check engine SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 6B-10 ENGINE COOLING
On-Vehicle Service
Cooling System Component
CAUTION:
Check to make sure that engine coolant temperature is cold before removing any part of cooling
system.
Disconnect negative cable at battery before removing any part.
1. Radiator 6. Thermostat 11. Water outlet cap
2. Reservoir 7. Thermostat cap 12. Thermostat case outlet pipe
3. Cooling fan shroud 8. Radiator outlet pipe 13. Thermostat cap bolt
4. Water outlet pipe 9. Heater pipe 14. Thermostat case bolt
5. Thermostat case 10. ECT sensor Tightening Torque
814 25 N·m (2.5 kg-m) 10 15 N·m (1.5 kg-m)
12 5
6
7
13 11 N·m
(1.1 kg-m) 119421
3

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INSPECTION
1) Make sure that air bleed valve (1) of thermostat is clear.
Should this valve be clogged, engine would tend to overheat.
2) Check valve seat for some foreign matters being stuck which
prevent valve from seating tight.
3) Check thermostatic movement of wax pellet as follows:
a) Immerse thermostat (1) in water, and heat water gradually.
b) Check that valve starts to open at specification temp.
c) If valve starts to open at a temperature substantially below
or above, thermostat unit should be replaced with a new
one.
Such a unit, if re-used, will bring about overcooling or over-
heating tendency.
Thermostat functional specification
INSTALLATION
1) When positioning the thermostat (2) on the thermostat case
(1), be sure to align its air breather valve (3) with mark (4).
2) Install thermostat cap (5) to thermostat case with align air
bleed valve and mark.
Then, tighten mounting bolts to specified torque.
Tightening torque
Thermostat cap bolts
(a) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Thermostat case bolts
(b) : 25 N·m (2.5 kg-m, 18.0 lb-ft)
3) Install intake manifold by referring to “Throttle Body and
Intake Manifold” in Section 6A1.
4) Fill the cooling system.
Temp. at which valve begins
to open80 – 84 °C (176 – 183 °F)
Temp. at which valve
becomes fully open93 – 97 °C (199 – 207 °F)
Valve liftMore than 8 mm at 95 °C
(203 °F)
2. Thermometer
3. Heater

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Water Pump Belt and Cooling Fan
REMOVAL
1) Remove radiator shroud securing bolts (1).
2) Remove radiator by referring to “Radiator” in this section.
3) Loosen water pump drive belt tension.
4) Remove cooling fan by removing securing nuts.
Remove power steering and/or compressor drive belt before
removing water pump belt.
5) Remove pump belt.
INSTALLATION
Once cooling fan or water pump belt has been removed, make
sure to tighten bolts and nuts securely in reinstallation and adjust
pump belt tension to specification. For specified tension, refer to
“Water Pump Belt Tension” in this section.
WATER PUMP BELT TENSION INSPECTION
1) Check belt tension. It should be within specification. Refer to
“Water Pump Belt Tension” in this section.
2) If tension is out of specification, adjust it.
For its adjustment, refer to “Water Pump Belt Tension” in this
section.
After adjustment, be sure to tighten bolts.
COOLING FAN CLUTCH INSPECTION
Inspect fluid coupling for oil leakage.
If necessary, replace fan clutch assembly. Do not disassemble
clutch assembly.

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Radiator
REMOVAL
1) Drain cooling system.
2) Remove radiator shroud.
3) Disconnect water hoses from radiator.
4) With automatic transmission (A/T) vehicle, disconnect addi-
tional two fluid hoses from radiator.
Place some container under radiator to receive A/T fluid
which will flow out when hose is disconnected.
5) Install radiator protection board to between radiator and
cooling fan.
6) Remove radiator after removing two bolts (1).
INSPECTION
If the water side of the radiator is found excessively rusted or cov-
ered with scales, clean it by flushing with the radiator cleaner
compound.
This flushing should be carried out at regular intervals for scale or
rust formation advances with time even where a recommended
type of coolant is used. Periodical flushing will prove more eco-
nomical.
Inspect the radiator cores and straighten the flattened or bent
fins, if any. Clean the cores, removing road grimes and trashes.
Excessive rust or scale formation on the wet side of the radiator
lowers the cooling efficiency.
Flattened or bent fins obstruct the flow of air through the core to
impede heat dissipation.
Radiator flushing interval recommended
Two years
INSTALLATION
Reverse removal procedures.
NOTE:
Refill cooling system with proper coolant referring to
“Coolant” and “Cooling System Flush and Refill” in
this section.
With automatic transmission vehicle, fill A/T fluid up to
specified level. For procedure to check A/T fluid and its
level, refer to “Changing Fluid” in Section 7B.
After installation, check each joint for leakage.

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INSPECTION
Rotate water pump by hand to check for smooth operation.
If pump does not rotate smoothly or makes an abnormal
noise, replace it.
INSTALLATION
1) Apply sealant to water pump (1).
“A” : Sealant 99000-31150
Sealant quantity for mating surface of water pump
Width “a” : 3mm (0.12 in.)
Height “b” : 2mm (0.08 in.)
2) Install water pump (1) to cylinder block.
Tightening torque
Water pump bolts (a) : 23 N·m (2.3 kg-m, 17.0 lb-ft)
3) Install water pump pulley (2) with fan clutch (3).
Tightening torque
Water pump pulley nuts (b) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
Fan clutch bolts (c) : 11 N·m (1.1 kg-m, 8.0 lb-ft)
4) Install water pump drive belt, cooling fan and radiator
shroud.
5) Adjust water pump belt tension.
Refer to “Water Pump Belt Tension” in this section.
6) Connect negative cable at battery.
7) Fill the cooling system.NOTE:
Do not disassemble water pump.
If any repair is required on pump, replace it as assembly.

Downloaded from www.Manualslib.com manuals search engine 6C-4 ENGINE FUEL
On-Vehicle Service
Before work, refer to “Precaution on Fuel System Service” in Sec-
tion 6.
Fuel Lines
Due to the fact that fuel feed line is under high pressure, use spe-
cial care when servicing it.
INSPECTION
Visually inspect fuel lines for evidence of fuel leakage, hose crack
and deterioration, or damage. Make sure all clamps are secure.
Replace parts as needed.
Fuel Filler Cap
Remove cap (1) and check gasket (2) for even filler neck imprint
and deterioration or any damage. If gasket is in malcondition,
replace cap.
Fuel Tank
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres-
sure Relief Procedure” in Section 6.
2) Disconnect negative cable at battery.
3) Remove fuel filler cap.
NOTE:
If cap requires replacement, only a cap with the same fea-
tures should be used. Failure to use correct cap can
result in critical malfunction of system.
WARNING:
Before starting the following procedure, be sure to
observe “Precaution on Fuel System Service” in Sec-
tion 6.
Keep fuel tank horizontally and stably when removing
it. Fuel may come out if tank is tilted. Also, fuel tank
may drop and cause personal injury.

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INSTALLATION
1) Install fuel pump (1) assembly to fuel tank. Refer to “Fuel
Pump Assembly” in this section. Install protector to fuel tank.
2) Install inlet valve to fuel tank.
If deformed or damaged in any other way, replace with a new
one.
3) Connect fuel filler and breather hoses to fuel tank and vapor
hose to fuel pump assembly. Clamp them securely.
4) Lift up fuel tank on jack.
Connect fuel feed hose (4) and return hose (3) to pipes as
shown in figure and clamp them securely.
5) Install fuel tank to vehicle and connect wire harness coupler.
6) Connect fuel filler hose and breather hose to fuel filler neck.
Connect fuel vapor hose to pipe. Clamp them securely.
7) Install fuel filler hose protector.
Fuel Pump Assembly
REMOVAL
1) Remove fuel tank from vehicle. Refer to “Fuel Tank” in this
section.
2) Disconnect wire harness coupler and fuel vapor hose from
fuel pump assembly.
3) Remove fuel pump assembly from fuel tank by removing
bolts. CAUTION:
When connecting joint, clean outside surfaces of pipe
where joint is to be inserted, push joint into pipe till joint
lock clicks and check to ensure that pipes are connected
securely, or fuel leak may occur.
2. Quick joint
WARNING:
Before starting the following procedure, be sure to
observe “Precaution on Fuel System Service” in Section
6.

Downloaded from www.Manualslib.com manuals search engine 6C-8 ENGINE FUEL
INSPECTION
Check fuel pump assembly for damage.
Check fuel suction filter (1) for evidence of dirt and contamination.
If present, replace or clean and check for presence of dirt in fuel
tank.
For inspection of fuel pump itself, refer to “Table B – 3 Fuel Pres-
sure Check” in Section 6.
For inspection of fuel level gauge, refer to “Fuel Meter / Fuel
Gauge Unit” in Section 8.
DISASSEMBLY / REASSEMBLY
2. Fuel filter & bracket assembly
3. Fuel pump motor & level gauge assembly
“A” : Apply oil 4. Housing 8. Cushion
1. Bracket sub assembly (including fuel filter) 5. Lead wire 9. Bracket
2. Grommet 6. Fuel level gauge 10. Spacer
3. Tube 7. Fuel pump

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-15
On-Vehicle Service
Accelerator cable adjustment
1) With throttle valve closed, check accelerator pedal play
which should be within following specification.
If measured value is out of specification, adjust it to specifi-
cation with cable adjusting nut (1).
Accelerator pedal play
“a” : 2 – 7 mm (0.08 – 0.27 in.)
2) With accelerator pedal depressed fully, check clearance
between throttle lever (2) and lever stopper (3) (throttle
body) which should be within following specification.
If measured value is out of specification, adjust it to specifi-
cation by changing height of pedal stopper bolt (1).
Accelerator cable adjustment clearance
(With pedal depressed fully)
“a” : 0.5 – 2.0 mm (0.02 – 0.07 in.)
Idle speed / idle air control (IAC) duty inspection
Before idle speed / IAC duty check, make sure of the following.
Lead wires and hoses of Electronic Fuel Injection and engine
emission control systems are connected securely.
Accelerator cable has some play, that is, it is not tight.
Valve lash is checked and adjusted according to mainte-
nance schedule.
Ignition timing is within specification.
All accessories (wipers, heater, lights, A/C, etc.) are out of
service.
Air cleaner has been properly installed and is in good condi-
tion.
No abnormal air inhaling from air intake system.
After above items are all confirmed, check idle speed and IAC
duty as follows.
NOTE:
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
vehicle), and set parking brake and block drive wheels.

Downloaded from www.Manualslib.com manuals search engine 6E-16 ENGINE AND EMISSION CONTROL SYSTEM
1) Connect SUZUKI scan tool to DLC with ignition switch OFF,
if it is available.
2) Warm up engine to normal operating temperature.
3) Check engine idle speed and “IAC duty” as follows:
a) When using SUZUKI scan tool:
i) Select “Data List” mode on scan tool to check “IAC duty”.
(A) : SUZUKI scan tool
b) When using duty meter (3) (Vehicle without immobilizer
indicator lamp):
i) Set tachometer.
ii) Using service wire (2), ground “Diag. switch terminal” in
monitor connector (1) and connect duty meter between
“Duty output terminal (4)” and “Ground terminal (5)” of
monitor connector (1).
4) If duty and/or idle speed is out of specifications, inspect idle
air control system referring to “Diagnostic Flow Table B-4 Idle
Air Control System Check” in Section 6.
Engine idle speed and IAC duty
5) Remove service wire from monitor connector.
6) Check that specified engine idle speed is obtained with A/C
ON if vehicle is equipped with A/C.
If not, check A/C ON signal circuit and idle air control sys-
tem. NOTE:
IAC duty can be checked using monitor connector only
for vehicle not equipped with immobilizer indicator lamp.
[A] : When using SUZUKI scan tool
[B] : When using duty meter (Vehicle without immobilizer indicator lamp)
A/C OFF A/C ON
M/T vehicle700 ± 50 r/min (rpm)
5 – 25 %900 ± 50 r/min
(rpm)
A/T vehicle
at P/N range750 ± 50 r/min (rpm)
5 – 25 %900 ± 50 r/min
(rpm)
NOTE:
Above duty values are ON duty (low voltage rate) meter
indications.