air 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-4 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
IGNITION SYSTEM DIAGNOSTIC FLOW TABLE
Step Action Yes No
1Was “Engine Diagnostic Flow Table” in Section 6 per-
formed?Go to Step 2. Go to “Engine Diag.
Flow Table” in Section
6.
2Ignition Spark Test
1) Check all spark plugs for condition and type refer-
ring to “Spark Plugs” section.
2) If OK, perform ignition spark test, referring to “Igni-
tion Spark Test” section.
Is spark emitted from all spark plugs?Go to Step 11. Go to Step 3.
3Diagnostic Trouble Code (DTC) Check
Is DTC stored in ECM?Go to applicable DTC
Diag. Flow Table in
Section 6.Go to Step 4.
4Electrical Connection Check
1) Check ignition coil assemblies and high-tension
cords for electrical connection.
Are they connected securely?Go to Step 5. Connect securely.
5High-tension Cords Check
1) Check high-tension cord for resistance referring to
“High-Tension Cords” section.
Is check result satisfactory?Go to Step 6. Replace high-tension
cord(s).
6Ignition Coil Assembly Power Supply and Ground Cir-
cuit Check
1) Check ignition coil assembly power supply and
ground circuits for open and short.
Are circuits in good condition?Go to Step 7. Repair or replace.
7Ignition Coil Assembly Check
1) Check ignition coil for resistance referring to “Igni-
tion Coil Assembly” section.
Is check result satisfactory?Go to Step 8. Replace ignition coil
assembly.
8Crankshaft Position (CKP) Sensor Check
1) Check crankshaft position sensor referring to Step
2 and 6 of “DTC P0335 (No.23) CKP Sensor Cir-
cuit Malfunction” in Section 6.
Is check result satisfactory?Go to Step 9. Tighten CKP sensor
bolt, replace CKP sen-
sor or CKP sensor
plate.
9Ignition Trigger Signal Circuit Check
1) Check ignition trigger signal wire for open, short
and poor connection.
Is circuit in good condition?Go to Step 10. Repair or replace.
10A Known-good Ignition Coil Assembly Substitution
1) Substitute a known-good ignition coil assembly
and then repeat Step 2.
Is check result of Step 2 satisfactory?Go to Step 11. Substitute a known-
good ECM and then
repeat Step 2.
11Ignition Timing Check
1) Check initial ignition timing and ignition timing
advance referring to “Ignition Timing” section.
Is check result satisfactory?System is in good con-
dition.Check CKP sensor,
CKP sensor plate and
input signals related to
this system.

Downloaded from www.Manualslib.com manuals search engine IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-7
4) If any abnormality is found, adjust air gap, clean with spark
plug cleaner or replace them with specified new plugs.
For iridium/platinum spark plugs, replace them with new
plugs.
Spark plug air gap “a”
1.0 – 1.1 mm (0.040 – 0.043 in.)
Spark plug type
NGK : BKR6E-11, IFR5E11
DENSO : K20PR-U11, SK16PR-A11
5) Install spark plugs and torque them to specification.
Tightening torque
Spark plug : 25 N·m (2.5 kg-m, 18.0 lb-ft)
6) Install ignition coil assemblies referring to “Ignition Coil
Assembly” in this section.
7) Install high-tension cords securely by gripping their caps.
Ignition Coil Assembly (Including Ignitor)
1) Disconnect negative cable at battery.
2) Remove cylinder head upper cover.
3) Disconnect ignition coil connector.
4) Disconnect high-tension cord (3) from ignition coil assembly
(2).
5) Remove ignition coil bolts (1) and then pull out ignition coil
assembly. NOTE:
NGK IFR5E11 or DENSO SK16PR-A11 is highly recom-
mended for better engine starting performance under –
25°C (– 13°F).
CAUTION:
When servicing the iridium/platinum spark plugs (slender
center electrode type plugs), do not touch the center
electrode to avoid damage to it. The electrode is not
strong enough against mechanical force as it is slender
and its material is not mechanically tough.

Downloaded from www.Manualslib.com manuals search engine 6F-8 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
6) Measure resistance between terminals as follows by using
analog type ohmmeter.
If check result is not satisfactory, replace ignition coil assem-
bly.
Secondary coil resistance
“a” – “b” : 7.5 – 14 k
Ω (at 20°C, 68°F)
7) Install ignition coil assembly.
8) Tighten ignition coil bolts, and then connect ignition coil cou-
pler.
9) Install high-tension cord to ignition coil assembly while grip-
ping its cap.
10) Install cylinder head upper cover.
Crankshaft Position Sensor (CKP Sensor)
Refer to “Crankshaft Position Sensor” in Section 6E for removal,
inspection and installation.
Ignition Timing
INSPECTION
1) When using SUZUKI scan tool (1), connect SUZUKI scan
tool to DLC (2) with ignition switch OFF.
Special tool
(A) : SUZUKI scan tool
2) Start engine and warm it up to normal operating tempera-
ture.
3) Make sure that all of electrical loads except ignition are
switched off.
4) Check to be sure that idle speed is within specification.
(Refer to “Idle Speed/Idle Air Control Duty Inspection” in
Section 6E.)
NOTE:
Ignition timing is not adjustable. If ignition timing is
out of specification, check system related parts.
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for
A/T model), and set parking brake.

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 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 CHARGING SYSTEM 6H-7
How to use the temperature-corrected state-of-charge
graph
Suppose your S.G. reading is 1.28 and the battery temperature is
–5 °C (23 °F). Locate the intersection of the –5 °C line and the
1.28 S.G. line.
The intersection is within the “A” zone (shaded area in the graph)
and that means CHARGED STATE.
To know how much the battery is charged, draw a line parallel to
the zone demarcation line and extend it to the right till it meets
with the percentage scale. In the present example, the line meets
at about 85% point on the percentage scale. Therefore, the bat-
tery is charged up to the 85% level.
Generator
Trouble in charging system will show up as one or more of follow-
ing conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow cranking or
indicator dark.
3) An overcharged battery as evidenced by excessive spewing
of electrolyte from vents.
Noise from generator may be caused by a loose drive pulley,
loose mounting bolts, worn or dirty bearings, defective diode, or
defective stator.
FAULTY INDICATOR LAMP OPERATION
CAUTION:
Do not mistake polarities of IG terminal and L terminal.
Do not make a short circuit between IG and L termi-
nals. Always connect these terminals through a lamp.
Do not connect any load between L and E.
When connecting a charger or a booster battery to
vehicle battery, refer to this section describing battery
charging.
B: Generator output (Battery terminal)
E: Ground
IG: Ignition terminal
L: Lamp terminal
Condition Possible Cause Correction
Charge light does not
light with ignition ON
and engine offFuse blown Check fuse.
Light burned out Replace light.
Wiring connection loose Tighten loose connection.
IC regulator or field coil faulty Check generator.
Charge light does not go
out with engine running
(battery requires fre-
quent recharging)Drive belt loose or worn Adjust or replace drive belt.
IC regulator or generator faulty Check charging system.
Wiring faulty Repair wiring.

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.