turn SUZUKI JIMNY 2005 3.G Service Workshop Manual

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 6E-22 ENGINE AND EMISSION CONTROL SYSTEM
Fuel Delivery System
Fuel pressure inspection
1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres-
sure Relief Procedure” in Section 6.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel delivery pipe
(1) and fuel feed hose (2) as shown in figure, and clamp
hoses securely to ensure no leaks occur during checking.
Special tool
(A) : 09912-58442
(B) : 09912-58432
(C) : 09912-58490
4) Check that battery voltage is above 11 V.
5) Turn ignition switch ON to operate fuel pump and after 2 sec-
onds turn it OFF. Repeat this 3 or 4 times and then check
fuel pressure.
Fuel pressure specification WARNING:
Be sure to perform work in a well-ventilated area and
away from any open flames, or there is a risk of a fire
breaking out.
CAUTION:
A small amount of fuel may be released when fuel hose is
disconnected. Place container under the joint with a
shop cloth so that released fuel is caught in container or
absorbed in cloth. Place that cloth in an approved con-
tainer.
3. Fuel return pipe
CONDITION FUEL PRESSURE
With fuel pump operating and
engine stopped270 – 310 kPa
2.7 – 3.1 kg/cm
2,
38.4 – 44.0 psi
At specified idle speed 210 – 260 kPa
2.1 – 2.6 kg/cm
2,
29.8 – 37.0 psi
With 1 min. after engine (fuel
pump) stop (Pressure
reduces as time passes)over 200 kPa
2.0 kg/cm
2, 28.4 psi

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-23
6) Start engine and warm it up to normal operating tempera-
ture.
7) Measure fuel pressure at idling.
If measured pressure doesn’t satisfy specification, refer to
“Diagnostic Flow Table B-3” in Section 6 and check each
possibly defective part. Replace if found defective.
8) After checking fuel pressure, remove fuel pressure gauge.
9) Remove special tools from fuel delivery pipe.
10) Connect fuel feed hose to fuel delivery pipe and clamp it
securely.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
Fuel pump
ON-VEHICLE INSPECTION
1) Remove filler cap and turn ON ignition switch (2). Then fuel
pump operating sound should be heard from fuel filler (1) for
about 2 seconds and stop. Be sure to reinstall fuel filler cap
after checking.
If above check result is not satisfactory, advance to “Diag-
nostic Flow Table B-2” in Section 6.
2) Turn OFF ignition switch and leave over 10 minutes as it is.CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following pro-
cedures.
Place fuel container under joint.
Cover joint with rag and loosen joint nut slowly to
release fuel pressure gradually.
CAUTION:
When fuel filler cap is removed in any procedure, work
must be done in a well-ventilated area, keep away from
any open flames and without smoking.
NOTE:
The fuel pressure regulator is the one body with the fuel
pump assembly so individual inspection of it is impossi-
ble.

Downloaded from www.Manualslib.com manuals search engine 6E-24 ENGINE AND EMISSION CONTROL SYSTEM
3) Fuel pressure should be felt at fuel feed hose (1) for 2 sec-
onds after ignition switch ON.
If fuel pressure is not felt, advance to “Diagnostic Flow Table
B-3” in Section 6.
REMOVAL
Remove fuel tank from body according to procedure described in
“Fuel Tank” of Section 6C and remove fuel pump from fuel tank.
INSPECTION
Check fuel pump filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel tank.
INSTALLATION
1) Install fuel pump to its bracket.
2) Install fuel pump to fuel tank and then install fuel tank to
body according to procedure described in “Fuel Tank” of
Section 6C.
Fuel pressure regulator
ON-VEHICLE INSPECTION
Perform fuel pressure inspection according to procedure
described in “Fuel Pressure Inspection” of this section.
REMOVAL
1) Relieve fuel pressure according to procedure described on
“Fuel Pressure Relief Procedure” in Section 6.
2) Disconnect battery negative cable from battery.
3) Disconnect vacuum hose (1) from fuel pressure regulator
(2).
4) Remove fuel pressure regulator from fuel delivery pipe.
5) Disconnect fuel return hose (3) from fuel pressure regulator.
CAUTION:
A small amount of fuel may be released when it is from
delivery pipe.
Place a shop cloth under delivery pipe so that released
fuel is absorbed in it.

Downloaded from www.Manualslib.com manuals search engine 6E-26 ENGINE AND EMISSION CONTROL SYSTEM
REMOVAL
1) Relieve fuel pressure according to procedure described in
“Fuel Pressure Relief Procedure” in Section 6.
2) Disconnect battery negative cable at battery.
3) Disconnect fuel injector couplers and release wire harness
from clamps.
4) Remove clamp bolt for fuel feed pipe and return pipe.
5) Remove fuel delivery pipe bolts (2).
6) Remove fuel injector(s) (3).
INSPECTION
1) Install injector (3) and fuel pressure regulator (4) to special
tool (injector checking tool).
Special tool
(A) : 09912-58421
2) Connect special tools (hose and attachment) to fuel feed
hose (1) of vehicle.
Special tool
(B) : 09912-58432
3) Connect special tool (test lead) to injector.
Special tool
(C) : 09930-88530
4) Install suitable vinyl tube onto injector nozzle to prevent fuel
from splashing out when injecting. CAUTION:
A small amount of fuel may come out after removal of
fuel injectors, cover them with shop cloth.
WARNING:
As fuel is injected in this inspection, perform in a well
ventilated area and away from open flames.
Use special care to prevent sparking when connecting
and disconnecting test lead to and from battery.
2. Fuel return line

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-27
5) Put graduated cylinder under injector as shown.
6) Operate fuel pump and apply fuel pressure to injector as fol-
lows:
a) When using SUZUKI scan tool :
i) Connect SUZUKI scan tool to DLC with ignition switch
OFF.
ii) Turn ignition switch ON, clear DTC and select “MISC
TEST” mode on SUZUKI scan tool.
iii) Turn fuel pump ON by using SUZUKI scan tool.
(A) : SUZUKI scan tool
b) Without using SUZUKI scan tool :
i) Remove fuel pump relay from connector.
ii) Connect two terminals of relay connector using service
wire (1) as shown in figure.
iii) Turn ignition switch ON.
7) Apply battery voltage (3) to injector (2) for 15 seconds and
measure injected fuel volume with graduated cylinder.
Test each injector two or three times.
If not within specification, replace injector.
Injected fuel volume
43 – 47 cc/15 sec. (1.45/1.51 – 1.58/1.65 US/Imp. oz/15 sec.)
8) Check fuel leakage from injector nozzle. Do not operate
injector for this check (but fuel pump should be at work).
If fuel leaks (1) more than following specifications, replace.
Fuel leakage (1)
Less than 1 drop/min. CAUTION:
Check to make sure that connection is made between
correct terminals. Wrong connection can cause damage
to ECM, wire harness, etc.
4. Keep as far apart as possible
[A] : When using SUZUKI scan tool
[B] : Without using SUZUKI scan tool

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 6E-38 ENGINE AND EMISSION CONTROL SYSTEM
2) Connect battery (3) to A/C condenser fan motor coupler (2)
as shown in figure, then check that the A/C condenser fan
motor (1) operates smoothly.
If A/C condenser fan motor does not operate smoothly,
replace motor.
Reference current data of A/C condenser fan motor
Approx. 6.7 – 8.3 A at 12 V
Output signals of throttle valve opening and engine
coolant temp. (Vehicle with A/T only)
THROTTLE VALVE OPENING SIGNAL INSPECTION
Check throttle valve opening (throttle position) signal referring to
step 1 of “DTC P1700 (No.32 or 33) Flow Table” in Section 7B.
If check result is not satisfactory, check each wire harness, circuit
connections and TP sensor.
ENGINE COOLANT TEMP. SIGNAL INSPECTION
Check engine coolant temp. signal referring to step 1 of “DTC
P1709 (No.51) Flow Table” in Section 7B.
If check result is not satisfactory, check each wire harness, circuit
connection and ECT sensor.
Emission Control System
EGR system (If equipped)
SYSTEM INSPECTION (USING SUZUKI SCAN TOOL)
1) Connect SUZUKI scan tool to DLC with ignition switch OFF.
2) Turn ignition switch ON and then select “DATA LIST” mode
on scan tool.
3) Make sure that vehicle condition is as following.
Vehicle speed = 0 km/h (0 KPH)
Engine speed ≤ 3000 rpm
4) Clear DTC by using “CLEAR INFO” mode.
5) With engine idling (without depressing accelerator pedal),
open EGR valve by using “STEP EGR” mode in “MISC
TEST” menu.
In this state, according as EGR valve opening increases
engine idle speed drops. If not, possible cause is clogged
EGR gas passage, stuck or faulty EGR valve, poor perfor-
mance of ECT sensor or TP sensor or DTC and/or pending
DTC is (are) stored in ECM memory.
1. SUZUKI scan tool display
2. EGR valve opening (0: Close, 100: Full Open)

Downloaded from www.Manualslib.com manuals search engine 6E-40 ENGINE AND EMISSION CONTROL SYSTEM
1) Disconnect purge hose (1) from EVAP canister.
2) Place finger against the end of disconnected hose and check
that vacuum is not felt there when engine is cool and running
at idle speed.
3) Connect purge hose to EVAP canister and warm up engine
to normal operating temperature.
4) Turn ignition switch OFF.
5) Restart engine and run it at 2000 r/min. for 2 min. or more.
6) Disconnect purge hose from EVAP canister.
7) Also check that vacuum is felt when engine is running at
3000 r/min.
8) If vacuum is not felt in Step 7), run engine at idle for 8 min. or
more and then repeat check in Step 7).
If check result is not satisfactory in Steps 2) and 8), check vac-
uum passage, hoses, EVAP canister purge valve, wire harness
and ECM.
VACUUM PASSAGE INSPECTION
Start engine and run it at idle speed. Disconnect vacuum hose (1)
from EVAP canister purge valve (2). With finger placed against
hose disconnected, check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.
VACUUM HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration.
Replace as necessary.
EVAP CANISTER PURGE VALVE INSPECTION
Check EVAP canister purge valve referring to step 2 of “DTC
P0443 Flow Table” in Section 6.
If found malfunction, replace.NOTE:
ECM detects a change in the purge fuel vapor concentra-
tion and sometimes stops purging for several seconds
but this is nothing abnormal.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-43
Tightening Torque Specifications
09931-76030
16/14 pin DLC cable Tech 2 kit (SUZUKI scan
tool) (See NOTE “C”.)
NOTE:
“A”: This kit includes the following items.
1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose & clamp,
6. Body attachment-2 & washer, 7. Hose attachment-1, 8. Hose attachment-2
“B”: This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable (14/26 pin, 09931-76040),
5. Test lead / probe, 6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
“C”: This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply
Fastening partTightening torque
Nm kg-m lb-ft
TP sensor mounting screw 2.5 0.25 1.8
IAC valve screw 3.5 0.35 2.5
ECT sensor 15 1.5 11.5
Heated oxygen sensor-1 and -2 45 4.5 32.5
Camshaft position sensor 10 1.0 7.5
Fuel pressure regulator bolt 10 1.0 7.5