SUZUKI JIMNY 2005 3.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 0A-16 GENERAL INFORMATION
 Improperly formed or damaged terminals.
Check each connector terminal in problem circuits carefully
to ensure good contact tension by using the corresponding
mating terminal.
If contact tension is not enough, reform it to increase contact
tension or replace.
 Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor con-
nection by shaking it by hand lightly. If any abnormal condi-
tion is found, repair or replace.
 Wire insulation which is rubbed through, causing an intermit-
tent short as the bare area touches other wiring or parts of
the vehicle.
 Wiring broken inside the insulation. This condition could
cause continuity check to show a good circuit, but if only 1 or
2 strands of a multi-strand-type wire are intact, resistance
could be far too high.
If any abnormality is found, repair or replace.
Precaution For Installing Mobile Communica-
tion Equipment
When installing mobile communication equipment such as CB
(Citizens-Band)-radio or cellular-telephone, be sure to observe
the following precautions.
Failure to follow cautions may adversely affect electronic control
system.
 Keep the antenna as far away as possible from the vehicle’s
electronic control unit.
 Keep the antenna feeder more than 20 cm (7.9 in) away from
electronic control unit and its wire harnesses.
 Do not run the antenna feeder parallel with other wire har-
nesses.
 Confirm that the antenna and feeder are correctly adjusted.
1. Check contact tension by inserting and removing just once
2. Check each terminal for bend and proper alignment

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 0A-18 GENERAL INFORMATION
Warning, Caution and Information Labels
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
NOTE:
Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
1. Emission control label (Australia only) 3. Air bag label on sun visor 5. Engine cooling fan label
2. Air bag label on engine hood 4. Radiator cap label
1. Air bag warning label on driver air bag (inflator) module 4. Air bag label on SDM
2. Air bag warning label on contact coil and combination switch assembly 5. Air bag label on passenger air bag (inflator) module
3. Air bag warning label on steering column 6. Seat belt pretensioner label on retractor

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-19
Vehicle Lifting Points
When Using Frame Contact Hoist
WARNING:
 Before applying hoist to underbody, always take vehicle balance throughout service into consider-
ation. Vehicle balance on hoist may change depending on what part to be removed.
 Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe,
fuel pipe, bracket or any other part.
 When using frame contact hoist, apply hoist as shown (right and left at the same position). Lift up
the vehicle till 4 tires are a little off the ground and make sure that the vehicle will not fall off by try-
ing to move vehicle body in both ways. Work can be started only after this confirmation.
 Make absolutely sure to lock hoist after vehicle is hoisted up.
1. Front lifting point
2. Rear lifting point
3. Front

Downloaded from www.Manualslib.com manuals search engine 0A-20 GENERAL INFORMATION
When Using Floor Jack
In raising front or rear vehicle end off the floor by jacking, be sure
to put the jack against the center portion of the front axle housing
(1) or rear axle housing (2).
To perform service with either front or rear vehicle end jacked up,
be sure to place safety stands (1) under chassis frame so that
body is securely supported. And then check to ensure that chas-
sis frame does not slide on safety stands (1) and the vehicle is
held stable for safety’s sake. WARNING:
If the vehicle to be jacked up only at the front or rear end,
be sure to block the wheels on ground in order to ensure
safety.
After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on the
vehicle raised on jack alone.
CAUTION:
Never apply jack against suspension parts (i.e., stabi-
lizer, etc.) or vehicle floor, or it may get deformed.
[A]: Front
[B]: Rear

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-22 GENERAL INFORMATION
LLH
LSPVLeft Hand
Load Sensing Proportioning Valve
TTBI
TCC
TCM
TP Sensor
TVV
TWC
2WDThrottle Body Fuel Injection
(Single-Point Fuel Injection, SPI)
Torque Converter Clutch
Transmission Control Module
(A/T Controller, A/T Control Mod-
ule)
Throttle Position Sensor
Thermal Vacuum Valve
(Thermal Vacuum Switching Valve,
TVSV, Bimetal Vacuum Switching
Valve, BVSV)
Three Way Catalytic Converter
(Three Way Catalyst)
2 Wheel Drive MMAF Sensor
MAP Sensor
Max
MFI
Min
MIL
M/TMass Air Flow Sensor
(Air Flow Sensor, AFS, Air Flow
Meter, AFM)
Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Maximum
Multiport Fuel Injection
(Multipoint Fuel Injection)
Minimum
Malfunction Indicator Lamp
(“CHECK ENGINE” Light)
Manual Transmission
N NOx Nitrogen Oxides VVIN
VSSVehicle Identification Number
Vehicle Speed Sensor
OOBD
O/D
OHCOn-Board Diagnostic System
(Self-Diagnosis Function)
Overdrive
Over Head CamshaftWWU-OC
WU-TWCWarm Up Oxidation Catalytic
Converter
Warm Up Three Way Catalytic
Converter
PPNP
P/S
PSP Switch
PCM
PCVPark/Neutral Position
Power Steering
Power Steering Pressure Switch
(P/S Pressure Switch)
Powertrain Control Module
Positive Crankcase Ventilation
R RH Right Hand
SSAE
SDM
SFI
SOHCSociety of Automotive Engineers
Sensing and Diagnostic Module
(Air bag controller, Air bag control
module)
Sequential Multiport Fuel Injection
Single Over Head Camshaft

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-23
SYMBOLS
WIRE COLOR SYMBOLS
There are two kinds of colored wire used in this vehicle. One is
single-colored wire and the other is dual-colored (striped) wire.
The single-colored wire uses only one color symbol (i.e. “GRN”).
The dual-colored wire uses two color symbols (i.e. “GRN/YEL”).
The first symbol represents the base color of the wire (“GRN” in
the figure) and the second symbol represents the color of the
stripe (“YEL” in the figure). SYMBOL DEFINITION SYMBOL DEFINITION
Tightening torque Apply SUZUKI BOND NO. 1216
99000-31160
Apply oil (engine, transmission, trans-
fer, differential)Apply SILICONE SEALANT
99000-31120
Apply fluid (brake, power steering or
automatic transmission fluid)Apply SEALING COMPOUND 366E
99000-31090
Apply SUZUKI SUPER GREASE A
99000-25010
Apply SUZUKI SUPER GREASE C
99000-25030Apply THREAD LOCK 1322
99000-32110
Apply SUZUKI SUPER GREASE E
99000-25050Apply THREAD LOCK 1333B
99000-32020
Apply SUZUKI SUPER GREASE H
99000-25120Apply THREAD LOCK 1342
99000-32050
Apply SUZUKI SUPER GREASE I
99000-25210
Apply SUZUKI BOND NO. 1215
99000-31110Do not reuse
Apply SUZUKI BOND NO. 1207C
99000-31150Note on reassembly
Symbol Wire Color Symbol Wire Color
B BLK Black O, Or ORN Orange
Bl BLU Blue R RED Red
Br BRN Brown W WHT White
GGRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
Lbl LT BLU Light blue V PPL Violet
Lg LT GRN Light green

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 GENERAL INFORMATION 0A-25
Tightening torque chart
Thread Diameter (Nominal Diameter) (mm)
4 5 6 8 10 12 14 16 18
StrengthAn equivalent of 4T strength
fastenerN·m 1.5 3.0 5.5 13 29 45 65 105 160
kg-m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16
lb-ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0
An equivalent of 6.8 strength
fastener without flangeN·m 2.4 4.7 8.4 20 42 80 125 193 280
kg-m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28
lb-ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5
An equivalent of 6.8 strength
fastener without flangeN·m 2.4 4.9 8.8 21 44 84 133 203 298
kg-m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8
lb-ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5
An equivalent of 7T strength
fastenerN·m 2.3 4.5 10 23 50 85 135 210 240
kg-m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24
lb-ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0
An equivalent of 8.8 strength
fastener without flangeN·m 3.1 6.3 11 27 56 105 168 258 373
kg-m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3
lb-ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0
An equivalent of 8.8 strength
fastener without flangeN·m 3.2 6.5 12 29 59 113 175 270 395
kg-m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5
lb-ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0
✱: Self-lock nut