sensor SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 6E-18 ENGINE AND EMISSION CONTROL SYSTEM
Air Intake System
Throttle body
ON-VEHICLE INSPECTION
Check that throttle valve lever (1) moves smoothly.
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Disconnect accelerator cable (1) from throttle valve lever.
1. Throttle body 4. Gasket 7. TP sensor screws
2. Throttle body gasket 5. Idle air control valve Tightening torque
3. TP sensor 6. IAC valve screws Do not reuse

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-19
4) Disconnect air cleaner outlet NO.2 hose (1) from throttle
body.
5) Disconnect electric connector from TP sensor (1) and IAC
valve (2).
6) Remove throttle body from intake manifold.
7) Disconnect engine coolant hoses from throttle body.
DISASSEMBLY
1) Remove TP sensor and IAC valve from throttle body.
CLEANING
Clean throttle body bore (1) and idle air passage (2) by blowing
compressed air.
REASSEMBLY
1) Install IAC valve to throttle body referring to “Idle Air Control
Valve” in this section.
2) Install TP sensor to throttle body referring to “Throttle Posi-
tion Sensor” in this section for installation.
NOTE:
While disassembling and assembling throttle body, use
special care not to deform levers on throttle valve shaft
or cause damage to any other parts.
NOTE:
TP sensor, idle air control valve or other components
containing rubber must not be placed in a solvent or
cleaner bath. A chemical reaction will cause these parts
to swell, harden or get distorted.

Downloaded from www.Manualslib.com manuals search engine 6E-20 ENGINE AND EMISSION CONTROL SYSTEM
INSTALLATION
1) Clean mating surfaces and install throttle body gasket to
intake manifold.
Use new gasket.
2) Connect engine coolant hoses.
3) Install throttle body (1) to intake manifold.
4) Connect connectors to TP sensor (2) and IAC valve (3)
securely.
5) Install air cleaner outlet No.2 hose (1) and pipe.
6) Connect accelerator cable and adjust cable play to specifica-
tion.
7) Refill cooling system.
8) Connect negative cable at battery.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-21
Idle air control valve (IAC valve)
REMOVAL
1) Remove throttle body from intake manifold referring to
“Throttle Body” in this section for removal.
2) Remove IAC valve from throttle body.
INSPECTION
1) Connect each connector to IAC valve (1), TP sensor and IAT
sensor.
2) Check that rotary valve (2) of lAC valve opens and closes
once and then stops in about 60 ms as soon as ignition
switch is turned ON.
INSTALLATION
1) Install new O-ring (2) to IAC valve (1).
2) Install IAC valve (1) to throttle body (3).
Tighten IAC valve screws to specified torque.
Tightening torque
IAC valve screws (a) : 3.5 N·m (0.35 kg-m, 2.5 lb-ft)
3) Install throttle body to intake manifold referring to “Throttle
Body” in this section for installation. NOTE:
This check should be performed by two people, one
person turns on ignition switch while the other checks
valve operation.
As valve operation is momentary, it may be over-
looked. To prevent this, perform this operation check 3
times or more continuously.
If rotary valve of lAC valve does not operate at all,
check wire harness for open and short. If wire harness
is in good condition, replace lAC valve and recheck.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-29
Electronic Control System
Engine control module (ECM)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disable air bag system, refer to “Disabling Air Bag System”
in Section 10B if equipped.
3) Remove glove box.
4) Disconnect ECM (1) and TCM (3) (if equipped) connectors.
5) Loosen 2 nuts (2) and remove ECM and TCM (if equipped).
INSTALLATION
1) Reverse removal procedure noting the following:
Connect connectors to ECM and TCM (if equipped)
securely.
Manifold absolute pressure sensor (MAP sensor)
INSPECTION
Check MAP sensor referring to “MAP Sensor Individual Check” in
DTC P0105 (No.11) Flow Table of Section 6. If malfunction is
found, replace.CAUTION:
As ECM consists of precision parts, be careful not to
expose it to excessive shock.

Downloaded from www.Manualslib.com manuals search engine 6E-30 ENGINE AND EMISSION CONTROL SYSTEM
Throttle position sensor (TP sensor)
INSPECTION
1) Disconnect negative cable at battery and connector from TP
sensor.
2) Using ohmmeter, check resistance between terminals under
each condition given in table below.
If check result is not satisfactory, replace TP sensor.
TP sensor resistance
3) Connect TP sensor connector securely.
4) Connect negative cable to battery.
REMOVAL
1) Remove throttle body from intake manifold referring to
“Throttle Body” in this section for removal.
2) Remove TP sensor from throttle body.
INSTALLATION
1) Install TP sensor (1) to throttle body.
Fit TP sensor to throttle body in such way that its holes (3)
are a little away from TP sensor screw holes (2) and turn TP
sensor clockwise so that those holes align.
Tightening torque
TP sensor screws (a) : 2.5 N·m (0.25 kg-m, 1.8 lb-ft)
2) Connect connector to TP sensor securely.
3) Connect battery negative cable to battery.TERMINALS RESISTANCE
Between 1 and
3 terminals4.0 – 6.0 k
Ω
ΩΩ Ω
Between 2 and
3 terminals20.0
Ω
ΩΩ Ω – 6.0 k
Ω
ΩΩ Ω, varying according to
throttle valve opening.
NOTE:
There should be more than 2 k
Ω
ΩΩ Ω resistance difference
between when throttle valve is at idle position and when
it is fully open.
1. Reference voltage terminal
2. Output voltage terminal
3. Ground terminal

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-31
Intake air temperature sensor (IAT sensor)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disconnect connector from IAT sensor (1).
3) Remove IAT sensor (1) from air cleaner case (2).
INSPECTION
Immerse temperature sensing part of IAT sensor in water (or ice)
and measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t show such characteristic as
shown in left figure, replace IAT sensor.
INSTALLATION
Reverse removal procedure noting the following.
Clean mating surfaces of IAT sensor and air cleaner case.
Connect IAT sensor connector (1) securely.

Downloaded from www.Manualslib.com manuals search engine 6E-32 ENGINE AND EMISSION CONTROL SYSTEM
Engine coolant temperature sensor (ECT sensor)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Drain coolant referring to Step 6) of “Cooling System Flush
and Refill” in Section 6B.
3) Disconnect connector from ECT sensor.
4) Remove ECT sensor (1) from water outlet cap.
INSPECTION
Immerse temperature sensing part of ECT sensor (1) in water (or
ice) and measure resistance between terminal “A” and “B” while
heating water gradually.
If measured resistance doesn’t show such characteristic as
shown in left figure, replace ECT sensor (1).
INSTALLATION
Reverse removal procedure noting the following:
Clean mating surfaces of ECT sensor (1) and water outlet
cap.
Check O-ring for damage and replace if necessary. WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-33
Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a) : 15 N·m (1.5 kg-m, 11.5 lb-ft)
Connect connector to ECT sensor (1) securely.
Refill coolant referring to “Cooling System Flush and Refill”
in Section 6B.
Heated oxygen sensor (Sensor-1 and sensor-2)
OXYGEN SENSOR HEATER INSPECTION
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals
“V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
Resistance of oxygen sensor heater
HO2S-1 : 5.0 – 6.4
Ω
ΩΩ Ω at 20 °C, 68 °F
HO2S-2 : 11.7 – 14.3
Ω
ΩΩ Ω at 20 °C, 68 °F
3) Connect sensor connector securely.
REMOVAL
NOTE:
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
1. Viewed from terminal side
WARNING:
To avoid danger of being burned, do not touch exhaust
system when system is hot. Oxygen sensor removal
should be performed when system is cool.

Downloaded from www.Manualslib.com manuals search engine 6E-34 ENGINE AND EMISSION CONTROL SYSTEM
1) Disconnect negative cable at battery.
2) For sensor-1, remove exhaust manifold cover (1) and dis-
connect connector of heated oxygen sensor and release its
wire harness from clamps.
3) For sensor-2, disconnect connector of heated oxygen sensor
and release its wire harness from clamp. Hoist vehicle and
then remove exhaust No.1 pipe covers (3).
4) Remove heated oxygen sensor (2) from exhaust manifold or
exhaust No.1 pipe.
INSTALLATION
Reverse removal procedure noting the following.
Tighten heated oxygen sensor (2) to specified torque.
Tightening torque
Heated oxygen sensor (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft)
Connect connector of heated oxygen sensor (2) and clamp
wire harness securely.
After installing heated oxygen sensor (2), start engine and
check that no exhaust gas leakage exists.
Camshaft position sensor
INSPECTION
Check camshaft position sensor referring to “DTC P0340 (No. 15)
Diag. Flow Table” in Section 6. If malfunction is found, replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect connector from camshaft position sensor.
3) Remove camshaft position sensor from cylinder head.
INSTALLATION
1) Check that O-ring is free from damage.
2) Check that camshaft position sensor and signal rotor tooth
are free from any metal particles and damage.
3) Install camshaft position sensor to sensor case.
Tightening torque
Camshaft position sensor bolt
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
4) Connect connector to it securely.
5) Connect negative cable to battery.
[A] : HO2S-1
[B] : HO2S-2