turn SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM) 6F-1
6G
6F2
6G
6H
7D
7E
7F
7A1
7A1
7D
7E
7F
8A
8B
8C
8D
8E
6K
6F
7A
10
10A
10B
SECTION 6F
IGNITION SYSTEM
(ELECTRONIC IGNITION SYSTEM)
CONTENTS
General Description ........................................ 6F-2
Diagnosis ......................................................... 6F-3
On-Vehicle Service.......................................... 6F-5
Ignition Spark Test ........................................ 6F-5
High-tension Cords ....................................... 6F-5
Spark Plugs ................................................... 6F-6Ignition Coil Assembly (Including Ignitor) ...... 6F-7
Crankshaft Position Sensor (CKP Sensor) ... 6F-8
Ignition Timing............................................... 6F-8
Special Tools ................................................. 6F-10
Tightening Torque Specification ................. 6F-10

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).

Downloaded from www.Manualslib.com manuals search engine 6F-2 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
General Description
The ignition system is an electronic (distributorless) ignition system. It consists of the parts as described below
and has an electronic ignition control system.
ECM
It detects the engine and vehicle conditions through the signals from the sensors, determines the most suit-
able ignition timing and time for electricity to flow to the primary coil and sends a signal to the ignitor (power
unit) in the ignition coil assembly.
Ignition coil assembly (including an ignitor)
The ignition coil assembly has a built-in ignitor which turns ON and OFF the current flow to the primary coil
according to the signal from ECM. When the current flow to the primary coil is turned OFF, a high voltage is
induced in the secondary coil.
High tension cords and spark plugs.
CMP sensor (Camshaft position sensor) and CKP sensor (Crankshaft position sensor)
Using signals from these sensors, ECM identifies the specific cylinder whose piston is in the compression
stroke, detects the crank angle and adjust initial ignition timing automatically.
TP sensor, ECT sensor, MAP sensor and other sensors/switches
Refer to “Electronic Control System” in Section 6E for details.
Although this ignition system does not have a distributor, it has two ignition coil assemblies (one is for No.1 and
No.4 spark plugs and the other is for No.2 and No.3 spark plugs). When an ignition signal is sent from ECM to
the ignitor in the ignition coil assembly for No.1 and No.4 spark plugs, a high voltage is induced in the secondary
coil and that passes through the high-tension cords and causes No.1 and No.4 spark plugs to spark simulta-
neously. Likewise, when an ignition signal is sent to the ignitor in the other ignition coil assembly, No.2 and No.3
spark plugs spark simultaneously.
SYSTEM COMPONENTS
1. ECM 7. ECT sensor 13. Monitor connector
2. Ignition coil assembly for No.1 and No.4 spark plugs 8. IAT sensor 14. Knock sensor
3. Ignition coil assembly for No.2 and No.3 spark plugs 9. TP sensor 15. DLC
4. CMP sensor 10. VSS 16. Spark plugs
5. CKP sensor 11. Transmission range switch (A/T)
6. MAP sensor 12. High-tension cords

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-1
6F1
6F2
6H
7C1
7D
7E
7C1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
6G
7A1
10A
10B
SECTION 6G
CRANKING SYSTEM
CONTENTS
General Description ....................................... 6G-2
Cranking Circuit ............................................ 6G-2
Diagnosis ........................................................ 6G-2
Diagnosis Table ........................................... 6G-2Performance Test .........................................6G-4
On-Vehicle Service .........................................6G-5
Starting Motor ...............................................6G-5
Specifications..................................................6G-7

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:
Starting motor varies depending on specifications, etc. Therefore, be sure to check model and speci-
fication of vehicle being serviced before replacing parts.

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-3
Condition Possible Cause Correction
Motor not running
(No operating sound of
magnetic switch)Shift lever switch is not in P or N, or not adjusted
(A/T)Shift in P or N, or adjust switch.
Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Poor contact in battery terminal connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch and mag-
netic switchReplace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and magnetic
switchRepair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Motor not running
(Operating sound of
magnetic switch
heard)Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor contacting action
of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfac-
tory, inspect starting
motor)Insufficient contact of magnetic switch main con-
tactsReplace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn commutator Repair commutator or replace
armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor run-
ning, but not cranking
engineWorn pinion tip Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel (M/T) or drive
plate (A/T).
Noise
Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace pinion or flywheel
(M/T) or drive plate (A/T).
Poor sliding of pinion (failure in return movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.

Downloaded from www.Manualslib.com manuals search engine 6G-4 CRANKING SYSTEM
Performance Test
PULL-IN TEST
Connect battery to magnetic switch as shown.
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace magnetic switch.
HOLD-IN TEST
While connected as above with plunger out, disconnect negative
lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace magnetic switch.
PLUNGER AND PINION RETURN TEST
Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace magnetic switch. Starting motor does
not stop runningFused contact points of magnetic switch Replace magnetic switch.
Short-circuit between turns of magnetic switch coil
(layer short-circuit)Replace magnetic switch.
Failure of returning action in ignition switch Replace.
CAUTION:
Each test must be performed within 3 – 5 seconds to
avoid coil from burning.
NOTE:
Before testing, disconnect lead wire from terminal M.
1. Terminal “S”
2. Terminal “M”
3. Lead wire (switch to motor)
Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-1
6F1
6F2
6G
6K
7D
7E
7F
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
7A
6H
7B1
10B
SECTION 6H
CHARGING SYSTEM
CONTENTS
General Description ....................................... 6H-2
Battery .......................................................... 6H-2
Generator ..................................................... 6H-4
Diagnosis ........................................................ 6H-6
Battery .......................................................... 6H-6
Generator ..................................................... 6H-7
On-Vehicle Service......................................... 6H-9
Battery .......................................................... 6H-9
Jump starting in case of emergency......... 6H-9
Dismounting ........................................... 6H-11
Handling ................................................. 6H-11
Remounting ............................................ 6H-11Generator ................................................... 6H-11
Generator belt ........................................ 6H-11
Unit Repair Overhaul ................................... 6H-12
Generator ................................................... 6H-12
Dismounting ........................................... 6H-12
Remounting ............................................ 6H-13
Disassembly and reassembly ................ 6H-13
Inspection ............................................... 6H-14
Specifications............................................... 6H-17
Battery........................................................ 6H-17
Generator ................................................... 6H-17
Tightening Torque Specification ................ 6H-17

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).

Downloaded from www.Manualslib.com manuals search engine 6H-2 CHARGING SYSTEM
General Description
Battery
The battery has three major functions in the electrical system.
It is a source of electrical energy for cranking the engine.
It acts as a voltage stabilizer for the electrical system.
It can, for a limited time, provide energy when the electrical
load exceeds the output of the generator.
CARRIER AND HOLD-DOWN
The battery carrier should be in good condition so that it will sup-
port the battery securely and keep it level.
Before installing the battery, the battery carrier and hold-down
clamp should be clean and free from corrosion and make certain
there are no parts in carrier.
To prevent the battery from shaking in its carrier, the hold-down
bolts should be tight enough but not over-tightened.
ELECTROLYTE FREEZING
The freezing point of electrolyte depends on its specific gravity.
Since freezing may ruin a battery, it should be protected against
freezing by keeping it in a fully charged condition. If a battery is
frozen accidentally, it should not be charged until it is warmed.
SULFATION
If the battery is allowed to stand for a long period in discharged
condition, the lead sulfate becomes converted into a hard, crystal-
line substance, which will not easily turn back to the active mate-
rial again during the subsequent recharging. “Sulfation” means
the result as well as the process of that reaction.
Such a battery can be revived by very slow charging and may be
restored to usable condition but its capacity is lower than before.

Downloaded from www.Manualslib.com manuals search engine 6H-8 CHARGING SYSTEM
UNDERCHARGED BATTERY
This condition, as evidenced by slow cranking or indicator clear
with red dot can be caused by one or more of the following condi-
tions even though indicator lamp may be operating normal.
Following procedure also applies to cars with voltmeter and
ammeter.
1) Make sure that undercharged condition has not been caused
by accessories left on for extended period of time.
2) Check drive belt for proper tension.
3) If battery defect is suspected, refer to BATTERY section.
4) Inspect wiring for defects. Check all connections for tight-
ness and cleanliness, battery cable connections at battery,
starting motor and ignition ground cable.
5) Connect voltmeter and ammeter as shown in the figure.
6) Measure current and voltage.
No-load Check
1) Run engine from idling up to 2,000 rpm and read meters.
Standard current
10 A maximum
Standard voltage
14.4 – 15.0 V (at 20 °C, 68 °F)
Higher Voltage
If voltage is higher than standard value, check ground of brushes.
If brushes are not grounded, replace IC regulator.
Lower Voltage
If voltage is below or in standard value, increase engine speed up
to 2,000 – 2,500 rpm soon after starting engine, and read maxi-
mum value on ammeter immediately.
If current is less than 49 A, repair or replace generator.NOTE:
Use fully charged battery.
1. Generator
2. Ammeter (between generator (B) terminal and battery (+) terminal)
3. Voltmeter (between generator (B) terminal and ground)
4. Battery
5. Load
6. Switch
NOTE:
Turn off switches of all accessories (wiper, heater etc.).
NOTE:
Consideration should be taken that voltage will differ
somewhat with regulator case temperature as shown in
the graph.

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-9
2) Ground F terminal and start engine, then measure voltage at
B terminal as shown in left figure.
Voltage is higher than standard value
It is considered that generator itself is good but IC regulator
has been damaged, replace IC regulator.
Voltage is lower than standard value
Generator itself has problem, check the generator.
Load Check
1) Run engine at 2,000 rpm and turn on head light and heater
motor.
2) Measure current and if it is less than 20 A repair or replace
generator.
OVERCHARGED BATTERY
1) To determine battery condition, refer to Battery section.
2) If obvious overcharged condition exists as evidenced by
excessive spewing of electrolyte, measure generator B ter-
minal voltage at engine 2,000 rpm.
3) If measured voltage is higher than upper limit value, proceed
to disassembly section of generator service.
4) Check ground of brushes. If brushes are not grounded,
replace IC regulator. Then check field coil for grounds and
shorts, referring to “INSPECTION” section.
On-Vehicle Service
Battery
Jump starting in case of emergency
WITH AUXILIARY (BOOSTER) BATTERY
Both booster and discharged battery should be treated carefully
when using jumper cables. Follow procedure outlined below,
being careful not to cause sparks.
CAUTION:
If vehicle is manual transmission model and has a cata-
lytic converter, do not push or tow it to start. Damage to
its emission system and/or to other parts may result.

Downloaded from www.Manualslib.com manuals search engine 6H-10 CHARGING SYSTEM
1) Set parking brake and place automatic transmission in
PARK (NEUTRAL on manual transmission). Turn off ignition,
turn off lights and all other electrical loads.
2) Check electrolyte level. If it is below low level line, add dis-
tilled water.
3) Attach end of one jumper cable to positive terminal of
booster battery and the other end of the same cable to posi-
tive terminal of discharged battery. (Use 12-volt battery only
to jump start engine).
4) Attach one end of the remaining negative cable to negative
terminal of booster battery, and the other end to a solid
engine ground (such as exhaust manifold) at least 45 cm (18
in.) away from battery of vehicle being started.
5) Start engine of vehicle with booster battery and turn off elec-
trical accessories. Then start engine of the vehicle with dis-
charged battery.
6) Disconnect jumper cables in the exact reverse order.
WITH CHARGING EQUIPMENT
WARNING:
Departure from these conditions or procedure
described below could result in:
–Serious personal injury (particularly to eyes) or
property damage from such causes as battery explo-
sion, battery acid, or electrical burns.
–Damage to electronic components of either vehicle.
Remove rings, watches, and other jewelry. Wear
approved eye protection.
Be careful so that metal tools or jumper cables do not
contact positive battery terminal (or metal in contact
with it) and any other metal on vehicle, because a short
circuit could occur.
WARNING:
Do not connect negative cable directly to negative termi-
nal of dead battery.
CAUTION:
When jump starting engine with charging equipment, be
sure equipment used is 12-volt and negative ground. Do
not use 24-volt charging equipment. Using such equip-
ment can cause serious damage to electrical system or
electronic parts.