cooling SUZUKI JIMNY 2005 3.G Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 1B-34 AIR CONDITIONING (OPTIONAL)
Cooling Unit (Evaporator)
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Recover refrigerant from A/C system by referring to “Recov-
ery” in this section. CAUTION:
Be careful not to damage A/C evaporator fins. If A/C evaporator fin is bent, straighten A/C evaporator
fin by using flat head screwdriver or pair of pliers.
1. A/C evaporator 3. Expansion valve 5. Packing 7. O-ring
2. A/C evaporator thermistor
(A/C evaporator temperature sensor)4. Evaporator case 6. Air inlet door 8. Door link
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-35
3) Drain engine coolant and disconnect heater hoses (1) from
heater unit.
4) Disable air bag system referring to “Disabling Air Bag Sys-
tem” in Section 10B (if equipped).
5) Remove attaching bolt (1).
6) Disconnect suction hose (2) and receiver / dryer outlet pipe
(3) from expansion valve (4).
7) Remove instrument panel referring to “Instrument Panel” in
Section 9.
8) Remove cooling unit (1) with heater unit (2) from vehicle
body.
9) Remove cooling unit (1) from heater unit (2).
INSPECTION
Check the following.
Check clog of A/C evaporator fins.
If any clogs are found, A/C evaporator fins should be
washed with water, and should be dried with compressed
air.
Check A/C evaporator fins for leakage and breakage.
If any defects are found, repair or replace A/C evaporator.
Check A/C evaporator fittings for leakage.
If any defects are found, repair or replace A/C evaporator.

Downloaded from www.Manualslib.com manuals search engine 1B-36 AIR CONDITIONING (OPTIONAL)
INSTALLATION
Reverse removal procedure to install cooling unit, and then noting
the following instructions.
If A/C evaporator thermistor removed, its should be rein-
stalled in original position.
Install uniformly the packing (1) to installation hole.
Replenish specified amount of compressor oil to compressor
suction side by referring to “Replenishing Compressor Oil” in
this section.
Evacuate and charge refrigerant by referring to “Evacuating”
and “Charging” in this section.
Adjust mode control cable, temperature control cable and
fresh air control cable by referring to “Heater Control Lever
Assembly” in Section 1A.
Enable air bag system referring to “Enable Air Bag System”
in Section 10B. (if equipped)
Fill engine coolant to radiator, referring to “Cooling System
Flush and Refill” in Section 6B.

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A/C Switch
REMOVAL AND INSTALLATION
Refer to “Heater Control Lever Assembly” in Section 1A.
INSPECTION
Press A/C switch button and check if there is continuity
between terminals “A” and “B”.
With battery voltage (+) connected to terminal “C” and (–) to
terminal “A”, press A/C Switch button and blower fan switch
to “Hi” (3rd position).
Check if indicator lamp lights.
Condenser Cooling Fan Motor Relay
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove condenser cooling fan motor relay (1) from vehicle.
3) Check that there is no continuity between terminal “a” and
“b”. If there is continuity, replace relay.
4) Check that there is continuity between terminals “a” and “b”
when battery is connected to terminal “c” and “d”.
If there is no continuity, replace relay.
Compressor
REMOVAL
1) Run engine at idle speed with air conditioning ON for 10 min-
utes. After that stop the engine.
2) Disconnect negative (–) cable at battery.
3) Recover refrigerant from refrigeration system by referring to
“Recovery” in this section.
1. Blower fan and A/C switch
NOTE:
The amount of removed compressor oil must be mea-
sured for replenishing compressor oil.

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Replacement Wheels
Wheels must be replaced if they are bent, dented, have excessive
lateral or radial runout, leak air through welds, have elongated
bolt holes, if lug nuts won’t stay tight, or if they are heavily rusted.
Wheels with greater runout than shown in “How to Measure
Wheel Runout” may cause objectional vibrations.
Wheels for replacement must be equivalent to the originally
equipped wheels in load capacity, diameter, rim width, off-set and
mounting configuration. A wheel of improper size or type may
affect wheel and bearing life, brake cooling, speedometer / odom-
eter calibration, ground clearance to the body and chassis.
How To Measure Wheel Runout
To measure the wheel runout, it is necessary to use accurate dial
indicator. The tire may be on or off the wheel. The wheel should
be installed to the wheel balancer of the like for proper measure-
ment.Take measurements of both lateral runout (1) and radial
runout (2) at both inside and outside of the rim flange. With dial
indicator set in place securely, turn the wheel one full revolution
slowly and record every reading of the indicator.
When the measured runout exceeds the specification and correc-
tion by the balancer adjustment is impossible, replace the wheel.
If the reading is affected by welding, paint or scratch, it should be
ignored.
Lateral runout limit
“a” : 1.20 mm (0.047 in.)
Radial runout limit
“b” : 1.20 mm (0.047 in.)
Metric Lug Nuts and Wheel Studs
All models use metric lug nuts and wheel studs.
Metric lug nuts and wheel studs size
: M12 x 1.25

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8B
6
8D
8E
8B
9
10A
10B
SECTION 6
ENGINE GENERAL INFORMATION AND
DIAGNOSIS
GENERAL INFORMATION AND ENGINE DIAGNOSIS ..............................................................................
6-1
ENGINE MECHANICAL ...........................................................................................................................
6A1-1
ENGINE COOLING.....................................................................................................................................
6B-1
ENGINE FUEL ............................................................................................................................................
6C-1
ENGINE AND EMISSION CONTROL SYSTEM ........................................................................................
6E-1
IGNITION SYSTEM ....................................................................................................................................
6F-1
CRANKING SYSTEM .................................................................................................................................
6G-1
CHARGING SYSTEM .................................................................................................................................
6H-1
EXHAUST SYSTEM ...................................................................................................................................
6K-1
CONTENTS
General Information .......................................... 6-3
Statement on Cleanliness and Care ............... 6-3
General Information on Engine Service .......... 6-3
Precaution on fuel system service............... 6-4
Fuel pressure relief procedure .................... 6-5
Fuel leakage check procedure .................... 6-5
Engine Diagnosis .............................................. 6-6
General Description ........................................ 6-6
On-Board Diagnostic System (Vehicle with
Immobilizer Indicator Lamp) ............................ 6-6On-Board Diagnostic System (Vehicle without
Immobilizer Indicator Lamp)............................ 6-9
Precaution in Diagnosing Trouble ................. 6-10
Engine Diagnostic Flow Table ...................... 6-11
Customer problem inspection form
(example) .................................................. 6-13
Malfunction indicator lamp (MIL) check..... 6-14
Diagnostic trouble code (DTC) check ....... 6-14
Diagnostic trouble code (DTC)
clearance................................................... 6-15 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:
Whether the following systems (parts) are used in the particular vehicle or not depends on vehicle
specifications. Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor(s) or CO adjusting resistor
Three-way catalytic converter (TWC) and warm up three-way catalytic converter (WU-TWC)

Downloaded from www.Manualslib.com manuals search engine 6-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Engine Diagnosis
General Description
This vehicle is equipped with an engine and emission control system which are under control of ECM.
The engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnos-
tic system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of “On-
Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis accord-
ing to “ENGINE DIAGNOSTIC FLOW TABLE”.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust
system, etc. and the engine and emission control system in their structure and operation. In case of an engine
trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to
this flow table.
On-Board Diagnostic System (Vehicle with
Immobilizer Indicator Lamp)
ECM in this vehicle has following functions.
When the ignition switch is turned ON with the engine at a
stop, malfunction indicator lamp (MIL) (1) turns ON to check
the bulb of the malfunction indicator lamp (1).
When ECM detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it
makes the malfunction indicator lamp (1) in the meter cluster
of the instrument panel turn ON or flash (flashing only when
detecting a misfire which can cause damage to the catalyst)
and stores the malfunction area in its memory.
(If it detects that continuously 3 driving cycles are normal
after detecting a malfunction, however, it makes MIL (1) turn
OFF although DTC stored in its memory will remain.)
As a condition for detecting a malfunction in some areas in
the system being monitored by ECM and turning ON the
malfunction indicator lamp (1) due to that malfunction, 2 driv-
ing cycle detection logic is adopted to prevent erroneous
detection.
When a malfunction is detected, engine and driving condi-
tions then are stored in ECM memory as freeze frame data.
(For the details, refer to description on Freeze frame data.)
It is possible to communicate by using not only SUZUKI scan
tool (2) but also generic scan tool. (Diagnostic information
can be accessed by using a scan tool.)
WARM-UP CYCLE
A warm-up cycle means sufficient vehicle operation such that the
coolant temperature has risen by at least 22 °C (40 °F) from
engine starting and reaches a minimum temperature of 70 °C
(160 °F).

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-121
TAble B-7 A/C Condenser Fan Control System Check
INSPECTION
Step Action Yes No
1 Check Fan Control System.
1) Connect scan tool to DLC with ignition switch OFF. See
Fig. 1.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Warm up engine until coolant temp. is 110 °C, 230 °F or
higher and A/C switch turn OFF. (If engine coolant temp.
does not rise, check engine cooling system or ECT sen-
sor.)
Is A/C condenser fan started when engine coolant temp.
reached above temp.?A/C condenser fan con-
trol system is in good
condition.Go to Step 2.
2 Check A/C Condenser Fan Relay and Its Circuit.
1) Check DTC and pending DTC with scan tool.
Is DTC P0481 displayed?Go to DTC P0481 Diag.
Flow Table.Go to Step 3.
3 Check A/C Condenser Fan Relay (1).
1) Turn ignition switch OFF and remove A/C condenser fan
relay.
2) Check for proper connection to relay at terminals “A”
and “B”.
3) If OK, check that there is continuity between “A” and “B”
when battery is connected to terminals “C” and “D”. See
Fig. 2.
Is check result satisfactory?Go to Step 4. Replace A/C
condenser fan
relay.

Downloaded from www.Manualslib.com manuals search engine 6A1-20 ENGINE MECHANICAL (M13 ENGINE)
13) Remove intake manifold (1) with throttle body (2) and EGR
pipe (3) from cylinder head (4), and then its gasket.
INSTALLATION
Reverse removal procedure for installation noting the followings.
Use new intake manifold gasket and EGR pipe gasket.
Tighten long bolt (1), short bolt (3) and nuts (2) to specified
torque.
Tightening torque
Intake manifold bolts and nuts
(a) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
Refill cooling system referring to “Cooling System Flush and
Refill” in Section 6B.
Upon completion of installation, turn ignition switch ON but
engine OFF and check for fuel leaks.
Finally, start engine and check for engine coolant leaks.

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5) Drain coolant.
6) Disconnect radiator inlet and outlet hoses from each pipe.
7) Disconnect A/T fluid hoses (1) (vehicle with A/T) and release
its clamps. Place some container under radiator to receive
A/T fluid which will flow out when hose is disconnected.
8) Remove fan shroud upper bolts and install board (1) or the
like. This prevents damage to radiator fins when removing
and installing radiator.
9) Remove radiator with cooling fan. Then remove water pump
pulley. Refer to “Radiator” and “Water Pump Belt and Cool-
ing Fan” in Section 6B.
10) Remove A/C compressor and/or P/S pump belt tension pul-
ley (1) (if equipped).
11) With hose connected, detach P/S pump from its bracket and
then remove P/S pump bracket (2) (if equipped) referring to
“Power Steering Pump” in Section 3B1. 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.
NOTE:
Suspend removed P/S pump at a place where no damage
will be caused during removal and installation of timing
chain cover.