resistor SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine HEATER AND VENTILATION 1A-1
6F1
6G
1A
6K
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 1A
HEATER AND VENTILATION
CONTENTS
General Description ....................................... 1A-2
Diagnosis ........................................................ 1A-3
Diagnosis Table ........................................... 1A-3
Wiring Circuit ................................................ 1A-3
On Vehicle Service ......................................... 1A-4Heater Blower Motor .................................... 1A-4
Heater Blower Resistor ................................ 1A-5
Heater Control Lever Assembly ................... 1A-5
Heater Blower Fan Switch ........................... 1A-7
Heater Unit/Boost Ventilation ....................... 1A-7

WARNING:
For vehicles equipped with Supplement 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 Section 10B in order to confirm whether you are performing service on or
near the air bag system components or wiring. Please observe all WARNINGS and “Service Precau-
tions” under “On-Vehicle Service” in Section 10B before performing service on or around the air
bag system components or wiring. Failure to follow WARNINGS could result in unintentional activa-
tion of the system or could render the system inoperative. Either or 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 the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
The link mechanism of the heater varies depending on the specifications.

Downloaded from www.Manualslib.com manuals search engine 1A-2 HEATER AND VENTILATION
General Description
The heater, an in and out air selectable-type hot water heater, is so constructed that it is possible to assure an
agreeable ventilation at all times by providing the ventilator air outlets at the center and both sides (right and left)
of the instrument panel, the hot air outlet at a place close to the feet of front passengers, and the defroster air
outlets at places, right and left, along the windshield glass.
The heater and ventilation consist of following parts.
1. Side ventilator outlet 6. Ventilator duct 11. Heater core
2. Side defroster outlet 7. Control lever 12. Damper
3. Center ventilator outlet 8. Blower motor 13. Air inlet box (without air conditioning, without
other parts marked *)/cooling unit (if equipped
with air conditioning) 4. Heater unit 9. Blower resistor
5. Defroster duct 10. Blower fan switch/Blower fan and A/C
switch (if equipped with air conditioning)

Downloaded from www.Manualslib.com manuals search engine HEATER AND VENTILATION 1A-3
Diagnosis
Diagnosis Table
Wiring Circuit
Condition Possible Cause Correction
Heater blower won’t
work even when its
switch is ON.Blower fuse blown Replace fuse to check for short.
Blower resistor faulty Check resistor.
Blower fan switch faulty Check blower fan switch.
Blower motor faulty Replace motor.
Wiring or grounding faulty Repair as necessary.
Incorrect temperature
output.Control cables broken or binding Check cables.
Temperature control lever faulty Check control lever.
Control cable clamp position is faulty Check and adjustment.
Air damper broken Repair damper.
Air ducts clogged Repair air ducts.
Heater radiator leaking or clogged Replace radiator.
Heater hoses leaking or clogged Replace hoses.
When mode control
lever is changed, air
outlet port is not
changed.Control cable broken or binding Check cable.
Mode control lever faulty Check control lever.
Control cable clamp position is faulty Check and adjustment.
Air damper broken Repair damper.
Air ducts leaking on clogged Repair air ducts.
1. Heater motor 3. Heater blower motor switch 5. To ECM 7. To 4WD controller or A/C controller
(if equipped)
2. Fuse box 4. Heater resister 6. To combination switch

Downloaded from www.Manualslib.com manuals search engine HEATER AND VENTILATION 1A-5
Heater Blower Resistor
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disable air bag system, if equipped.
Refer to “Disabling Air Bag System” in Section 10B.
3) Disconnect resistor coupler.
4) Remove blower motor resistor (3) as shown figure.
INSPECTION
Measure each terminal-to-terminal resistance on resistor
If measured resistance is incorrect, replace heater blower motor
resistor.
Heater blower resistor resistance
Me-Lo: approx. 2.4
Ω
Me-Hi: approx. 1.2
Ω
INSTALLATION
1) Reverse removal procedure for installation.
2) Enable air bag system, if equipped.
Refer to “Enabling Air Bag System” in Section 10B.
Heater Control Lever Assembly
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disable air bag system, if equipped.
Refer to “Disabling Air Bag System” in Section 10B.
3) Remove meter cluster hood, ashtray, center garnish, instru-
ment glove box and radio or accessory case (if equipped),
Then remove mounting screws (2) from heater control lever
assembly (1).
1. Heater unit
2. Blower motor

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Diagnosis
General Diagnosis Table
Condition Possible Cause Correction
Cool air won’t come
out (A/C system won’t
operative)No refrigerant Perform recover, evacuation and charging.
Fuse blown Check fuses in main and circuit fuse
boxes, and check short circuit to ground.
A/C switch faulty Check A/C switch.
Blower fan switch faulty Check blower fan switch referring to Sec-
tion 1A.
A/C evaporator thermistor faulty Check A/C evaporator thermistor.
Dual pressure switch faulty Check dual pressure switch.
Wiring or grounding faulty Repair as necessary.
ECT sensor faulty Check ECT sensor referring to Section 6E.
ECM and its circuit faulty Check ECM and its circuit referring to Sec-
tion 6E.
4WD controller faulty Check 4WD controller referring to Section
3D.
Cool air won’t come
out (A/C compressor
won't operative)ECM faulty Check ECM and its circuit referring to Sec-
tion 6E.
Magnet clutch faulty Check magnet clutch.
Compressor drive belt loosen or broken Adjust or replace drive belt.
Compressor faulty Check compressor.
Cool air won’t come
out (A/C condenser
cooling fan motor
won’t operative)Fuse blown Check “A/C” fuse in main fuse box, and
check short circuit to ground.
Wiring or grounding faulty Repair as necessary.
Condenser cooling fan motor relay
faultyCheck condenser cooling fan motor relay.
Condenser cooling fan motor faulty Check condenser cooling fan motor.
Cool air won’t come
out (Blower fan motor
won’t operative)Fuse blown Check fuses in main and circuit fuse
boxes, and check short circuit to ground.
Blower fan motor resistor faulty Check blower fan motor resistor referring
to Section 1A.
Blower fan switch faulty Check blower fan switch referring to Sec-
tion 1A.
Wiring or grounding faulty Repair as necessary.
Blower fan motor faulty Check blower fan motor referring to Sec-
tion 1A.

Downloaded from www.Manualslib.com manuals search engine 1B-16 AIR CONDITIONING (OPTIONAL)
Electronical Diagnosis
Wiring Diagram
[A]: 4WD model 4. Dual pressure switch 9. Thermal switch 14. Circuit fuse box
[B]: 2WD model 5. 4WD controller 10. Ignition switch 15. Main fuse box
1. Blower fan motor 6. Condenser cooling fan motor relay 11. A/C evaporator thermistor 16. Generator
2. Blower fan motor resistor 7. Condenser cooling fan motor 12. ECT sensor 17. ECM
3. Blower fan motor switch and A/C switch 8. Compressor 13. Lighting switch

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8B
6
8D
8E
8B
9
10A
10B
SECTION 6
ENGINE GENERAL INFORMATION AND
DIAGNOSIS
GENERAL INFORMATION AND ENGINE DIAGNOSIS ..............................................................................
6-1
ENGINE MECHANICAL ...........................................................................................................................
6A1-1
ENGINE COOLING.....................................................................................................................................
6B-1
ENGINE FUEL ............................................................................................................................................
6C-1
ENGINE AND EMISSION CONTROL SYSTEM ........................................................................................
6E-1
IGNITION SYSTEM ....................................................................................................................................
6F-1
CRANKING SYSTEM .................................................................................................................................
6G-1
CHARGING SYSTEM .................................................................................................................................
6H-1
EXHAUST SYSTEM ...................................................................................................................................
6K-1
CONTENTS
General Information .......................................... 6-3
Statement on Cleanliness and Care ............... 6-3
General Information on Engine Service .......... 6-3
Precaution on fuel system service............... 6-4
Fuel pressure relief procedure .................... 6-5
Fuel leakage check procedure .................... 6-5
Engine Diagnosis .............................................. 6-6
General Description ........................................ 6-6
On-Board Diagnostic System (Vehicle with
Immobilizer Indicator Lamp) ............................ 6-6On-Board Diagnostic System (Vehicle without
Immobilizer Indicator Lamp)............................ 6-9
Precaution in Diagnosing Trouble ................. 6-10
Engine Diagnostic Flow Table ...................... 6-11
Customer problem inspection form
(example) .................................................. 6-13
Malfunction indicator lamp (MIL) check..... 6-14
Diagnostic trouble code (DTC) check ....... 6-14
Diagnostic trouble code (DTC)
clearance................................................... 6-15 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 the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
Whether the following systems (parts) are used in the particular vehicle or not depends on vehicle
specifications. Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor(s) or CO adjusting resistor
Three-way catalytic converter (TWC) and warm up three-way catalytic converter (WU-TWC)

Downloaded from www.Manualslib.com manuals search engine 6-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS
ECM TERMINAL VOLTAGE VALUES TABLE
For TYPE A (See NOTE)
NOTE:
Type A is other than follows.
Type B is left hand steering vehicle equipped with fasten seat belt light and EGR valve or right hand
steering vehicle equipped with fasten seat belt light and immobilizer control system.
TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
E191Ground––
2Ground––
3Ground––
4 EVAP canister purge valve 10 – 14 V Ignition switch ON
5Power steering pressure switch
(if equipped)0 – 1.3 VWhile engine running at idle speed, turn
steering wheel to right or left as far as it
stops
10 – 14 V Ignition switch ON
6 Idle air control valve 0 – 13 VAt specified idle speed after engine
warmed up
7 Heater of HO2S-1 10 – 14 V Ignition switch ON
8 Fuel injector NO.4 10 – 14 V Ignition switch ON
9 Fuel injector NO.1 10 – 14 V Ignition switch ON
10 Sensor ground––
11 Camshaft position sensor0 – 0.8 V and
4 – 6 VIgnition switch ON
12–– –
13Heater oxygen sensor-1 Refer to DTC P0130 diag. flow table
CO adjusting resistor (w/o HO2S) 0 – 5 V Ignition switch ON position
14
Engine coolant temp. sensor 0.55 - 0.95 VIgnition switch ON
Engine coolant temp. : 80 °C (176 °F)
15
Intake air temp. sensor 2.0 – 2.7 VIgnition switch ON
Intake air temp. : 20 °C (68 °F)
16 Throttle opening signal0.2 – 1.0 VIgnition switch ON position and throttle
valve at idle position
2.8 – 4.8 VIgnition switch ON position and throttle
valve fully open
17EGR valve (stepper motor coil 3, if
equipped)10 – 14 VIgnition switch ON position leaving engine
OFF
18EGR valve (stepper motor coil 1, if
equipped)10 – 14 VIgnition switch ON position leaving engine
OFF
19 Ignition coil #2––
20 Ignition coil #1––
21 Fuel injector NO.2 10 – 14 V Ignition switch ON
22 Power source for sensors 4.75 – 5.25 V Ignition switch ON
23 Crankshaft position sensor0 – 0.8 or
4 – 5 VIgnition switch ON position
24–– –
25 Knock sensor About 2.5 VAt specified idle speed after engine
warmed up

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-35
For TYPE B (See NOTE)
E1926 Manifold absolute pressure sensor 3.3 – 4.0 VIgnition switch ON
Barometric pressure : 100 kPa
(760 mmHg)
27 A/C evaporator temp. sensor 2.0 – 2.3 VIgnition switch ON A/C evaporation temp.
sensor at 25 °C (77 °F)
28EGR valve (stepper motor coil 4, if
equipped)10 – 14 VIgnition switch ON position leaving engine
OFF
29EGR valve (stepper motor coil 2, if
equipped)10 – 14 VIgnition switch ON position leaving engine
OFF
30–– –
31 Fuel injector NO.3 10 – 14 V Ignition switch ON TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
NOTE:
See NOTE in “ECM TERMINAL VOLTAGE VALUES TABLE” for applicable model.
TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
E191 Ground––
2 Ground––
3 Ground––
4 EVAP canister purge valve 10 – 14 V Ignition switch ON
5Power steering pressure switch
(if equipped)0 – 1.3 VWhile engine running at idle speed, turn
steering wheel to right or left as far as it
stops
10 – 14 V Ignition switch ON
6 Idle air control valve 0 – 13 VAt specified idle speed after engine
warmed up
7 Heater of HO2S-1 10 – 14 V Ignition switch ON
8 Fuel injector NO.4 10 – 14 V Ignition switch ON
9 Fuel injector NO.1 10 – 14 V Ignition switch ON
10 Sensor ground––
11 Camshaft position sensor0 – 0.8 V and
4 – 6 VIgnition switch ON
12–– –
13Heater oxygen sensor-1 Refer to DTC P0130 diag. flow table
CO adjusting resistor (w/o HO2S) 0 – 5 V Ignition switch ON position
14 Engine coolant temp. sensor 0.55 - 0.95 VIgnition switch ON
Engine coolant temp. : 80 °C (176 °F)
15 Intake air temp. sensor 2.0 – 2.7 VIgnition switch ON
Intake air temp. : 20 °C (68 °F)
16 Throttle opening signal0.2 – 1.0 VIgnition switch ON position and throttle
valve at idle position
2.8 – 4.8 VIgnition switch ON position and throttle
valve fully open
17EGR valve (stepper motor coil 3, if
equipped)10 – 14 VIgnition switch ON position leaving engine
OFF

Downloaded from www.Manualslib.com manuals search engine 6-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Component Location
NOTE:
The figure shows left-hand steering vehicle.
For right-hand steering vehicle, parts with (*) are installed at the other side.
1. IAT sensor a : Immobilizer indicator lamp (if equipped) A : ECM
2. TP sensor b : A/C condenser fan motor relay (if equipped) B : A/T control module
3. Monitor connector c : Main relay C : EVAP canister
4. CO adjusting resistor (if equipped) d : Fuel pump relay D : DLC
5. CKP sensor e : IAC valve E : ABS control module (if equipped)
6. MAP sensor f : EVAP canister purge valve
7. CMP sensor g : EGR valve (if equipped)
8. Transmission range switch h : Fuel injector
9. VSS i : Ignition coil assemblies
10. HO2S-1 (if equipped) j : MIL
11. HO2S-2 (if equipped)
12. ECT sensor
13. Knock sensor