT” mark
3.“LOW HOT” mark
CAUTION:
Use of specified fluid is absolutely necessary.
1. Drain plug

Downloaded from www.Manualslib.com manuals search engine 0B-20 MAINTENANCE AND LUBRICATION
Final Inspection
SEATS
Check that seat slides smoothly and locks securely at any position. Also check that reclining mechanism of front
seat back allows it to be locked at any angle.
SEAT BELT
Inspect belt system including webbing, buckles, latch plates, retractors and anchors for damage or wear.
If “REPLACE BELT” label on front seat belt is visible, replace belt. Check that seat belt is securely locked.
BATTERY ELECTROLYTE LEVEL CHECK
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If bat-
tery is equipped with built-in indicator, check battery condition by the indicator.
ACCELERATOR PEDAL OPERATION
Check that pedal operates smoothly without getting caught or interfered by any other part.
ENGINE START
Check engine start for readiness.
On automatic transmission vehicles, try to start the engine in each select lever position. The starting motor
should crank only in “P” (Park) or “N” (Neutral).
On manual transmission vehicles, place the shift lever in “Neutral,” depress clutch pedal fully any try to start.
EXHAUST SYSTEM CHECK
Check for leakage, cracks or loose supports.
CLUTCH (FOR MANUAL TRANSMISSION)
Check for the following.
Clutch is completely released when depressing clutch pedal,
No slipping clutch occurs when releasing pedal and accelerating.
Clutch itself is free from any abnormal condition. WARNING:
When carrying out road tests, select a safe place where no man or no running vehicle is seen so as to
prevent any accident.
WARNING:
Before performing the following check, be sure to have enough room around the vehicle. Then, firmly
apply both the parking brake and the regular brakes. Do not use the accelerator pedal. If the engine
starts, be ready to turn off the ignition promptly. Take these precautions because the vehicle could
move without warning and possibly cause personal injury or property damage.

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-21
GEARSHIFT OR SELECTOR LEVER (TRANSMISSION)
Check gear shift or selector lever for smooth shifting to all positions and for good performance of transmission in
any position.
With automatic transmission equipped vehicle, also check that shift indicator indicates properly according to
which position selector lever is shifted to.
With automatic transmission equipped vehicle, make sure that vehicle is at complete stop when shifting selector
lever to “P” range position and release all brakes.
BRAKE
Foot Brake
Check the following:
that brake pedal has proper travel,
that brake works properly,
that it is free from noise,
that braking force is applied equally on all wheels,
and that brake do not drag.
Parking Brake
Check that lever has proper travel.
Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
STEERING
Check to ensure that steering wheel is free from instability, or abnormally heavy feeling.
Check that the vehicle does not wander or pull to one side.
ENGINE
Check that engine responds readily at all speeds.
Check that engine is free from abnormal noise and abnormal vibration.
BODY, WHEELS AND POWER TRANSMITTING SYSTEM
Check that body, wheels and power transmitting system are free from abnormal noise and abnormal vibration or
any other abnormal condition.
METERS AND GAUGE
Check that speedometer, odometer, fuel meter, temperature gauge, etc. are operating accurately.
LIGHTS
Check that all lights operate properly.
WINDSHIELD DEFROSTER
Periodically check that air comes out from defroster outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan switch lever to “HI” position for this check. WARNING:
With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any per-
sonal injury or property damage. Be prepared to apply regular brake quickly even if vehicle should
start to move.

Downloaded from www.Manualslib.com manuals search engine 0B-22 MAINTENANCE AND LUBRICATION
Recommended Fluids and Lubricants
Engine oilSE, SF, SG, SH, SJ or SL
(Refer to “Engine Oil and Oil Filter” in this section for engine oil viscos-
ity.)
Engine coolant
(Ethylene glycol base coolant)“Antifreeze/Anticorrosion coolant”
Brake fluid DOT 3
Manual transmission oil Refer to “Maintenance Service” in Section 7A.
Transfer oil Refer to “Oil Change” in Section 7D.
Differential oil (front & rear) Refer to “Oil Change” in Section 7E and 7F.
Automatic transmission fluid
An equivalent of DEXRON
®-IIE or DEXRON®-III
Power steering fluid
An equivalent of DEXRON
®-II, DEXRON®-IIE or DEXRON®-III
Clutch linkage pivot points
Water resistance chassis grease
(SUZUKI SUPER GREASE A 99000-25010)
Steering knuckle seal
Door hinges
Engine oil or water resistance chassis grease
Hood latch assembly
Key lock cylinder Spray lubricant

Downloaded from www.Manualslib.com manuals search engine PROPELLER SHAFTS 4B-3
On-Vehicle Service
Propeller Shafts
REMOVAL
1) Hoist vehicle.
2) Drain transmission oil only when servicing propeller shaft
No. 1.
3) Before removing propeller shaft (2), give match marks (1) on
each joint flange (3) and propeller shaft (2) as shown.
4) Remove propeller shaft(s).
INSPECTION
Inspect propeller shaft and flange yoke for damage, and propeller
shaft for runout.
If damage is found or shaft runout exceeds its limit, replace.
Propeller shaft runout limit : 0.8 mm (0.031 in.)

Downloaded from www.Manualslib.com manuals search engine 4B-4 PROPELLER SHAFTS
INSTALLATION
Install propeller shaft(s) reversing removal procedure noting fol-
lowing points :
When installing propeller shaft, align the match marks.
Otherwise, vibration may occur during driving.
Use following specification to torque universal joint flange.
Tightening torque
Propeller shaft bolt (propeller shaft No.1, No.2 and No.3
rear differential side)
(a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
Propeller shaft bolt (propeller shaft No.3 transfer case
side)
(b) : 33 N·m (3.3 kg-m, 24 lb-ft)
Grease splines of propeller shaft No. 2 and No. 3.
“A” : Chassis Grease 99000-25030
Match marks (1) are provided on slip-on spline connections
of propeller shaft No. 2 and No. 3. Inserting splined end into
spIined bore without regard to match marks can be a possi-
ble cause of noise or vibration of propeller shaft. Be sure to
index marks. NOTE:
If transmission oil was drained for front propeller shaft
removal, pour specified gear oil into transmission case
to specified level.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-29
On-Vehicle Service
Precaution
When connectors are connected to ABS hydraulic unit / control
module assembly, do not disconnect connectors of sensors, fuse
etc. and turn ignition switch ON. Then DTC will be set in ABS con-
trol module.
ABS Hydraulic Unit Operation Check
1) Check that basic brake system other than ABS is in good
condition.
2) Check that battery voltage is 11 V or higher.
3) With ABS warning lamp, check that no abnormality is
detected in ABS. Refer to “Diagnostic Trouble Code (DTC)
Check” in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake drag-
ging occurs. If it does, correct.
7) With diag. switch terminal (3) of monitor connector (1) con-
nected to ground terminal (2) by using service wire (4), turn
ignition switch ON and check if ABS warning lamp indicates
DTC 12.
When other DTC’s appear on display, refer to “ABS Diagnos-
tic Flow Table” in this section.
8) Turn ignition switch OFF.
9) Perform following checks with help of another person.
Brake pedal (1) should be depressed and then ignition
switch (2) turned ON by one person and wheel (3) should be
turned by another person’s hand. At this time, check that:
Operation sound of solenoid is heard and wheel turns only
about 0.5 sec (Brake force is depressurized).
Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF → ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace
hydraulic unit.
11) Turn ignition switch OFF.
12) Remove service wire from monitor connector.

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-5
Fuel pressure relief procedure
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector
lever to “P” range for A/T model), set parking brake, and
block drive wheels.
2) Remove relay box cover.
3) Disconnect fuel pump relay (1) from its connector.
4) Remove fuel filler cap to release fuel vapor pressure in fuel
tank and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat
cranking engine 2-3 times for about 3 seconds each time to
dissipate fuel pressure in lines. Fuel connections are now
safe for servicing.
6) Upon completion of servicing, connect fuel pump relay (1) to
its connector.
Fuel leakage check procedure
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump)
and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pres-
sure to fuel line. (till fuel pressure is felt by hand placed on
fuel feed hose.)
2) In this state, check to see that there are no fuel leakages
from any part of fuel system. CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.

Downloaded from www.Manualslib.com manuals search engine 6-12 ENGINE GENERAL INFORMATION AND DIAGNOSIS
1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form will facilitate collecting information to the point required for proper anal-
ysis and diagnosis.
2. DIAGNOSTIC TROUBLE CODE (DTC) / FREEZE FRAME DATA CHECK, RECORD AND CLEAR-
ANCE
First, check DTC (including pending DTC), referring to “DTC check” section. If DTC is indicated, print it and
freeze frame data or write them down and then clear them by referring to “DTC clearance” section. DTC indi-
cates malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the
past and the normal condition has been restored now. To check which case applies, check the symptom in ques-
tion according to Step 4 and recheck DTC according to Step 5.
Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.
3. AND 4. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the engine
referring to “Visual Inspection” section.
5. TROUBLE SYMPTOM CONFIRMATION
Based on information obtained in Step 1 Customer complaint analysis and Step 2 DTC / freeze frame data
check, confirm trouble symptoms. Also, reconfirm DTC according to “DTC Confirmation Procedure” described in
each DTC Diagnosis section.
6. AND 7. RECHECKING AND RECORD OF DTC / FREEZE FRAME DATA
Refer to “DTC Check” section for checking procedure.
8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE
Perform basic engine check according to the “Engine Basic Inspection” first. When the end of the flow table has
been reached, check the parts of the system suspected as a possible cause referring to “Engine Diagnosis
Table” and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer com-
plaint analysis, trouble symptom confirmation and / or basic engine check) and repair or replace faulty parts, if
any.
9. TROUBLESHOOTING FOR DTC (SEE EACH DTC DIAG. FLOW TABLE)
Based on the DTC indicated in Step 5 and referring to the applicable DTC diag. flow table in this section, locate
the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ECM or other part and
repair or replace faulty parts.
10. CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connection” in Section 0A and related circuit of DTC recorded in Step 2.
11. FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the engine is free from any abnormal conditions. If what has
been repaired is related to the DTC, clear the DTC once, perform DTC confirmation procedure and confirm that
no DTC is indicated.NOTE:
If only Automatic transmission DTCs (P0702-P1717) or Immobilizer DTCs (P1620-P1623) are indicated
in this step, perform trouble diagnosis according to “Diagnosis” in Section 7B or Section 8G.

Downloaded from www.Manualslib.com manuals search engine 6-18 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC NO. DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
P0702 Transmission Control System Electrical
Refer to Section 7B.
These DTCs can not be read on vehicle without
Immobilizer indicator lamp (by ECM application of
SUZUKI scan tool). P0705 Temperature Sensor Circuit Malfunction
P0710Transmission Temperature Sensor Circuit Mal-
function
P0715Input / Turbine Speed Sensor Circuit Malfunc-
tion
P0720Output Shaft Speed Sensor Circuit Malfunc-
tion
P0725 Engine Speed Input Circuit Malfunction
P0730 Incorrect Gear Ratio
P0743 Torque Converter Clutch Circuit Electrical
P0753 Shift Solenoid A Electrical
P0758 Shift Solenoid B Electrical
P0763 Shift Solenoid C Electrical
P0768 Shift Solenoid D Electrical
P1700 Throttle Position Signal Input Malfunction
P1702Internal Control Module Memory Check Some
Error
P1709Engine Coolant Temperature Signal Input
Malfunction
P1887 Transfer Signal
P1620
(No.84)ECU code not registered
Refer to Section 8G. P1621
(No.83)No ECU code transmitted from Immobilizer
Control Module
P1622
(No.82)Faulty in ECM
P1623
(No.81)ECU code not matched
NOTE:
For ( ) marked No. in DTC column, it is used for vehicle without Immobilizer indicator lamp.
DTC No.12 appears when none of the other codes is identified (vehicle without Immobilizer indica-
tor lamp).