Oil sensor SUZUKI JIMNY 2005 3.G Service Owner's Manual

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Component Location
NOTE:
The figure shows left-hand steering vehicle.
For right-hand steering vehicle, parts with (*) are installed at the other side.
1. IAT sensor a : Immobilizer indicator lamp (if equipped) A : ECM
2. TP sensor b : A/C condenser fan motor relay (if equipped) B : A/T control module
3. Monitor connector c : Main relay C : EVAP canister
4. CO adjusting resistor (if equipped) d : Fuel pump relay D : DLC
5. CKP sensor e : IAC valve E : ABS control module (if equipped)
6. MAP sensor f : EVAP canister purge valve
7. CMP sensor g : EGR valve (if equipped)
8. Transmission range switch h : Fuel injector
9. VSS i : Ignition coil assemblies
10. HO2S-1 (if equipped) j : MIL
11. HO2S-2 (if equipped)
12. ECT sensor
13. Knock sensor

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DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders)
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
CIRCUIT DESCRIPTION
ECM monitors crankshaft revolution speed and engine speed via the crankshaft position sensor and cylinder No.
via the camshaft position sensor. Then it calculates the change in the crankshaft revolution speed and from how
many times such change occurred in every 200 or 1000 engine revolutions, it detects occurrence of misfire.
When ECM detects a misfire (misfire rate per 200 revolutions) which can cause overheat and damage to the
three way catalytic converter, it makes the malfunction indicator lamp (MIL) flash as long as misfire occurs at
that rate.
After that, however, when the misfire rate drops, MIL remains ON until it has been judged as normal 3 times
under the same driving conditions.
Also, when ECM detects a misfire (misfire rate per 1000 revolutions) which will not cause damage to three way
catalytic converter but can cause exhaust emission to be deteriorated, it makes MIL light according to the 2 driv-
ing cycle detection logic.
1. Ignition coil assembly (for No.1 and No.4 cylinder)
2. Ignition coil assembly (for No.2 and No.3 cylinder)
3. Fuel injector
4. CKP sensor
5. CMP sensor

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DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Check vehicle and environmental condition for :
–Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Ambient temp. : –10 °C, 14 °F or higher
–Intake air temp. : 70 °C, 158 °F or lower
–Engine coolant temp. : – 10 – 110 °C, 14 – 230 °F
4) Start engine and keep it at idle for 2 min. or more.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6) If DTC is not detected at idle, consult usual driving based on information obtained in “Customer complaint
analysis” and “Freeze frame data check”.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
Engine under other than high revolution condition
Not on rough road
Engine speed changing rate (below specified value)
Manifold absolute pressure changing rate (below
specified value)
Throttle opening changing rate (below specified
value)
Misfire rate per 200 or 1000 engine revolutions (how
much and how often crankshaft revolution speed
changes) is higher than specified valueEngine overheating
Vacuum leaks (air inhaling) from air intake system
Ignition system malfunction (spark plug(s), high-
tension cord(s), ignition coil assembly)
Fuel pressure out of specification
Fuel injector malfunction (clogged or leakage)
Engine compression out of specification
Valve lash (clearance) out of specification
Manifold absolute pressure sensor malfunction
Engine coolant temp. sensor malfunction
PCV valve malfunction
EVAP control system malfunction
EGR system malfunction
NOTE:
Among different types of random misfire, if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2
simultaneously, it may not possible to reconfirm DTC by using the following DTC confirmation proce-
dure. When diagnosing the trouble of DTC P0300 (Random misfire detected) of the engine which is
apparently misfiring, even if DTC P0300 cannot be reconfirmed by using the following DTC confirma-
tion procedure, proceed to the following Diag. Flow Table.
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine
Diag. Flow Table”.
2 Is there DTC other than Fuel system (DTC P0171/
P0172) and misfire (DTC P0300 – P0304)?Go to applicable DTC
Diag. Flow Table.Go to Step 3.

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6F1
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8C
6A1
8E
9
9
10B
SECTION 6A1
ENGINE MECHANICAL (M13 ENGINE)
CONTENTS
General Description ......................................6A1-2
Engine ......................................................... 6A1-2
Engine Lubrication ...................................... 6A1-3
Diagnosis .......................................................6A1-4
Diagnosis Table .......................................... 6A1-4
Compression Check .................................... 6A1-4
Engine Vacuum Check ................................ 6A1-6
Oil Pressure Check ..................................... 6A1-7
Valve Lash (Clearance) ............................... 6A1-9
On-Vehicle Service......................................6A1-13
Air Cleaner Element .................................. 6A1-13
Air Cleaner Assembly ................................ 6A1-14
Knock Sensor ............................................ 6A1-14
Cylinder Head Cover ................................. 6A1-15
Throttle Body and Intake Manifold ............ 6A1-18
Exhaust Manifold ....................................... 6A1-21Oil Pan and Oil Pump Strainer .................. 6A1-24
Timing Chain Cover .................................. 6A1-28
Oil Pump ................................................... 6A1-33
Timing Chain and Chain Tensioner .......... 6A1-37
Camshaft, Tappet and Shim ..................... 6A1-42
Valves and Cylinder Head ........................ 6A1-48
Pistons, Piston Rings, Connecting
Rods and Cylinders................................... 6A1-62
Engine Mountings ..................................... 6A1-72
Unit Repair Overhaul .................................. 6A1-73
Engine Assembly ...................................... 6A1-73
Main Bearings, Crankshaft and Cylinder
Block ......................................................... 6A1-79
Required Service Material .......................... 6A1-93
Tightening Torque Specification ............... 6A1-93
Special Tool ................................................. 6A1-94

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).

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12) Remove crankshaft pulley bolt.
To lock crankshaft pulley (1), use special tool with it as
shown in figure.
Special tool
(A) : 09917-68221
13) Remove crankshaft pulley (1).
If it is hard to remove, use special tools as shown in figure.
If bolts of special tool are too long, replace them with those
of suitable length.
Special tool
(A) : 09944-36011
(B) : 09926-58010
14) Remove oil pan referring to “Oil Pan and Oil Pump Strainer”
in this section.
15) Remove cylinder head cover referring to “Cylinder Head
Cover” in this section.
16) Disconnect CMP sensor coupler (1) and release its harness
clamps.
17) Remove water outlet pipe (2).
18) Remove timing chain cover (3).
CLEANING
Clean sealing surface on timing chain cover, cylinder block
and cylinder head.
Remove oil, old sealant and dust from sealing surface.

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REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Drain engine oil.
4) Drain coolant by loosening drain plug (1).
5) Remove air cleaner outlet No.1 and No.2 hoses and
breather hose.
6) Remove intake manifold bracket (1) with main harness from
intake manifold.
7) Disconnect the following electric lead wires:
EGR valve (if equipped)
IAC valve (2)
TP sensor (3)
MAP sensor (4)
CMP sensor
ECT sensor
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Heated oxygen sensor
Ground terminal (7) from intake manifold
Each wire harness clamps
8) Remove heated oxygen sensor bracket from cylinder head
and detach heated oxygen sensor coupler from its bracket. WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.

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a) For right hand steering vehicle:
With hose connected, detach A/C compressor from its
bracket.
b) For left hand steering vehicle:
i) Recover refrigerant from refrigeration system using recov-
ery and recycling equipment.
ii) Disconnect magnet clutch lead wire.
iii) Remove suction pipe and disconnect discharge pipe from
A/C compressor.
iv) Remove A/C compressor from its bracket.
When servicing above steps, refer to “Compressor” in Section 1B.
14) Remove air cleaner outlet No.1 and No.2 hoses.
15) Disconnect the following electric lead wires:
TP sensor (1)
MAP sensor (2)
CKP sensor (if equipped) (3)
CMP sensor
ECT sensor
Heated oxygen sensor
EGR valve (if equipped)
IAC valve (4)
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Generator
Starting motor
Oil pressure switch
Ground terminal from intake manifold and cylinder block
Each wire harness clamps
16) Remove intake manifold bracket (7) with main harness from
intake manifold.
17) Remove starting motor referring to “Dismounting” in Section
6G. NOTE:
Suspend removed A/C compressor at a place where no
damage will be caused during removal and installation of
engine assembly.

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18) Remove heated oxygen sensor bracket from cylinder head
and detach No.1 heated oxygen sensor coupler from its
bracket.
19) Release accelerator cable (1) from clamp (2) (for left hand
steering vehicle only) and disconnect accelerator cable from
throttle body.
20) Remove canister purge hose bracket from intake manifold.
21) Disconnect the following hoses:
Brake booster hose (3) from intake manifold
Canister purge hose (4) from EVAP canister purge valve
Fuel feed and return hoses (5) from each pipe
Heater inlet and outlet hoses from each pipe
Vacuum hose (6) (to check valve)
22) Disconnect exhaust pipe (1) from exhaust manifold.
23) Remove clutch housing (torque converter housing for A/T)
lower plate (1).
24) With drive plate locked by using a proper size rod (1) or the
like, remove torque converter bolts (2) (vehicle with A/T).
25) Support transmission. For A/T vehicle, do not jack under A/T
oil pan to support transmission.

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Main Bearings, Crankshaft and Cylinder Block
Tightening torque 4. Venturi plug 12. Input shaft bearing
Do not reuse. 5. Main bearing 13. Flywheel
Apply engine oil to inside / sliding
surface.6. Sensor plate 14. Main bearing cap
“a” : 3 mm (0.12 in.) 7. Crankshaft timing sprocket key 15. Flywheel mounting bolt
: Apply sealant 99000-31110 to thread
part.
“b” : 2 mm (0.08 in.) 8. Crankshaft 16. Rear oil seal housing mounting bolt
1. CKP sensor (if equipped) 9. Thrust bearing 17. Main bearing cap No.2 bolt
2. Knock sensor 10. Rear oil seal housing
: Apply specified amount [A] of seal-
ant 99000-31150 to mating surface. 18. Main bearing cap No.1 bolt
1) Tighten all bolts to 50 N·m (5.0 kg-m)
2) Then, turn all bolts to 60°
3. Cylinder block 11. Rear oil seal

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INSTALLATION
1) Install sensor plate (1) to crankshaft (2) and tighten bolts to
specified torque.
Tightening torque
Sensor plate bolts (a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
2) Install main bearings to cylinder block.
Upper half of bearing (1) has an oil groove (2).
Install it to cylinder block (3), and the other half without oil
groove to bearing cap.
Make sure that two halves are painted in the same color.
3) Install thrust bearings (1) to cylinder block between No.2 and
No.3 cylinders. Face oil groove (2) sides to crank webs.
4) Confirm that dowel pins(3) are installed to intake side of
each journal. NOTE:
All parts to be installed must be perfectly clean.
Be sure to oil crankshaft journals, journal bearings,
thrust bearings, crankpins, connecting rod bearings,
pistons, piston rings and cylinder bores.
Journal bearings, bearings caps, connecting rods, rod
bearings, rod bearing caps, pistons and piston rings
are in combination sets. Do not disturb such combina-
tion and make sure that each part goes back to where
it came from, when installing.
NOTE:
When installing sensor plate, align spring pin (3) on
crankshaft and hole of sensor plate.