ATE SUZUKI JIMNY 2005 3.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-9
 When disconnecting vacuum hoses, attach a tag
describing the correct installation positions so that the
hoses can be reinstalled correctly.
 After servicing fuel, oil, coolant, vacuum, exhaust or
brake systems, check all lines related to the system for
leaks.
 For vehicles equipped with fuel injection systems, never
disconnect the fuel line between the fuel pump and
injector without first releasing the fuel pressure, or fuel
can be sprayed out under pressure.
 When performing a work that produces a heat exceeding
80°C (176°F) in the vicinity of the electrical parts, remove
the heat sensitive electrical part(s) beforehand.
 Use care not to expose connectors and electrical parts
to water which will be a cause of a trouble.
 Always be careful not to handle electrical parts (com-
puter, relay, etc.) in a rough manner or drop them.

Downloaded from www.Manualslib.com manuals search engine 0A-12 GENERAL INFORMATION
 Never connect any tester (voltmeter, ohmmeter, or what-
ever) to electronic control unit when its coupler is dis-
connected. Attempt to do it may cause damage to it.
 Never connect an ohmmeter to electronic control unit
with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.
 Be sure to use a specified voltmeter / ohmmeter. Other-
wise, accurate measurements may not be obtained or
personal injury may result.
 When taking measurements at electrical connectors
using a tester probe (2), be sure to insert the probe from
the wire harness side (backside) of the connector (1).
 When connecting meter probe (2) from terminal side of
coupler (1) because it can’t be connected from harness
side, use extra care not to bend male terminal of coupler
of force its female terminal open for connection.
In case of such coupler as shown connect probe as
shown to avoid opening female terminal.
Never connect probe where male terminal is supposed
to fit.
 When checking connection of terminals, check its male
half for bend and female half for excessive opening and
both for locking (looseness), corrosion, dust, etc.
 Before measuring voltage to check for electrical system,
check to make sure that battery voltage is 11V or higher.
Such terminal voltage check at low battery voltage will
lead to erroneous diagnosis.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-13
Electrical Circuit Inspection Procedure
While there are various electrical circuit inspection methods,
described here is a general method to check its open and short
circuit by using an ohmmeter and a voltmeter.
Open circuit check
Possible causes for the open circuit are as follows. As the cause
is in the connector or terminal in many cases, they need to be
checked particularly carefully.
 Loose connection of connector
 Poor contact of terminal (due to dirt, corrosion or rust on it,
poor contact tension, entry of foreign object etc.)
 Wire harness being open
When checking system circuits including an electronic control unit
such as ECM, TCM, ABS control module, etc., it is important to
perform careful check, starting with items which are easier to
check.
1) Disconnect negative cable from battery
2) Check each connector at both ends of the circuit being
checked for loose connection. Also check lock condition of
connector if equipped with connector lock.
3) Using a test male terminal, check both terminals of the circuit
being checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly
caused by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.
4) Using the following continuity check or voltage check proce-
dure, check the wire harness for open circuit and poor con-
nection with its terminals. Locate abnormality, if any.
1. Check contact tension by inserting and removing just for once
1. Looseness of crimping
2. Open
3. Thin wire (single strand of wire)

Downloaded from www.Manualslib.com manuals search engine 0A-14 GENERAL INFORMATION
CONTINUITY CHECK
1) Measure resistance between connector terminals at both
ends of the circuit being checked (between A-1 and C-1 in
the figure).
If no continuity is indicated (infinity or over limit), that means
that the circuit is open between terminals A-1 and C-1.
2) Disconnect the connector included in the circuit (connector-B
in the figure) and measure resistance between terminals A-1
and B-1.
If no continuity is indicated, that means that the circuit is
open between terminals A-1 and B-1. If continuity is indi-
cated, there is an open circuit between terminals B-1 and C-
1 or an abnormality in connector-B.
VOLTAGE CHECK
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
1) With all connectors connected and voltage applied to the cir-
cuit being checked, measure voltage between each terminal
and body ground.
a) If measurements were taken as shown in the figure at the
left and results were as listed below, it means that the cir-
cuit is open between terminals B-1 and A-1.
Voltage Between
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: 0V
b) Also, if measured values were as listed below, it means that
there is a resistance (abnormality) of such level that corre-
sponds to the voltage drop in the circuit between terminals
A-1 and B-1.
Voltage Between
C-1 and body ground: Approx. 5V
B-1 and body ground: Approx. 5V
A-1 and body ground: Approx. 3V (2V voltage drop)

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-15
Short circuit check (wire harness to ground)
1) Disconnect negative cable from battery.
2) Disconnect connectors at both ends of the circuit to be
checked.
3) Measure resistance between terminal at one end of circuit
(A-1 terminal in figure) and body ground. If continuity is indi-
cated, it means that there is a short to ground between ter-
minals A-1 and C-1 of the circuit.
4) Disconnect the connector included in circuit (connector B)
and measure resistance between A-1 and body ground.
If continuity is indicated, it means that the circuit is shorted to
the ground between terminals A-1 and B-1.
Intermittent and Poor Connection
Most intermittent are caused by faulty electrical connections or
wiring, although a sticking relay or solenoid can occasionally be at
fault. When checking it for proper connection, perform careful
check of suspect circuits for:
 Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
 Dirt or corrosion on the terminals. The terminals must be
clean and free of any foreign material which could impede
proper terminal contact. However, cleaning the terminal with
a sand paper or the like is prohibited.
 Damaged connector body, exposing the terminals to mois-
ture and dirt, as well as not maintaining proper terminal ori-
entation with the component or mating connector. NOTE:
If the circuit to be checked is connected to other parts
(1), disconnect all connectors of those parts.
Otherwise, diagnosis will be misled.
1. To other parts

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-17
Identification Information
Body Number
The vehicle body number is punched on the chassis inside the
tire housing on the right rear side.
Engine Identification Number
The number is punched on the cylinder block.
Transmission Identification Number
The automatic transmission identification number is located on
the transmission case.
1. Right rear tire
M
13-
Serial number
Engine displacement
(13:1.3 L)
Engine type (M)

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-21
Abbreviations May Be Used In This Manual
Abbreviations
AABC
ATDC
API
ATF
ALR
AC
A/T
A/C
ABDC
A/F
A-ELRAnti-lock Brake System
After Top Dead Center
American Petroleum Institute
Automatic Transmission Fluid
Automatic Locking Retractor
Alternating Current
Automatic Transmission
Air Conditioning
After Bottom Dead Center
Air Fuel Mixture Ratio
Automatic-Emergency
Locking RetractorEEBCM
ECM
ECT Sensor
EGR
EGRT Sensor
EFE Heater
ELR
EPS
EVAP
EVAP CanisterElectronic Brake Control Module,
ABS Control Module
Engine Control Module
Engine Coolant Temperature
Sensor (Water Temp. Sensor,
WTS)
Exhaust Gas Recirculation
EGR Temperature Sensor
(Recirculated Exhaust Gas Temp.
Sensor, REGTS)
Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
Emergency Locking Retractor
Electronic Power Steering
Evaporative Emission
Evaporative Emission Canister
(Charcoal Canister) BB+
BTDC
BBDCBattery Positive Voltage
Before Top Dead Center
Before Bottom Dead Center
CCKT
CMP Sensor
CO
CPP Switch
CPU
CRSCircuit
Camshaft Position Sensor
(Crank Angle Sensor, CAS)
Carbon Monoxide
Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
Central Processing Unit
Child Restraint SystemF 4WD 4 Wheel Drive
GGEN
GNDGenerator
Ground
HHC
HO2SHydrocarbons
Heated Oxygen Sensor
DDC
DLC
DOHC
DOJ
DRL
DTCDirect Current
Data Link Connector
(Assembly Line Diag. Link, ALDL,
Serial Data Link, SDL)
Double Over Head Camshaft
Double Offset Joint
Daytime Running Light
Diagnostic Trouble Code
(Diagnostic Code)IIAC Valve
IAT Sensor
ICM
IG
ISC ActuatorIdle Air Control Valve (Idle Speed
Control Solenoid Valve, ISC
Solenoid Valve)
Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
Immobilizer Control Module
Ignition
Idle Speed Control Actuator
(Motor)

Downloaded from www.Manualslib.com manuals search engine 0A-24 GENERAL INFORMATION
Fasteners Information
Metric Fasteners
Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most impor-
tant that replacement fasteners be the correct diameter, thread pitch and strength.
Fastener Strength Identification
Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class
identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark
strength identification on the nut face. Figure shows the different strength markings.
When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the origi-
nal fasteners (the same number marking or higher). It is likewise important to select replacement fasteners of
the correct diameter and thread pitch. Correct replacement bolts and nuts are available through the parts divi-
sion.
Metric bolts: Identification class numbers or marks correspond to bolt strength (increasing numbers represent
increasing strength).
Standard Tightening Torque
Each fastener should be tightened to the torque specified in each section of this manual. If no description or
specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener.
When a fastener of greater strength than the original one is used, however, use the torque specified for the orig-
inal fastener.
1. Nuts strength identification
NOTE:
 For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening
torque given in the chart below.
 The chart below is applicable only where the fastened parts are made of steel light alloy.

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-1
0A 6F1
0B
0B
6G
1A 6H
1B 6K
37A
3A 7A1
3B1 7B1
3C1 7C1
3D 7D
3E 7E
3F 7F
4A2 8A
4B 8B
8C
58D
5A 8E
5B
5C 9
5E
5E1 10
10A
610B
6-1
6A1
6A2
6A4
6B
6C
6E1
6E2
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule .................................. 0B-2
Maintenance Schedule Under Normal
Driving Conditions ........................................ 0B-2
Maintenance Recommended Under Severe
Driving Conditions ........................................ 0B-4
Maintenance Service...................................... 0B-5
Engine .......................................................... 0B-5
Drive Belt .................................................. 0B-5
Valve Lash................................................ 0B-6
Engine Oil and Filter ................................. 0B-6
Engine Coolant ......................................... 0B-8
Exhaust System ....................................... 0B-8
Ignition System ............................................. 0B-9
Spark Plugs .............................................. 0B-9
Fuel System ................................................. 0B-9
Air Cleaner Filter ...................................... 0B-9
Fuel Lines and Connections ................... 0B-10
Fuel Filter ............................................... 0B-10
Fuel Tank ............................................... 0B-10
Emission Control System ........................... 0B-10
Crankcase Ventilation Hoses and
Connections ........................................... 0B-10
PCV (Positive Crankcase Ventilation)
Valve ..................................................... 0B-11Fuel Evaporative Emission Control
System ................................................... 0B-11
Chassis and Body ...................................... 0B-11
Clutch ..................................................... 0B-11
Brake Discs and Pads ............................ 0B-11
Brake Drums and Shoes ........................ 0B-12
Brake Hoses and Pipes.......................... 0B-12
Brake Fluid ............................................. 0B-12
Parking Brake Lever and Cable ............. 0B-13
Tires/Wheels .......................................... 0B-13
Suspension System ............................... 0B-14
Propeller Shafts...................................... 0B-15
Manual Transmission Oil........................ 0B-16
Automatic Transmission Fluid ................ 0B-16
Transfer and Differential Oil ................... 0B-17
Steering System ..................................... 0B-18
Steering Knuckle Seal ............................ 0B-18
Power Steering (P/S) System
(if equipped) ........................................... 0B-19
All Hinges, Latches and Locks ............... 0B-19
Final Inspection............................................ 0B-20
Recommended Fluids and Lubricants ....... 0B-22

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 0B-2 MAINTENANCE AND LUBRICATION
Maintenance Schedule
Maintenance Schedule Under Normal Driving Conditions
NOTE:
 This interval should be judged by odometer reading or months, whichever comes first.
 This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.
IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 1827364554
Months 12 24 36 48 60 72
ENGINE
Drive belt V-belt I R I R I R
V-rib belt (Flat type)––I––R
Valve lash (clearance) –I–I–I
Engine oil and oil filter R R R R R R
Engine coolant––R––R
Exhaust system–I–I–I
IGNITION SYSTEM
✱Spark plugs When
unleaded
fuel is usedVehicle without
HO2SNickel spark
plug–R–R–R
Iridium spark
plug––R––R
Vehicle with
HO2SNickel spark
plug––R––R
Iridium spark
plug–––R––
When leaded fuel is used, refer to “Maintenance Recommended Under Severe Driving Condi-
tions” in this section.
FUEL SYSTEM
Air cleaner filter I I R I I R
Fuel lines and connections–I–I–I
Fuel filter Replace every 210,000 km (126,000 miles).
Fuel tank––I––I
EMISSION CONTROL SYSTEM
Crankcase ventilation hoses and connections
(Vehicle without HO2S)––I––I
✱PCV valve Vehicle without HO2S––I––I
Vehicle with HO2S–––––I
✱Fuel evaporative emission
control systemVehicle without HO2S–I–I–I
Vehicle with HO2S–––––I
NOTE:
“R”: Replace or change
“I”: Inspect and correct, replace or lubricate if necessary
 For Sweden, items with
✱
✱✱ ✱ (asterisk) should be performed by odometer reading only.
 For spark plugs, replace every 50,000 km if the local law requires.
 Nickel spark plug: BKR6E-11 (NGK) or K20PR-U11 (DENSO)
 Iridium spark plug: IFR5E11 (NGK) or SK16PR-A11 (DENSO)