Switch SUZUKI JIMNY 2005 3.G Service Workshop Manual

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Engine Diagnosis
General Description
This vehicle is equipped with an engine and emission control system which are under control of ECM.
The engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnos-
tic system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of “On-
Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis accord-
ing to “ENGINE DIAGNOSTIC FLOW TABLE”.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust
system, etc. and the engine and emission control system in their structure and operation. In case of an engine
trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to
this flow table.
On-Board Diagnostic System (Vehicle with
Immobilizer Indicator Lamp)
ECM in this vehicle has following functions.
When the ignition switch is turned ON with the engine at a
stop, malfunction indicator lamp (MIL) (1) turns ON to check
the bulb of the malfunction indicator lamp (1).
When ECM detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it
makes the malfunction indicator lamp (1) in the meter cluster
of the instrument panel turn ON or flash (flashing only when
detecting a misfire which can cause damage to the catalyst)
and stores the malfunction area in its memory.
(If it detects that continuously 3 driving cycles are normal
after detecting a malfunction, however, it makes MIL (1) turn
OFF although DTC stored in its memory will remain.)
As a condition for detecting a malfunction in some areas in
the system being monitored by ECM and turning ON the
malfunction indicator lamp (1) due to that malfunction, 2 driv-
ing cycle detection logic is adopted to prevent erroneous
detection.
When a malfunction is detected, engine and driving condi-
tions then are stored in ECM memory as freeze frame data.
(For the details, refer to description on Freeze frame data.)
It is possible to communicate by using not only SUZUKI scan
tool (2) but also generic scan tool. (Diagnostic information
can be accessed by using a scan tool.)
WARM-UP CYCLE
A warm-up cycle means sufficient vehicle operation such that the
coolant temperature has risen by at least 22 °C (40 °F) from
engine starting and reaches a minimum temperature of 70 °C
(160 °F).

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On-Board Diagnostic System (Vehicle without
Immobilizer Indicator Lamp)
ECM diagnosis troubles which may occur in the area including
the following parts when the ignition switch is ON and the engine
is running, and indicates the result by turning on or flashing mal-
function indicator lamp (1).
Heated oxygen sensor (if equipped)
ECT sensor
TP sensor
IAT sensor
MAP sensor
CMP sensor
CKP sensor
Knock sensor
VSS
CPU (Central Processing Unit) of ECM
ECM and malfunction indicator lamp (1) operate as follows.
Malfunction indicator lamp (1) lights when the ignition switch
is turned ON (but the engine at stop) with the diagnosis
switch terminal ungrounded regardless of the condition of
Engine and Emission Control system. This is only to check
the malfunction indicator lamp (1) bulb and its circuit.
If the above areas of Engine and Emission Control system is
free from any trouble after the engine start (while engine is
running), malfunction indicator lamp (1) turns OFF.
When ECM detects a trouble which has occurred in the
above areas, it makes malfunction indicator lamp (1) turn ON
while the engine is running to warn the driver of such occur-
rence of trouble and at the same time it stores the trouble
area in ECM back-up memory. (The memory is kept as it is
even if the trouble was only temporary and disappeared
immediately. And it is not erased unless the power to ECM is
shut off for specified time below.)
ECM also indicates trouble area in memory by means of
flashing of malfunction indicator lamp (1) at the time of
inspection. (i.e. when connecting diagnosis switch terminal
(2) and ground terminal (4) of monitor connector (3) with a
service wire (5) and ignition switch is turned ON.)
NOTE:
When a trouble occurs in the above areas and disap-
pears soon while the diagnosis switch terminal is
ungrounded and the engine is running, malfunction
indicator lamp (1) lights and remains ON as long as the
trouble exists but it turns OFF when the normal condi-
tion is restored.
Time required to erase diagnostic trouble code mem-
ory thoroughly varies depending on ambient tempera-
ture as follows.

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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.

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Malfunction indicator lamp (MIL) check
1) Turn ON ignition switch (but the engine at stop) and check
that MIL lights.
If MIL does not light up (or MIL dims), go to “Diagnostic Flow
Table A-1” for troubleshooting.
If MIL flushes, go to “Diagnostic Flow Table A-3” for trouble
shooting (vehicle without immobilizer indicator lamp).
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM, go to
“Diagnostic Flow Table A-2” for troubleshooting.
Diagnostic trouble code (DTC) check
[Using SUZUKI Scan Tool]
1) Prepare SUZUKI scan tool.
2) With ignition switch OFF, connect it to data link connector
(DLC) (1) located on underside of instrument panel at
driver’s seat side.
Special tool
(A) : SUZUKI scan tool
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC, pending DTC and freeze frame data according to
instructions displayed on scan tool and print it or write it
down.
Refer to scan tool operator’s manual for further details.
If communication between scan tool and ECM is not possi-
ble, check if scan tool is communicable by connecting it to
ECM in another vehicle. If communication is possible in this
case, scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle with
which communication was not possible.
5) After completing the check, turn ignition switch off and dis-
connect scan tool from data link connector.
[Without Using SUZUKI Scan Tool] (Vehicle Without
Immobilizer Indicator Lamp)
1) Check malfunction indicator lamp referring to “Malfunction
Indicator Lamp Check” in this section.
2) With the ignition switch OFF position, connect diagnosis
switch terminal (3) and ground terminal (2) in monitor con-
nector (1) with service wire (4).
3) With the ignition switch ON position and leaving engine OFF,
read DTC from flashing pattern of malfunction indicator
lamp. Refer to “Diagnostic Trouble Code Table”.
If lamp does not flash or remains ON or OFF, go to “Diag-
nostic Flow Table A-4”.

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4) After completing the check, turn the ignition switch OFF posi-
tion and disconnect service wire from monitor coupler.
Diagnostic trouble code (DTC) clearance
[Using SUZUKI Scan Tool]
1) Connect SUZUKI scan tool to data link connector in the
same manner as when making this connection for DTC
check.
2) Turn ignition switch ON.
3) Erase DTC and pending DTC according to instructions dis-
played on scan tool. Refer to scan tool operator’s manual for
further details.
4) After completing the clearance, turn ignition switch off and
disconnect scan tool from data link connector.
[Without Using SUZUKI Scan Tool]
1) Turn the ignition switch OFF position.
2) Disconnect battery negative cable for specified time below to
erase diagnostic trouble code stored in ECM memory and
reconnect it.
Time required to erase DTC NOTE:
If abnormality or malfunction lies in two or more areas,
malfunction indicator lamp indicates applicable codes
three times each.
And flashing of these codes is repeated as long as
diagnosis terminal is grounded and ignition switch is
held at ON position.
Take a note of diagnostic trouble code indicated first.
NOTE:
DTC and freeze frame data stored in ECM memory are
also cleared in following cases. Be careful not to clear
them before keeping their record.
When power to ECM is cut off (by disconnecting bat-
tery cable, removing fuse or disconnecting ECM con-
nectors)
When the same malfunction (DTC) is not detected
again during 40 engine warm-up cycles.
Ambient temperature Time to cut power to ECM
Over 0 °C (32 °F) 30 sec. or longer
Under 0 °C (32 °F)Not specifiable.
Select a place with higher than
0 °C (32 °F) temperature.

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Engine basic inspection
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been
found in visual inspection.
Follow the flow table carefully.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check battery voltage.
Is it 11 V or more?Go to Step 3. Charge or replace battery.
3 Is engine cranked? Go to Step 4. Go to “Diagnosis” in Sec-
tion 6G.
4 Does engine start? Go to Step 5. Go to Step 9.
5 Check idle speed as follows :
1) Warm up engine to normal operating temp.
2) Shift transmission to neutral position for M/T
(“P” position for A/T).
3) All of electrical loads are switched off.
4) Check engine idle speed with scan tool.
See Fig. 1.
Is it 650 – 750 r/min (700 – 800 r/min. for A/T
vehicle)?Go to Step 6. Go to “Engine Diagnosis
Table”.
6 Is SUZUKI scan tool available? Go to Step 8. Go to Step 7.
7 Check ignition timing as follows :
1) Connect test switch terminal (2) of monitor
coupler (1) to ground. See Fig. 2.
2) Remove air cleaner bolt and crips and shift
air cleaner position to observe ignition tim-
ing.
3) Using timing light (1), check initial ignition
timing.
See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “Engine Diagnosis
Table”.Check ignition control
related parts referring to
Section 6F.
8 Check ignition timing as follows :
1) Select “MISC” mode on SUZUKI scan tool
and fix ignition timing to initial one. See Fig.
3.
2) Remove air cleaner bolt and crips and shift
air cleaner position to observe ignition tim-
ing.
3) Using timing light (1), check initial ignition
timing. See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “Engine Diagnosis
Table”.Check ignition control
related parts referring to
Section 6F.
9 Check immobilizer system malfunction as fol-
lows (if equipped) :
1) Check immobilizer indicator lamp or MIL
(malfunction indicator lamp) for flashing.
Is it flashing when ignition switch is turned to
ON position?Go to “Diagnosis” in Sec-
tion 8G.Go to Step 10.

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[A] Fig. 1 for Step 5 / [B] Fig. 2 for Step 7 / [C] Fig. 3 for Step 810 Check fuel supply as follows :
1) Check to make sure that enough fuel is filled
in fuel tank.
2) Turn ON ignition switch for 2 seconds and
then OFF. See Fig. 5.
Is fuel return pressure (returning sounds) felt
from fuel feed hose (1) when ignition switch is
turned ON?Go to Step 12. Go to Step 11.
11 Check fuel pump for operating.
1) Was fuel pump operating sound heard from
fuel filler for about 2 seconds after ignition
switch ON and stop?Go to “Diag. Flow Table
B-3”.Go to “Diag. Flow Table
B-2”.
12 Check ignition spark as follows :
1) Disconnect injector couplers.
2) Remove spark plugs and connect them to
high tension cords.
3) Ground spark plugs.
4) Crank engine and check if each spark plug
sparks.
Is it in good condition?Go to Step 13. Go to “Ignition Spark Test”
in Section 6F.
13 Check fuel injector for operation as follows :
1) Install spark plugs and connect injector con-
nectors.
2) Using sound scope (2), check operating
sound of each injector (3) when cranking
engine. See Fig. 6.
Was injector operating sound heard from all
injectors?Go to “Engine Diagnosis
Table”.Go to “Diag. Flow Table
B-1”. Step Action Yes No
[B] : When not using SUZUKI scan tool :
[C] : When using SUZUKI scan tool

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Excessive engine oil
consumptionSticky piston ring Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn piston and cylinder Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn piston ring groove and ring Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Improper location of piston ring gap Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn or damaged valve stem seal Valves and cylinder head in Section
6A1.
Worn valve stem Valves and cylinder head in Section
6A1.
Low oil pressure
Improper oil viscosity ITEM1-3 Engine oil and oil filter
change in Section 0B.
Malfunctioning oil pressure switch Oil pressure switch in Section 8.
Clogged oil strainer Oil pan and oil pump strainer in Sec-
tion 6A1.
Functional deterioration of oil pump Oil pump in Section 6A1.
Worn oil pump relief valve Oil pump in Section 6A1.
Excessive clearance in various sliding
partsRefer to Section 6A1.
Engine noise
See NOTE below.Improper valve lash Valve lash in Section 6A1.
Worn valve stem and guide Valves and cylinder head in Section
6A1.
Weak or broken valve spring Valve springs in Section 6A1.
Warped or bent valve Valves and cylinder head in Section
6A1.
Loose camshaft housing bolts Camshaft in Section 6A1.
Worn piston, ring and cylinder bore Pistons and cylinders in Section 6A1.
Worn crankpin bearing Crankpin and connecting rod bearing
in Section 6A1.
Worn crankpin Crankpin and connecting rod bearing
in Section 6A1.
Loose connecting rod nuts Connecting rod in Section 6A1.
Low oil pressure Previously outlined.
Worn crankshaft journal bearing Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Worn crankshaft journal Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Loose lower crankcase (bearing cap) bolts Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Excessive crankshaft thrust play Main bearings, Crankshaft and cylin-
der block in Section 6A1. Condition Possible Cause Reference Item
NOTE:
Before checking the mechanical noise, make sure that :
Ignition timing is properly adjusted.
Specified spark plug is used.
Specified fuel is used.

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Scan Tool Data
As the data values given below are standard values estimated on the basis of values obtained from the normally
operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condi-
tion, there may be cases where the checked value does not fall within each specified data range. Therefore,
judgment as abnormal should not be made by checking with these data alone.
Also, conditions in the below table that can be checked by the scan tool are those detected by ECM and output
from ECM as commands and there may be cases where the engine or actuator is not operating (in the condi-
tion) as indicated by the scan tool. Be sure to use the timing light to check the ignition timing.
NOTE:
With the generic scan tool, only star (
✱
✱✱ ✱) marked data in the table below can be read.
The triangle (
∆
∆∆ ∆) marked data in the table below can not be read for vehicle without immobilizer indi-
cator lamp at combination meter.
When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the
neutral gear position and A/T gear to the “Park” position and pull the parking brake fully. Also, if
nothing or “no load” is indicated, turn OFF A/C, all electric loads, P/S and all the other necessary
switches.
SCAN TOOL DATA CONDITION REFERENCE VALUES
✱
✱✱ ✱FUEL SYSTEM B1 (FUEL
SYSTEM STATUS)At specified idle speed after warming up CLOSED (closed loop)
✱
✱✱ ✱
CALC LOAD
(CALCULATED LOAD
VALUE)At specified idle speed with no load after
warming up3 – 9 %
At 2500 r/min with no load after warming up 12 – 17 %
✱
✱✱ ✱COOLANT TEMP.
(ENGINE COOLANT
TEMP.)At specified idle speed after warming up 80 – 100 °C, 176 – 212 °F
✱
✱✱ ✱SHORT FT B1 (SHORT
TERM FUEL TRIM)At specified idle speed after warming up– 20 – +20 %
✱
✱✱ ✱LONG FT B1 (LONG TERM
FUEL TRIM)At specified idle speed after warming up– 15 – +15 %
✱
✱✱ ✱MAP (INTAKE MANIFOLD
ABSOLUTE PRESSURE)At specified idle speed with no load after30 – 37 kPa,
220 – 340 mmHg
✱
✱✱ ✱
ENGINE SPEED At idling with no load after warming upDesired idle speed
±50 r/min
✱
✱✱ ✱VEHICLE SPEED At stop 0 km/h, 0 MPH
✱
✱✱ ✱IGNITION ADVANCE
(IGNITION TIMING
ADVANCE FOR NO.1 CYL-
INDER)At specified idle speed with no load after
warming up5 – 16° BTDC
✱
✱✱ ✱
INTAKE AIR TEMP. At specified idle speed after warming upAmbient temp. :
+15 °C (59 °F)
–5 °C (23 °F)
✱
✱✱ ✱MAF (MASS AIR FLOW
RATE)At specified idle speed with no load after
warming up1 – 4 gm/sec
✱
✱✱ ✱
THROTTLE POS
(THROTTLE POSITION)Ignition switch
ON / engine
stoppedThrottle valve fully closed 7 – 18 %
Throttle valve fully open 70 – 90 %
✱
✱✱ ✱O2S B1 S1 (HEATED OXY-
GEN SENSOR-1)At specified idle speed after warming up 0.01 – 0.95 V

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∆✱
✱✱ ✱O2S B1 S2 (HEATED OXY-
GEN SENSOR-2)When engine is running at 2000 r/min. for
3 min or longer after warming up.0.01 – 0.95 V
∆✱
✱✱ ✱PSP SW No load to power steering. OFF
DESIRED IDLE
(DESIRED IDLE SPEED)At idling with no load after warming up, M/T
at neutral, A/T at “P” rangeM/T 700 r/min
A/T 750 r/min
TP SENSOR VOLT
(THROTTLE POSITION
SENSOR OUTPUT VOLT-
AGE)Ignition switch
ON / engine
stoppedThrottle valve fully closed More than 0.2 V
Throttle valve fully open Less than 4.8 V
INJ PULSE WIDTH (FUEL
INJECTION PULSE
WIDTH)At specified idle speed with no load after
warming up2.0 – 3.6 msec.
At 2500 r/min with no load after warming up 2.0 – 3.6 msec.
IAC FLOW DUTY (IDLE
AIR CONTROL FLOW
DUTY)At idling with no load after warming up 5 – 25 %
TOTAL FT B1 At specified idle speed after warming up– 35 – +35 %
BATTERY VOLTAGE Ignition switch ON / engine stop 12 – 15 V
CANIST PRG DUTY
(EVAP CANISTER PURGE
FLOW DUTY)–0 – 100 %
CLOSED THROT POS
(CLOSED THROTTLE
POSITION)Throttle valve at idle position ON
Throttle valve opens larger than idle posi-
tionOFF
FUEL CUTWhen engine is at fuel cut condition ON
Other than fuel cut condition OFF
A/C CONDENSER FANIgnition switch
ONA/C not operating OFF
A/C operating ON
ELECTRIC LOADIgnition switch ON / Headlight, small light,
heater fan and rear window defogger all
turned OFFOFF
Ignition switch ON / Headlight, small light,
heater fan or rear window defogger turned
ONON
A/C SWITCHEngine running after warming up, A/C not
operatingOFF
Engine running after warming up, A/C oper-
atingON
PNP SIGNAL (PARK / NEU-
TRAL POSITION SIGNAL)
A/T onlyIgnition switch
ONSelector lever in “P” or “N”
positionP/N Range
Selector lever in “R”, “D”,
“2” or “L” positionD Range
EGR VALVE At specified idle speed after warming up 0 %
∆FUEL TANK LEVEL–0 – 100 %
BAROMETRIC PRESS–Display the barometric pres-
sure
FUEL PUMPWithin 3 seconds after ignition switch ON or
engine runningON
Engine stop at ignition switch ON. OFF SCAN TOOL DATA CONDITION REFERENCE VALUES