air SUZUKI JIMNY 2005 3.G Service Workshop Manual

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Idle mixture inspection / adjustment (vehicle without
heated oxygen sensor)
All vehicles not equipped with heated oxygen sensor are shipped
with their CO % factory adjusted as follows.
Engine idle mixture (CO %)
0.5 – 1.5 % at specified idle speed
Idle mixture adjustment should never be changed from the origi-
nal factory setting. However, if during diagnosis, the check indi-
cates idle mixture to be the cause of a driver performance
complaint or emission failure, the idle mixture can be adjusted
using the following procedures.
1) Check idle speed according to “Idle Speed / Idle Air Control
(IAC) Duty Inspection” in this section.
2) Using exhaust gas tester, check that idle mixture CO % is
within above specification. If it is out of specification, adjust it
to specification by turning resistor knob.
3) If idle mixture has been adjusted, confirm that idle speed is
within specification. NOTE:
For this inspection and adjustment, exhaust gas tester
(CO meter) and engine tachometer are necessary.
NOTE:
CO adjusting resistor knob to “A” increases CO % (A/F
mixture becomes rich) and turning it to “B” decreases
CO % (A/F mixture becomes lean).
1. CO adjusting resistor

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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

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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.

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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.

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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.

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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.

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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.

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REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect EGR valve connector.
3) Remove EGR pipe.
4) Remove EGR valve and gasket from cylinder head.
INSPECTION
1) Check resistance between following terminals of EGR valve
(1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance
2) Remove carbon from EGR valve (1) gas passage.
3) Inspect valve (2), valve seat (3) and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve assembly.
INSTALLATION
Reverse removal procedure noting following.
Clean mating surface of valve and cylinder head.
Use new gaskets.
Evaporative emission (EVAP) control system
EVAP CANISTER PURGE INSPECTION
Terminal Standard resistance
A – B
C – B
F – E
D – E 20 – 24
Ω
ΩΩ Ω
NOTE:
Do not use any sharp-edged tool to remove carbon.
Be careful not to damage or bend EGR valve, valve seat
and rod.
NOTE:
Before inspection, check to make sure that gear shift
lever is in neutral position (with A/T model, selector lever
in “P” range) and that parking brake lever is pulled all the
way up.

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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.

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EVAP CANISTER INSPECTION
1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there should be no restriction of flow through
purge pipe (1) and air pipe (2) when air is blown (4) into tank
pipe (3).
If any faulty condition is found in above inspection replace.
PCV system
PCV HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration.
Replace as necessary.
PCV VALVE INSPECTION
1) Disconnect PCV valve (1) from cylinder head cover and
install plug to head cover hole.
2) Run engine at idle.
3) Place your finger over end of PCV valve (1) to check for vac-
uum. If there is no vacuum, check for clogged valve.
Replace as necessary. WARNING:
DO NOT SUCK nozzles on EVAP canister. Fuel vapor
inside EVAP canister is harmful.
NOTE:
Be sure to check that there is no obstruction in PCV
valve or its hoses before checking IAC duty, for
obstructed PCV valve or hose hampers its accurate
adjustment.