SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 6-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Malfunction indicator lamp (MIL) check
1) Turn ON ignition switch (but the engine at stop) and check
that MIL lights.
If MIL does not light up (or MIL dims), go to “Diagnostic Flow
Table A-1” for troubleshooting.
If MIL flushes, go to “Diagnostic Flow Table A-3” for trouble
shooting (vehicle without immobilizer indicator lamp).
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM, go to
“Diagnostic Flow Table A-2” for troubleshooting.
Diagnostic trouble code (DTC) check
[Using SUZUKI Scan Tool]
1) Prepare SUZUKI scan tool.
2) With ignition switch OFF, connect it to data link connector
(DLC) (1) located on underside of instrument panel at
driver’s seat side.
Special tool
(A) : SUZUKI scan tool
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC, pending DTC and freeze frame data according to
instructions displayed on scan tool and print it or write it
down.
Refer to scan tool operator’s manual for further details.
If communication between scan tool and ECM is not possi-
ble, check if scan tool is communicable by connecting it to
ECM in another vehicle. If communication is possible in this
case, scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle with
which communication was not possible.
5) After completing the check, turn ignition switch off and dis-
connect scan tool from data link connector.
[Without Using SUZUKI Scan Tool] (Vehicle Without
Immobilizer Indicator Lamp)
1) Check malfunction indicator lamp referring to “Malfunction
Indicator Lamp Check” in this section.
2) With the ignition switch OFF position, connect diagnosis
switch terminal (3) and ground terminal (2) in monitor con-
nector (1) with service wire (4).
3) With the ignition switch ON position and leaving engine OFF,
read DTC from flashing pattern of malfunction indicator
lamp. Refer to “Diagnostic Trouble Code Table”.
If lamp does not flash or remains ON or OFF, go to “Diag-
nostic Flow Table A-4”.

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4) After completing the check, turn the ignition switch OFF posi-
tion and disconnect service wire from monitor coupler.
Diagnostic trouble code (DTC) clearance
[Using SUZUKI Scan Tool]
1) Connect SUZUKI scan tool to data link connector in the
same manner as when making this connection for DTC
check.
2) Turn ignition switch ON.
3) Erase DTC and pending DTC according to instructions dis-
played on scan tool. Refer to scan tool operator’s manual for
further details.
4) After completing the clearance, turn ignition switch off and
disconnect scan tool from data link connector.
[Without Using SUZUKI Scan Tool]
1) Turn the ignition switch OFF position.
2) Disconnect battery negative cable for specified time below to
erase diagnostic trouble code stored in ECM memory and
reconnect it.
Time required to erase DTC NOTE:
If abnormality or malfunction lies in two or more areas,
malfunction indicator lamp indicates applicable codes
three times each.
And flashing of these codes is repeated as long as
diagnosis terminal is grounded and ignition switch is
held at ON position.
Take a note of diagnostic trouble code indicated first.
NOTE:
DTC and freeze frame data stored in ECM memory are
also cleared in following cases. Be careful not to clear
them before keeping their record.
When power to ECM is cut off (by disconnecting bat-
tery cable, removing fuse or disconnecting ECM con-
nectors)
When the same malfunction (DTC) is not detected
again during 40 engine warm-up cycles.
Ambient temperature Time to cut power to ECM
Over 0 °C (32 °F) 30 sec. or longer
Under 0 °C (32 °F)Not specifiable.
Select a place with higher than
0 °C (32 °F) temperature.

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Diagnostic trouble code (DTC) table
DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)
P0105
(No.11)Manifold absolute pressure
circuit malfunctionLow pressure-high vacuum-low voltage
(or MAP sensor circuit shorted to ground)
High pressure-low vacuum-high voltage
(or MAP sensor circuit open)1 driving
cycle1 driving
cycle
P0110
(No.18)Intake air temp. circuit mal-
functionIntake air temp. circuit low input
Intake air temp. circuit high input1 driving
cycle1 driving
cycle
P0115
(No.19)Engine coolant temp. cir-
cuit malfunctionEngine coolant temp. circuit low input
Engine coolant temp. circuit high input1 driving
cycle1 driving
cycle
P0120
(No.13)Throttle position circuit mal-
functionThrottle position circuit low input
Throttle position circuit high input1 driving
cycle1 driving
cycle
P0121Throttle position circuit per-
formance problemPoor performance of TP sensor 2 driving
cyclesNot
applicable
P0130
(No.14)HO2S circuit malfunction
(Sensor-1)Min. output voltage of HO2S-higher than
specification
Max. output voltage of HO2S-lower than
specification2 driving
cycles1 driving
cycle
P0133HO2S circuit slow response
(Sensor-1)Response time of HO2S-1 output voltage
between rich and lean is longer than spec-
ification.2 driving
cyclesNot
applicable
P0135
(No.14)HO2S heater circuit mal-
function (Sensor-1)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.2 driving
cycles1 driving
cycle
P0136HO2S circuit malfunction
(Sensor-2)HO2S-2 voltage is higher than specifica-
tion2 driving
cyclesNot
applicable
P0141HO2S heater circuit mal-
function (Sensor-2)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.
(or heater circuit or short)2 driving
cyclesNot
applicable
P0171 Fuel system too leanShort term fuel trim or total fuel trim (short
and long terms added) is larger than spec-
ification for specified time or longer.
(fuel trim toward rich side is large.)2 driving
cyclesNot
applicable
P0172 Fuel system too richShort term fuel trim or total fuel trim (short
and long term added) is smaller than spec-
ification for specified time or longer.
(fuel trim toward lean side is large.)2 driving
cyclesNot
applicable
P0300
P0301
P0302
P0303
P0304Random misfire detected
Cylinder 1 misfire detected
Cylinder 2 misfire detected
Cylinder 3 misfire detected
Cylinder 4 misfire detectedMisfire of such level as to cause damage
to three way catalystMIL flashing
during mis-
fire detec-
tionNot
applicable
Misfire of such level as to deteriorate emis-
sion but not to cause damage to three way
catalyst2 driving
cyclesNot
applicable
P0325
(No.17)Knock sensor circuit mal-
functionKnock sensor circuit low input
Knock sensor circuit high input1 driving
cycle1 driving
cycle

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P0335
(No.23)Crankshaft position sensor
circuit malfunctionNo signal for 2 sec. During engine crank-
ing1 driving
cycle1 driving
cycle
P0340
(No.15)Camshaft position sensor
circuit malfunctionNo signal during engine running1 driving
cycle1 driving
cycle
P0400Exhaust gas recirculation
flow malfunction detectedExcessive or insufficient EGR flow2 driving
cyclesNot
applicable
P0420Catalyst system efficiency
below thresholdOutput waveforms of HO2S-1 and HO2S-2
are similar.
(Time from output voltage change of
HO2S-1 to that of HO2S-2 is shorter than
specification.)2 driving
cyclesNot
applicable
P0443Purge control valve circuit
malfunctionPurge control valve circuit is open or
shorted to ground2 driving
cyclesNot
applicable
P0481A/C condenser fan control
circuit malfunctionA/C condenser fan relay terminal voltage is
low when fan command is not outputted2 driving
cyclesNot
applicable
P0500
(No.16)Vehicle speed sensor mal-
functionNo signal while running in “D” range or
during fuel cut at decelerating2 driving
cycles1 driving
cycle
P0505 Idle control system malfunc-
tionNo closed signal to IAC valve is detected2 driving
cyclesNot
applicable
P0601
(No.71)Internal control module
memory check sum errorData write error (or check sum error) when
written into ECM2 driving
cyclesNot
applicable
P1450 Barometric pressure sen-
sor circuit malfunctionBarometric pressure is lower or higher
than specification. (or sensor malfunction)1 driving
cycleNot
applicable
P1451Barometric pressure sen-
sor performance problemDifference between manifold absolute
pressure (MAP sensor value) and baro-
metric pressure (barometric pressure sen-
sor value) is larger than specification
during cranking.2 driving
cyclesNot
applicable
P1500Starter signal circuit mal-
functionStarter signal is not inputted from engine
cranking till its start and after or it is always
inputted2 driving
cyclesNot
applicable
P1510ECM backup power source
malfunctionNo backup power after starting engine1 driving
cycleNot
applicable
P1600Serial communication prob-
lem between ECM and
TCMNo signal or check sum error while engine
running1 driving
cycleNot
applicable
P1717AT D-range signal circuit
malfunctionNo “D” range (park / neutral position sig-
nal) is inputted while vehicle running2 driving
cyclesNot
applicable
P1570ABS signal circuit malfunc-
tionABS signal ON (low voltage) when engine
startNot
applicable1 driving
cycle DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)

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DTC NO. DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
P0702 Transmission Control System Electrical
Refer to Section 7B.
These DTCs can not be read on vehicle without
Immobilizer indicator lamp (by ECM application of
SUZUKI scan tool). P0705 Temperature Sensor Circuit Malfunction
P0710Transmission Temperature Sensor Circuit Mal-
function
P0715Input / Turbine Speed Sensor Circuit Malfunc-
tion
P0720Output Shaft Speed Sensor Circuit Malfunc-
tion
P0725 Engine Speed Input Circuit Malfunction
P0730 Incorrect Gear Ratio
P0743 Torque Converter Clutch Circuit Electrical
P0753 Shift Solenoid A Electrical
P0758 Shift Solenoid B Electrical
P0763 Shift Solenoid C Electrical
P0768 Shift Solenoid D Electrical
P1700 Throttle Position Signal Input Malfunction
P1702Internal Control Module Memory Check Some
Error
P1709Engine Coolant Temperature Signal Input
Malfunction
P1887 Transfer Signal
P1620
(No.84)ECU code not registered
Refer to Section 8G. P1621
(No.83)No ECU code transmitted from Immobilizer
Control Module
P1622
(No.82)Faulty in ECM
P1623
(No.81)ECU code not matched
NOTE:
For ( ) marked No. in DTC column, it is used for vehicle without Immobilizer indicator lamp.
DTC No.12 appears when none of the other codes is identified (vehicle without Immobilizer indica-
tor lamp).

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Fail-safe table
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to
exist but that mode is canceled when ECM detects normal condition after that.
DTC NO. DETECTED ITEM FAIL-SAFE OPERATION (SYMPTOM)
P0105
(No.11)Manifold absolute pressure sensor circuit
malfunctionECM uses value determined by throttle opening and
engine speed.
P0110
(No.18)Intake air temp. sensor circuit malfunctionECM controls actuators assuming that intake air tem-
perature is 20 °C (68 °F).
P0115
(No.19)Engine coolant temp. sensor circuit mal-
functionECM controls actuators assuming that engine coolant
temperature is 80 °C (176 °F).
P0120
(No.13)Throttle position sensor circuit malfunc-
tionECM controls actuators assuming that throttle opening
is 20°. (High idle speed)
P0335
(No.23)Crankshaft position sensor circuit mal-
functionECM controls injection system sequential injection to
synchronous injection. (Cranking for a few seconds to
start engine)
P0340
(No.15)Camshaft position sensor circuit malfunc-
tionECM controls injection system sequential injection to
synchronous injection. (Cranking for a few seconds to
start engine)
P0500
(No.16)Vehicle speed sensor malfunction ECM stops idle air control.
P1450Barometric pressure sensor low / high
inputECM controls actuators assuming that barometric
pressure is 100 kPa (760 mmHg).
P1570
(No.21)ABS signal circuit malfunctionECM controls actuators assuming that ABS signal is
OFF.

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Visual inspection
Visually check following parts and systems.
INSPECTION ITEM REFERRING SECTION
Engine oil – level, leakage Section 0B
Engine coolant – level, leakage Section 0B
Fuel – level, leakage Section 0B
A/T fluid – level, leakage Section 0B
Air cleaner element – dirt, clogging Section 0B
Battery – fluid level, corrosion of terminal
Water pump belt – tension, damage Section 0B
Throttle cable – play, installation
Section 6E Vacuum hoses of air intake system – disconnection, looseness,
deterioration, bend
Connectors of electric wire harness – disconnection, friction
Fuses – burning Section 8
Parts – installation, bolt – looseness
Parts – deformation
Other parts that can be checked visually
Also check following items at engine start, if possible
Malfunction indicator lamp – operation Section 6
Charge warning lamp – operation Section 6H
Engine oil pressure warning lamp – operation Section 8 (Section 6 for pressure check)
Engine coolant temp. meter – operation Section 8
Fuel level meter – operation Section 8
Tachometer, if equipped – operation
Abnormal air being inhaled from air intake system
Exhaust system – leakage of exhaust gas, noise
Other parts that can be checked visually

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Engine basic inspection
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been
found in visual inspection.
Follow the flow table carefully.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check battery voltage.
Is it 11 V or more?Go to Step 3. Charge or replace battery.
3 Is engine cranked? Go to Step 4. Go to “Diagnosis” in Sec-
tion 6G.
4 Does engine start? Go to Step 5. Go to Step 9.
5 Check idle speed as follows :
1) Warm up engine to normal operating temp.
2) Shift transmission to neutral position for M/T
(“P” position for A/T).
3) All of electrical loads are switched off.
4) Check engine idle speed with scan tool.
See Fig. 1.
Is it 650 – 750 r/min (700 – 800 r/min. for A/T
vehicle)?Go to Step 6. Go to “Engine Diagnosis
Table”.
6 Is SUZUKI scan tool available? Go to Step 8. Go to Step 7.
7 Check ignition timing as follows :
1) Connect test switch terminal (2) of monitor
coupler (1) to ground. See Fig. 2.
2) Remove air cleaner bolt and crips and shift
air cleaner position to observe ignition tim-
ing.
3) Using timing light (1), check initial ignition
timing.
See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “Engine Diagnosis
Table”.Check ignition control
related parts referring to
Section 6F.
8 Check ignition timing as follows :
1) Select “MISC” mode on SUZUKI scan tool
and fix ignition timing to initial one. See Fig.
3.
2) Remove air cleaner bolt and crips and shift
air cleaner position to observe ignition tim-
ing.
3) Using timing light (1), check initial ignition
timing. See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “Engine Diagnosis
Table”.Check ignition control
related parts referring to
Section 6F.
9 Check immobilizer system malfunction as fol-
lows (if equipped) :
1) Check immobilizer indicator lamp or MIL
(malfunction indicator lamp) for flashing.
Is it flashing when ignition switch is turned to
ON position?Go to “Diagnosis” in Sec-
tion 8G.Go to Step 10.

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[A] Fig. 1 for Step 5 / [B] Fig. 2 for Step 7 / [C] Fig. 3 for Step 810 Check fuel supply as follows :
1) Check to make sure that enough fuel is filled
in fuel tank.
2) Turn ON ignition switch for 2 seconds and
then OFF. See Fig. 5.
Is fuel return pressure (returning sounds) felt
from fuel feed hose (1) when ignition switch is
turned ON?Go to Step 12. Go to Step 11.
11 Check fuel pump for operating.
1) Was fuel pump operating sound heard from
fuel filler for about 2 seconds after ignition
switch ON and stop?Go to “Diag. Flow Table
B-3”.Go to “Diag. Flow Table
B-2”.
12 Check ignition spark as follows :
1) Disconnect injector couplers.
2) Remove spark plugs and connect them to
high tension cords.
3) Ground spark plugs.
4) Crank engine and check if each spark plug
sparks.
Is it in good condition?Go to Step 13. Go to “Ignition Spark Test”
in Section 6F.
13 Check fuel injector for operation as follows :
1) Install spark plugs and connect injector con-
nectors.
2) Using sound scope (2), check operating
sound of each injector (3) when cranking
engine. See Fig. 6.
Was injector operating sound heard from all
injectors?Go to “Engine Diagnosis
Table”.Go to “Diag. Flow Table
B-1”. Step Action Yes No
[B] : When not using SUZUKI scan tool :
[C] : When using SUZUKI scan tool

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[D] Fig. 4 for Step 7 or 8 / [E] Fig. 5 for Step 10 / [F] Fig. 6 for Step 13
Engine diagnosis table
Perform troubleshooting referring to following table when ECM has no DTC and no abnormality found in visual
inspection and engine basic inspection previously.
Condition Possible Cause Reference Item
Hard Starting
(Engine cranks OK)Faulty ignition coil Ignition coil assembly in Section 6F.
Faulty CMP sensing rotor or CKP sensing
rotorCMP sensing rotor or CKP sensing
rotor inspection in Section 6E.
Faulty idle air control system Diagnostic Flow Table B-4
Faulty ECT sensor, TP sensor, CKP sen-
sor, CMP sensor or MAP sensorECT sensor, TP sensor, CKP sensor,
CMP sensor or MAP sensor in Sec-
tion 6E.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty fuel injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning PCV system PCV system in Section 6E.
Low compression Compression check in Section 6A1.
Improper valve lash Valve lash in Section 6A1.
Improper valve timing Timing chain and chain tensioner in
Section 6A1.
Compression leak from valve seat Valves and cylinder head in Section
6A1.
Sticky valve stem Valves and cylinder head in Section
6A1.
Weak or damaged valve springs Valves and cylinder head in Section
6A1.
Compression leak at cylinder head gasket Valves and cylinder head in Section
6A1.
Sticking or damaged piston ring Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn piston, ring or cylinder Pistons, piston rings, connecting rods
and cylinders in Section 6A1.