ect SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-9
5) Fix ignition timing to initial one as follows.
a) When using SUZUKI scan tool:
Select “MISC” mode on SUZUKI scan tool and fix ignition
timing to initial one.
b) Without using SUZUKI scan tool: (vehicle without immobi-
lizer indicator lamp)
Disconnect scan tool from DLC, and connect D and E ter-
minals of monitor connector (1) or E to body ground by
using service wire so that ignition timing is fixed on initial
one.
6) Using timing light (1), check that ignition timing is within
specification.
Initial ignition timing (test switch terminal grounded or
fixed with SUZUKI scan tool)
5
± 3° BTDC at idle speed
Ignition order
1-3-4-2
7) If ignition timing is out of specification, check the followings:
CKP sensor
CKP sensor plate
TP sensor
Test switch signal circuit
VSS
Timing chain cover installation
8) After checking Initial Ignition Timing, release ignition timing
fixation by using SUZUKI scan tool or disconnect service
wire from monitor connector.
9) With engine idling (test switch terminal ungrounded, throttle
opening at closed position and car stopped), check that igni-
tion timing is about 7°–17° BTDC. (Constant variation within
a few degrees from 7°–17° indicates no abnormality but
proves operation of electronic timing control system.) Also,
check that increasing engine speed advances ignition timing.
If above check results are not satisfactory, check CKP sen-
sor, test switch terminal circuit and ECM.

Downloaded from www.Manualslib.com manuals search engine 6F-10 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
Special Tools
Tightening Torque Specification
09931-76011 09931-76030
Tech 1A kit (SUZUKI scan
tool) (See NOTE “A”.)Mass storage cartridge for
Tech 1A16/14 pin DLC adapter for
Tech 1ATech 2 kit (SUZUKI scan
tool) (See NOTE “B”. )
NOTE:
“A” : This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable (14/26 pin, 09931-76040),
5. Test lead/probe, 6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
“B” : This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply
Fastening partTightening torque
Nm kg-m lb-ft
Spark plug 25 2.5 18.0

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-1
6F1
6F2
6H
7C1
7D
7E
7C1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
6G
7A1
10A
10B
SECTION 6G
CRANKING SYSTEM
CONTENTS
General Description ....................................... 6G-2
Cranking Circuit ............................................ 6G-2
Diagnosis ........................................................ 6G-2
Diagnosis Table ........................................... 6G-2Performance Test .........................................6G-4
On-Vehicle Service .........................................6G-5
Starting Motor ...............................................6G-5
Specifications..................................................6G-7

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:
Starting motor varies depending on specifications, etc. Therefore, be sure to check model and speci-
fication of vehicle being serviced before replacing parts.

Downloaded from www.Manualslib.com manuals search engine 6G-2 CRANKING SYSTEM
General Description
Cranking Circuit
Diagnosis
Diagnosis Table
Possible symptoms due to starting system trouble would be as follows:
Starting motor does not run (or runs slowly)
Starting motor runs but fails to crank engine
Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies.....in battery, wiring
harness, (including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check following items and narrow down scope
of possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor termi-
nals
3) Discharge of battery
4) Mounting of starting motor
1. Pinion drive lever 5. Plunger 9. A/T: Transmission range switch (shift lever switch)
2. Pinion & Over-running clutch 6. Magnetic switch contacts 10. Ignition & Starter switch
3. Magnetic switch 7. Pull-in coil 11. Battery
4. Hold-in coil 8. Starting motor

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-3
Condition Possible Cause Correction
Motor not running
(No operating sound of
magnetic switch)Shift lever switch is not in P or N, or not adjusted
(A/T)Shift in P or N, or adjust switch.
Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Poor contact in battery terminal connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch and mag-
netic switchReplace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and magnetic
switchRepair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Motor not running
(Operating sound of
magnetic switch
heard)Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor contacting action
of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfac-
tory, inspect starting
motor)Insufficient contact of magnetic switch main con-
tactsReplace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn commutator Repair commutator or replace
armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor run-
ning, but not cranking
engineWorn pinion tip Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel (M/T) or drive
plate (A/T).
Noise
Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace pinion or flywheel
(M/T) or drive plate (A/T).
Poor sliding of pinion (failure in return movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.

Downloaded from www.Manualslib.com manuals search engine 6G-4 CRANKING SYSTEM
Performance Test
PULL-IN TEST
Connect battery to magnetic switch as shown.
Check that plunger and pinion move outward.
If plunger and pinion don’t move, replace magnetic switch.
HOLD-IN TEST
While connected as above with plunger out, disconnect negative
lead from terminal “M”.
Check that plunger and pinion remain out.
If plunger and pinion return inward, replace magnetic switch.
PLUNGER AND PINION RETURN TEST
Disconnect negative lead from starting motor body.
Check that plunger and pinion return inward.
If plunger and pinion don’t return, replace magnetic switch. Starting motor does
not stop runningFused contact points of magnetic switch Replace magnetic switch.
Short-circuit between turns of magnetic switch coil
(layer short-circuit)Replace magnetic switch.
Failure of returning action in ignition switch Replace.
CAUTION:
Each test must be performed within 3 – 5 seconds to
avoid coil from burning.
NOTE:
Before testing, disconnect lead wire from terminal M.
1. Terminal “S”
2. Terminal “M”
3. Lead wire (switch to motor)
Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-5
NO-LOAD PERFORMANCE TEST
Connect battery and ammeter to starter as shown.
Check that starter rotates smoothly and steadily with pinion mov-
ing out. Check that ammeter indicates specified current.
Specified current (No-load performance test)
: 90 A MAX. at 11 V
On-Vehicle Service
Starting Motor
DISMOUNTING
1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (6) and battery cable (7) from starting motor terminals.
3) Remove starting motor mount bolts (4) and nut (5).
4) Remove starting motor (1).
REMOUNTING
Reverse the dismounting procedure.
1. Starting motor 3. Transmission case 5. Starting motor mounting nut 7. Battery cable
2. Clutch housing upper plate 4. Starting motor mounting bolt 6. Magnetic switch lead wire Tightening Torque

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-7
Specifications
Voltage 12 volts
Output 0.9 kW 1.2 kW
Rating 30 seconds
Direction of rotation Clockwise as viewed from pinion side
Brush length 12.3 mm (0.48 in.) 12.3 mm (0.48 in.)
Number of pinion teeth 8
Performance Condition Guarantee
Around at
20° C (68 °F)No load characteristic 11.0 V90 A maximum
2,800 rpm minimum90 A maximum
2,500 rpm minimum
Load characteristic8.0 V
200 A4.8 N·m (0.48 kg-m,
3.5 lb-ft) minimum
1,260 rpm minimum–
7.5 V
300 A–10.5 N·m (1.05 kg-m,
7.6 lb-ft) minimum
880 rpm minimum
Locked rotor current3.5 V550 A maximum
12.2 N·m (1.22 kg-m,
8.8 lb-ft) minimum–
4.0 V–760 A maximum
19.5 N·m (1.95 kg-m,
14.1 lb-ft) minimum
Magnetic switch operating voltage 8 volts maximum

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-1
6F1
6F2
6G
6K
7D
7E
7F
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
7A
6H
7B1
10B
SECTION 6H
CHARGING SYSTEM
CONTENTS
General Description ....................................... 6H-2
Battery .......................................................... 6H-2
Generator ..................................................... 6H-4
Diagnosis ........................................................ 6H-6
Battery .......................................................... 6H-6
Generator ..................................................... 6H-7
On-Vehicle Service......................................... 6H-9
Battery .......................................................... 6H-9
Jump starting in case of emergency......... 6H-9
Dismounting ........................................... 6H-11
Handling ................................................. 6H-11
Remounting ............................................ 6H-11Generator ................................................... 6H-11
Generator belt ........................................ 6H-11
Unit Repair Overhaul ................................... 6H-12
Generator ................................................... 6H-12
Dismounting ........................................... 6H-12
Remounting ............................................ 6H-13
Disassembly and reassembly ................ 6H-13
Inspection ............................................... 6H-14
Specifications............................................... 6H-17
Battery........................................................ 6H-17
Generator ................................................... 6H-17
Tightening Torque Specification ................ 6H-17

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).

Downloaded from www.Manualslib.com manuals search engine 6H-2 CHARGING SYSTEM
General Description
Battery
The battery has three major functions in the electrical system.
It is a source of electrical energy for cranking the engine.
It acts as a voltage stabilizer for the electrical system.
It can, for a limited time, provide energy when the electrical
load exceeds the output of the generator.
CARRIER AND HOLD-DOWN
The battery carrier should be in good condition so that it will sup-
port the battery securely and keep it level.
Before installing the battery, the battery carrier and hold-down
clamp should be clean and free from corrosion and make certain
there are no parts in carrier.
To prevent the battery from shaking in its carrier, the hold-down
bolts should be tight enough but not over-tightened.
ELECTROLYTE FREEZING
The freezing point of electrolyte depends on its specific gravity.
Since freezing may ruin a battery, it should be protected against
freezing by keeping it in a fully charged condition. If a battery is
frozen accidentally, it should not be charged until it is warmed.
SULFATION
If the battery is allowed to stand for a long period in discharged
condition, the lead sulfate becomes converted into a hard, crystal-
line substance, which will not easily turn back to the active mate-
rial again during the subsequent recharging. “Sulfation” means
the result as well as the process of that reaction.
Such a battery can be revived by very slow charging and may be
restored to usable condition but its capacity is lower than before.