ignition SUZUKI JIMNY 2005 3.G Service User Guide

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-17
A/C System Inspection of ECM and ITS Cir-
cuits
ECM and its circuits can be checked at ECM wiring couplers by
measuring voltage.
Voltage Check
1) Remove ECM from vehicle by referring to “Engine Control
Module” in Section 6E.
2) Connect ECM couplers (1) to ECM (2).
3) Check voltage at each terminal of couplers connected.CAUTION:
ECM cannot be checked by itself. It is strictly prohibited
to connect voltmeter or ohmmeter to ECM with couplers
disconnected from ECM.
NOTE:
Because each terminal voltage is affected by the battery
voltage, confirm that the battery voltage is 11 V or more
when ignition switch is ON.
[A] : Fig. A
[B] : Fig. B
3. E19-3

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-19
ECM VOLTAGE VALUES TABLE FOR RELATION OF A/C CONTROL
Terminal Wire CircuitMeasurement
groundNormal value Condition
E18-1 PCompressor
magnet clutch
outputGround to
engine (Fig B)10 – 14 voltBlower fan motor switch and A/C
switch ON with engine running
0 – 1 voltsExcept the above-mentioned condi-
tion with engine running
E18-5 Bl/BMain power sup-
ply for ECMGround to
engine (Fig B)10 – 14 voltsIgnition switch ON with engine
stopped
E18-6 Bl/BMain power sup-
ply for ECMGround to
engine (Fig B)10 – 14 voltsIgnition switch ON with engine
stopped
E18-10 Bl Main relay driveGround to
engine (Fig B)0.5 – 1.2 voltIgnition switch ON with engine
stopped
0 volts Ignition switch OFF
E18-16 G/W A/C switch inputGround to
engine (Fig B)12 – 15 voltsBlower fan motor switch or A/C switch
OFF with engine running
0 – 1 voltBlower fan motor switch and A/C
switch ON with engine running
12 – 15 voltsWithin several seconds after operate
transfer lever between 2WD and 4WD
with above condition
E18-18 P/BCompressor
cooling fan relay
outputGround to
engine (Fig B)0 – 1 voltBlower fan motor switch and A/C
switch ON or engine coolant tempera-
ture at more than 110 °C (230 °F) with
engine running.
12 – 15 voltsExcept the above-mentioned condi-
tion with engine running
E18-20 B/BlSensor ground
for A/C evapora-
torGround to
body (Fig A)–0.5 – 0 volt Engine running
E18-24 Bl/YBlower fan
speed inputGround to
engine (Fig B)0 – 1 voltBlower fan motor switch 2nd or 3rd
with engine running
4 – 7 voltsBlower fan motor switch 1st with
engine running
12 – 15 voltsBlower fan motor switch and A/C
switch OFF with engine running
E19-1 BMain ground for
ECMGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-2 B/RECM ground for
power circuitGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-3 B/RECM ground for
power circuitGround to
engine (Fig A)–0.5 – 1 volt Engine running
E19-10 B/BlSensor ground
for ECT sensorGround to
body (Fig A)–0.5 – 1 volt Engine running

Downloaded from www.Manualslib.com manuals search engine STEERING GEAR BOX (MANUAL TYPE) AND LINKAGE 3B-1
6F1
6F2
6G
6H
3B
7C1
7D
7E
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B
STEERING GEAR BOX (MANUAL TYPE)
AND LINKAGE
CONTENTS
General Description ....................................... 3B-2
Diagnosis ........................................................ 3B-3
Diagnosis Table ........................................... 3B-3
Steering Wheel Play Check ......................... 3B-3
Tie Rod And Drag Rod Check ...................... 3B-3
Steering Gear Box Oil Level Check ............. 3B-4
Adjustment of Worm Shaft Starting Torque . 3B-4On-Vehicle Service ........................................ 3B-6
Steering Gear Box ....................................... 3B-6
Tie Rod And Drag Rod................................. 3B-8
Tightening Torque Specifications .............. 3B-10
Required Service Material ........................... 3B-10
Special Tools ................................................ 3B-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 negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM)
NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified dur-
ing reassembly to assure proper retention of these parts.

Downloaded from www.Manualslib.com manuals search engine POWER STEERING (P/S) SYSTEM (If equipped) 3B1-1
6F1
6F2
6G
6H
6K
3B1
7D
7E
7F
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3B1
POWER STEERING (P/S) SYSTEM
(If equipped)
CONTENTS
General Description ......................................3B1-2
Diagnosis .......................................................3B1-3
Diagnosis Table .......................................... 3B1-3
Steering Wheel Play Check ........................ 3B1-5
Steering Force Check ................................. 3B1-5
Power Steering Belt Check ......................... 3B1-6
Power Steering Belt Tension Adjustment .... 3B1-6
Power Steering Fluid Level Check .............. 3B1-6
Idle-Up System Check ................................ 3B1-7
Power Steering Fluid Leakage Check ......... 3B1-7Air Bleeding Procedure ............................... 3B1-8
Hydraulic Pressure In P/S Circuit Check .. 3B1-10
On-Vehicle Service ..................................... 3B1-12
Power Steering Belt .................................. 3B1-12
Power Steering (P/S) Pump ...................... 3B1-12
Power Steering (P/S) Gear Box ................ 3B1-18
Tightening Torque Specifications ............. 3B1-21
Required Service Materials ........................ 3B1-21
Special Tools ............................................... 3B1-21 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 negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
All steering gear fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified dur-
ing reassembly to assure proper retention of these parts.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-1
6F1
6F2
6G
6H
6K
7A
3C
7E
7F
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3C
STEERING WHEEL AND COLUMN
CONTENTS
General Description ....................................... 3C-2
Diagnosis ........................................................ 3C-3
Inspection and Repair Required
After Accident ............................................... 3C-3
On-Vehicle Service......................................... 3C-3
Service Precautions (For Vehicle with
Air Bag System) ........................................... 3C-3
Diagnosis and servicing ........................... 3C-3
Disabling air bag system .......................... 3C-3
Enabling air bag system ........................... 3C-3
Handling and storage ............................... 3C-3
Disposal.................................................... 3C-3
Drive Air Bag (Inflator) Module (For Vehicle
with Air Bag System) .................................... 3C-4
Steering Wheel ............................................. 3C-5Centering contact coil (for vehicle with
air bag system)......................................... 3C-8
Combination Switch (For Vehicle without
Air Bag System)/Contact Coil and
Combination Switch Assembly (For Vehicle
with Air Bag System).................................... 3C-9
Steering Column Assembly........................ 3C-11
Steering Lock Assembly
(Ignition Switch) ......................................... 3C-15
Steering Lower Shaft ................................. 3C-16
Checking Steering Column for Accident
Damage ......................................................... 3C-18
Tightening Torque Specifications .............. 3C-19
Required Service Material ........................... 3C-19
Special Tool .................................................. 3C-19

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. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem 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.
The procedures in this section must be followed in the order listed to temporarily disable the air
bag system and prevent false diagnostic codes from setting. Failure to follow procedures could
result in possible air bag system activation, personal injury or otherwise unneeded air bag system
repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.

Downloaded from www.Manualslib.com manuals search engine 3C-2 STEERING WHEEL AND COLUMN
General Description
This double tube type steering column has the following three important features in addition to the steering func-
tion:
The column is energy absorbing, designed to compress in a front-end collision.
The ignition switch and lock are mounted conveniently on this column.
With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehi-
cle.
To insure the energy absorbing action, it is important that only the specified screws, bolts and nuts be used as
designated and that they are tightened to the specified torque.
When the column assembly is removed from the vehicle, special care must be taken in handling it. Use of a
steering wheel puller other than the one recommended in this manual or a sharp blow on the end of the steering
shaft, leaning on the assembly, or dropping the assembly could shear the plastic shear pins which maintain col-
umn length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver’s and passenger’s seat belts by deploying the air bags.
The air bag (inflator) module should be handled with care to prevent accidental deployment. When servicing, be
sure to observe all WARNINGS and CAUTIONS in this section and “Service Precautions” in Section 10B.
1. Driver air bag (inflator) module 6. Steering column upper cover 11. Steering lower shaft
2. Steering wheel 7. Steering column lower cover [A] : For vehicle with air bag system
3. Steering wheel side cap 8. Steering column assembly [B] : For vehicle without air bag system
4. Steering wheel nut 9. Steering lock assembly (ignition switch)
5. Combination switch or contact coil and com-
bination switch assembly10. Steering column hole cover

Downloaded from www.Manualslib.com manuals search engine 3C-8 STEERING WHEEL AND COLUMN
3) Tighten steering shaft nut to specified torque.
Tightening torque
Steering shaft nut (a) : 33 N·m (3.3 kg-m, 23.5 lb-ft)
4) Install steering wheel pad (for vehicle without air bag system)
or driver air bag (inflator) module (for vehicle with air bag
system) as follows.
For vehicle without air bag system
–For TYPE A
a) Connect horn connector.
b) Install steering wheel pad.
–For TYPE B
a) To install the pad, hook (1) the upper part of the pad to the
pawl of the steering wheel and push in the lower part of the
pad until it fits to the set spring securely.
For vehicle with air bag system
a) Install driver air bag (inflator) module to steering wheel.
Refer to “Driver Air Bag (Inflator) Module” in this section.
Centering contact coil (for vehicle with air bag sys-
tem)
1) Check that vehicle’s wheels (front tires) are set at straight-
ahead position.
2) Check that ignition switch is at “LOCK” position.
3) Turn contact coil counterclockwise slowly with a light force till
contact coil will not turn any further. NOTE:
After installing the steering wheel, turn the steering
wheel about 1 full rotation so that the cancel cam pin fits
into the pin hole in the steering wheel and then check the
turn signal lever for proper function.
NOTE:
Contact coil can turn about 5 turns at maximum, that is, if
it is at the center position, can turn about two and a half
turns both clockwise and counterclockwise.

Downloaded from www.Manualslib.com manuals search engine 3C-10 STEERING WHEEL AND COLUMN
7) Remove combination switch/contact coil and combination
switch assembly (1) from steering column.
INSPECTION
For vehicle with air bag system
Check contact coil and combination switch wire harness for
any signs of scorching, melting or other damage. If it is dam-
aged, replace.
INSTALLATION
1) Check to make sure that vehicle’s front tires are set at
straight-ahead position and then ignition switch is at “LOCK”
position.
2) Install combination switch/contact coil and combination
switch assembly to steering column.
3) Connect all connectors that have been disconnected in
“REMOVAL”.
4) Install steering column upper (3) and lower cover (4), and
then tighten steering column cover standard screw (1) and
tapping screws (2).
1. Contact coil and combination switch assembly
2. To horn
3. Connector to driver air bag (inflator) module
4. Connector to air bag wire harness
NOTE:
For vehicle with air bag system
New contact coil and combination switch assembly is
supplied with contact coil set and held at its center posi-
tion with a lock pin (2) and seal (1). Remove this lock pin
after installing contact coil and combination switch
assembly to steering column.
CAUTION:
When installing lower cover (3) and upper cover (2), be
careful so that combination switch/contact coil and com-
bination switch lead wirer is not caught between covers.

Downloaded from www.Manualslib.com manuals search engine 3C-12 STEERING WHEEL AND COLUMN
REMOVAL
1) Disconnect negative battery cable at battery terminal.
2) For vehicle equipped with air bag system, disable air bag
system referring to “Disabling Air Bag System” in Section
10B.
3) If necessary, remove steering wheel and combination switch
assembly referring to “Steering Wheel” and “Combination
switch/Contact Coil and Combination Switch Assembly” in
this section.
If not removing steering wheel and/or combination switch
assembly, perform the following procedure.
a) Turn steering wheel so that vehicle’s front tires are at
straight ahead position.
b) Turn ignition switch to “LOCK” position and remove key.
4) Remove steering column hole cover (1).
5) Disconnect all connectors of the following parts.
Combination switch/contact coil and combination switch
assembly.
Ignition switch.
Immobilizer control system parts (if equipped).
6) Remove joint bolt (steering column side) (3) and loosen joint
bolt (steering gear box side).
7) Remove steering column mounting nuts (2) and bolts (1).WARNING:
For vehicle with air bag system
Never rest a steering column assembly on the steering
wheel with the air bag (inflator) module face down and
column vertical. Otherwise, personal injury may result.

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-13
8) If equipped with shift (key) interlock cable (1), remove shift
(key) interlock cable screw (2) and then disconnect its cable
from ignition switch in order a) – c) as shown in the figure.
9) Remove steering column from vehicle.
10) Remove steering column seal (1) from steering column lower
bracket.
INSPECTION
CHECKING PROCEDURE
1) Check that two capsules (1) are attached to steering column
bracket (2) securely. Check clearance between capsules and
steering column bracket. Clearance should be 0.0 mm (0.0
in.) on both sides.
If found loose or clearance, replace steering column assem-
bly.
2) Check two plates (3) for any damages such as crack or
breakage.
If anything is found faulty, replace as steering column
assembly.
CAUTION:
Don’t separate double tube type steering column assem-
bly into steering column and shaft. If column or shaft is
defective, replace as and assembly.
NOTE:
Vehicles involved in accidents resulting in body damage,
where steering column has been impacted (or air bag
deployed), may have a damaged or misaligned steering
column.