ECT SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 6E-32 ENGINE AND EMISSION CONTROL SYSTEM
Engine coolant temperature sensor (ECT sensor)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Drain coolant referring to Step 6) of “Cooling System Flush
and Refill” in Section 6B.
3) Disconnect connector from ECT sensor.
4) Remove ECT sensor (1) from water outlet cap.
INSPECTION
Immerse temperature sensing part of ECT sensor (1) in water (or
ice) and measure resistance between terminal “A” and “B” while
heating water gradually.
If measured resistance doesn’t show such characteristic as
shown in left figure, replace ECT sensor (1).
INSTALLATION
Reverse removal procedure noting the following:
Clean mating surfaces of ECT sensor (1) and water outlet
cap.
Check O-ring for damage and replace if necessary. WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-33
Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a) : 15 N·m (1.5 kg-m, 11.5 lb-ft)
Connect connector to ECT sensor (1) securely.
Refill coolant referring to “Cooling System Flush and Refill”
in Section 6B.
Heated oxygen sensor (Sensor-1 and sensor-2)
OXYGEN SENSOR HEATER INSPECTION
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals
“V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
Resistance of oxygen sensor heater
HO2S-1 : 5.0 – 6.4
Ω
ΩΩ Ω at 20 °C, 68 °F
HO2S-2 : 11.7 – 14.3
Ω
ΩΩ Ω at 20 °C, 68 °F
3) Connect sensor connector securely.
REMOVAL
NOTE:
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
1. Viewed from terminal side
WARNING:
To avoid danger of being burned, do not touch exhaust
system when system is hot. Oxygen sensor removal
should be performed when system is cool.

Downloaded from www.Manualslib.com manuals search engine 6E-34 ENGINE AND EMISSION CONTROL SYSTEM
1) Disconnect negative cable at battery.
2) For sensor-1, remove exhaust manifold cover (1) and dis-
connect connector of heated oxygen sensor and release its
wire harness from clamps.
3) For sensor-2, disconnect connector of heated oxygen sensor
and release its wire harness from clamp. Hoist vehicle and
then remove exhaust No.1 pipe covers (3).
4) Remove heated oxygen sensor (2) from exhaust manifold or
exhaust No.1 pipe.
INSTALLATION
Reverse removal procedure noting the following.
Tighten heated oxygen sensor (2) to specified torque.
Tightening torque
Heated oxygen sensor (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft)
Connect connector of heated oxygen sensor (2) and clamp
wire harness securely.
After installing heated oxygen sensor (2), start engine and
check that no exhaust gas leakage exists.
Camshaft position sensor
INSPECTION
Check camshaft position sensor referring to “DTC P0340 (No. 15)
Diag. Flow Table” in Section 6. If malfunction is found, replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect connector from camshaft position sensor.
3) Remove camshaft position sensor from cylinder head.
INSTALLATION
1) Check that O-ring is free from damage.
2) Check that camshaft position sensor and signal rotor tooth
are free from any metal particles and damage.
3) Install camshaft position sensor to sensor case.
Tightening torque
Camshaft position sensor bolt
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
4) Connect connector to it securely.
5) Connect negative cable to battery.
[A] : HO2S-1
[B] : HO2S-2

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-35
Crankshaft position sensor
INSPECTION
Check crankshaft position sensor referring to step 2 and 6 of
“DTC P0335 (No.23) Flow Table” in Section 6. If malfunction is
found, replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Remove generator drive belt, loosen pivot bolt and move
generator outward.
3) Disconnect connector from crankshaft position sensor.
4) Remove crankshaft position sensor (1) from cylinder block.
INSTALLATION
1) Check to make sure that crankshaft position sensor and pul-
ley tooth is free from any metal particles and damage.
2) Install crankshaft position sensor to cylinder block.
3) Connect connector to it securely.
4) Adjust generator belt tension, refer to “Water Pump Belt Ten-
sion” in Section 6B.
5) Connect negative cable to battery.

Downloaded from www.Manualslib.com manuals search engine 6E-36 ENGINE AND EMISSION CONTROL SYSTEM
Vehicle speed sensor (VSS)
INSPECTION
Check vehicle speed sensor referring to step 7 of “DTC P0500
(No.16) Flow Table” in Section 6. If malfunction is found, replace.
Fuel level sensor (GAUGE)
INSPECTION
Refer to “Fuel Meter / Fuel Gauge Unit” in Section 8.
REMOVAL / INSTALLATION
Refer to “Fuel Pump Assembly” in Section 6C.
Knock sensor
INSPECTION
Check knock sensor referring to “DTC P0325 (No.17) Flow Table”
in Section 6. If malfunction is found, replace.
REMOVAL / INSTALLATION
Refer to “Knock Sensor” in Section 6A1.
Main relay, fuel pump relay and A/C condenser fan
control relay
INSPECTION
1) Disconnect negative cable at battery.
2) Remove main relay (1), fuel pump relay (2) and A/C con-
denser fan control relay (3) from vehicle.
3) Check that there is no continuity between terminal “A” and
“B”. If there is continuity, replace relay.
4) Connect battery positive (+) terminal to terminal “C” of relay.
Connect battery negative (–) terminal “D” of relay.
Check continuity between terminal “A” and “B”.
If there is no continuity when relay is connected to the bat-
tery, replace relay.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-37
Fuel cut operation
INSPECTION
1) Warm up engine to normal operating temperature.
2) While listening to sound of injector (1) by using sound scope
(2) or such, increase engine speed to higher than 3,000 r/
min.
3) Check to make sure that sound to indicate operation of injec-
tor stops when throttle valve is closed instantly and it is
heard again when engine speed is reduced to less than
about 2,000 r/min.
A/C condenser fan control system
SYSTEM INSPECTION
Check system for operation referring to “Flow Table B-7” in Sec-
tion 6.
If A/C condenser fan fails to operate properly, check relay, A/C
condenser fan and electrical circuit.
A/C condenser fan
INSPECTION
1) Check continuity between each two terminals.
If there is no continuity, replace A/C condenser fan motor. NOTE:
Before inspection, check to make sure that gear shift
lever is in neutral position (with A/T model, selector lever
in “P” range), A/C is OFF and that parking brake lever is
pulled all the way up.
WARNING:
Keep hands, tools, and clothing away from A/C con-
denser fan to help prevent personal injury. This fan is
electric and can come on whether or not the engine is
running. The fan can start automatically in response to
the ECT sensor with the ignition switch in the “ON” posi-
tion.

Downloaded from www.Manualslib.com manuals search engine 6E-38 ENGINE AND EMISSION CONTROL SYSTEM
2) Connect battery (3) to A/C condenser fan motor coupler (2)
as shown in figure, then check that the A/C condenser fan
motor (1) operates smoothly.
If A/C condenser fan motor does not operate smoothly,
replace motor.
Reference current data of A/C condenser fan motor
Approx. 6.7 – 8.3 A at 12 V
Output signals of throttle valve opening and engine
coolant temp. (Vehicle with A/T only)
THROTTLE VALVE OPENING SIGNAL INSPECTION
Check throttle valve opening (throttle position) signal referring to
step 1 of “DTC P1700 (No.32 or 33) Flow Table” in Section 7B.
If check result is not satisfactory, check each wire harness, circuit
connections and TP sensor.
ENGINE COOLANT TEMP. SIGNAL INSPECTION
Check engine coolant temp. signal referring to step 1 of “DTC
P1709 (No.51) Flow Table” in Section 7B.
If check result is not satisfactory, check each wire harness, circuit
connection and ECT sensor.
Emission Control System
EGR system (If equipped)
SYSTEM INSPECTION (USING SUZUKI SCAN TOOL)
1) Connect SUZUKI scan tool to DLC with ignition switch OFF.
2) Turn ignition switch ON and then select “DATA LIST” mode
on scan tool.
3) Make sure that vehicle condition is as following.
Vehicle speed = 0 km/h (0 KPH)
Engine speed ≤ 3000 rpm
4) Clear DTC by using “CLEAR INFO” mode.
5) With engine idling (without depressing accelerator pedal),
open EGR valve by using “STEP EGR” mode in “MISC
TEST” menu.
In this state, according as EGR valve opening increases
engine idle speed drops. If not, possible cause is clogged
EGR gas passage, stuck or faulty EGR valve, poor perfor-
mance of ECT sensor or TP sensor or DTC and/or pending
DTC is (are) stored in ECM memory.
1. SUZUKI scan tool display
2. EGR valve opening (0: Close, 100: Full Open)

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-39
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect EGR valve connector.
3) Remove EGR pipe.
4) Remove EGR valve and gasket from cylinder head.
INSPECTION
1) Check resistance between following terminals of EGR valve
(1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance
2) Remove carbon from EGR valve (1) gas passage.
3) Inspect valve (2), valve seat (3) and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve assembly.
INSTALLATION
Reverse removal procedure noting following.
Clean mating surface of valve and cylinder head.
Use new gaskets.
Evaporative emission (EVAP) control system
EVAP CANISTER PURGE INSPECTION
Terminal Standard resistance
A – B
C – B
F – E
D – E 20 – 24
Ω
ΩΩ Ω
NOTE:
Do not use any sharp-edged tool to remove carbon.
Be careful not to damage or bend EGR valve, valve seat
and rod.
NOTE:
Before inspection, check to make sure that gear shift
lever is in neutral position (with A/T model, selector lever
in “P” range) and that parking brake lever is pulled all the
way up.

Downloaded from www.Manualslib.com manuals search engine 6E-40 ENGINE AND EMISSION CONTROL SYSTEM
1) Disconnect purge hose (1) from EVAP canister.
2) Place finger against the end of disconnected hose and check
that vacuum is not felt there when engine is cool and running
at idle speed.
3) Connect purge hose to EVAP canister and warm up engine
to normal operating temperature.
4) Turn ignition switch OFF.
5) Restart engine and run it at 2000 r/min. for 2 min. or more.
6) Disconnect purge hose from EVAP canister.
7) Also check that vacuum is felt when engine is running at
3000 r/min.
8) If vacuum is not felt in Step 7), run engine at idle for 8 min. or
more and then repeat check in Step 7).
If check result is not satisfactory in Steps 2) and 8), check vac-
uum passage, hoses, EVAP canister purge valve, wire harness
and ECM.
VACUUM PASSAGE INSPECTION
Start engine and run it at idle speed. Disconnect vacuum hose (1)
from EVAP canister purge valve (2). With finger placed against
hose disconnected, check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.
VACUUM HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration.
Replace as necessary.
EVAP CANISTER PURGE VALVE INSPECTION
Check EVAP canister purge valve referring to step 2 of “DTC
P0443 Flow Table” in Section 6.
If found malfunction, replace.NOTE:
ECM detects a change in the purge fuel vapor concentra-
tion and sometimes stops purging for several seconds
but this is nothing abnormal.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-41
EVAP CANISTER INSPECTION
1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there should be no restriction of flow through
purge pipe (1) and air pipe (2) when air is blown (4) into tank
pipe (3).
If any faulty condition is found in above inspection replace.
PCV system
PCV HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration.
Replace as necessary.
PCV VALVE INSPECTION
1) Disconnect PCV valve (1) from cylinder head cover and
install plug to head cover hole.
2) Run engine at idle.
3) Place your finger over end of PCV valve (1) to check for vac-
uum. If there is no vacuum, check for clogged valve.
Replace as necessary. WARNING:
DO NOT SUCK nozzles on EVAP canister. Fuel vapor
inside EVAP canister is harmful.
NOTE:
Be sure to check that there is no obstruction in PCV
valve or its hoses before checking IAC duty, for
obstructed PCV valve or hose hampers its accurate
adjustment.