Cylinder SUZUKI JIMNY 2005 3.G Service Repair Manual

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THROTTLE POS (ABSOLUTE THROTTLE POSITION, %)
When throttle position sensor is fully closed position, throttle opening is indicated as 0% and 100% full open
position.
OXYGEN SENSOR B1 S1 (HEATED OXYGEN SENSOR-1, V)
It indicates output voltage of HO2S-1 installed on exhaust manifold (pre-catalyst).
OXYGEN SENSOR B1 S2 (HEATED OXYGEN SENSOR-2, V)
It indicates output voltage of HO2S-2 installed on exhaust pipe (post-catalyst). It is used to detect catalyst dete-
rioration.
DESIRED IDLE (DESIRED IDLE SPEED, rpm)
The Desired Idle Speed is an ECM internal parameter which indicates the ECM requested idle. If the engine is
not running, this number is not valid.
TP SENSOR VOLT (THROTTLE POSITION SENSOR OUTPUT VOLTAGE, V)
The Throttle Position Sensor reading provides throttle valve opening information in the form of voltage.
INJ PULSE WIDTH (FUEL INJECTION PULSE WIDTH, msec.)
This parameter indicates time of the injector drive (valve opening) pulse which is output from ECM (but injector
drive time of NO.1 cylinder for multiport fuel injection).
IAC FLOW DUTY (IDLE AIR (SPEED) CONTROL DUTY, %)
This parameter indicates current flow time rate within a certain set cycle of IAC valve (valve opening rate) which
controls the amount of bypass air (idle speed).
TOTAL FUEL TRIM (%)
The value of Total Fuel Trim is obtained by putting values of short Term Fuel Trim and Long Term Fuel Trim
together. This value indicates how much correction is necessary to keep the air / fuel mixture stoichiometrical.
BATTERY VOLTAGE (V)
This parameter indicates battery positive voltage inputted from main relay to ECM.
CANIST PURGE DUTY (EVAP CANISTER PURGE FLOW DUTY, %)
This parameter indicates valve ON (valve open) time rate within a certain set cycle of EVAP purge solenoid
valve which controls the amount of EVAP purge.
0% means that the purge valve is completely closed while 100% is a fully open valve.
CLOSED THROTTLE POSITION (ON / OFF)
This parameter will read ON when throttle valve is fully closed, or OFF when the throttle is not fully closed.
FUEL CUT (ON / OFF)
ON : Fuel being cut (output signal to injector is stopped)
OFF : Fuel not being cut
A/C CONDENSER FAN (A/C CONDENSER FAN RELAY, ON / OFF)
ON : Command for condenser fan relay operation being output.
OFF : Command for relay operation not being output.
ELECTRIC LOAD (ON / OFF)
ON : Headlight, small light, heater fan or rear window defogger ON signal inputted.
OFF : Above electric loads all turned OFF.
A/C SWITCH (ON / OFF)
ON : Command for A/C operation being output from ECM to A/C amplifier.
OFF : Command for A/C operation not being output.

Downloaded from www.Manualslib.com manuals search engine 6-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders)
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
CIRCUIT DESCRIPTION
ECM monitors crankshaft revolution speed and engine speed via the crankshaft position sensor and cylinder No.
via the camshaft position sensor. Then it calculates the change in the crankshaft revolution speed and from how
many times such change occurred in every 200 or 1000 engine revolutions, it detects occurrence of misfire.
When ECM detects a misfire (misfire rate per 200 revolutions) which can cause overheat and damage to the
three way catalytic converter, it makes the malfunction indicator lamp (MIL) flash as long as misfire occurs at
that rate.
After that, however, when the misfire rate drops, MIL remains ON until it has been judged as normal 3 times
under the same driving conditions.
Also, when ECM detects a misfire (misfire rate per 1000 revolutions) which will not cause damage to three way
catalytic converter but can cause exhaust emission to be deteriorated, it makes MIL light according to the 2 driv-
ing cycle detection logic.
1. Ignition coil assembly (for No.1 and No.4 cylinder)
2. Ignition coil assembly (for No.2 and No.3 cylinder)
3. Fuel injector
4. CKP sensor
5. CMP sensor

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DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Check vehicle and environmental condition for :
–Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Ambient temp. : –10 °C, 14 °F or higher
–Intake air temp. : 70 °C, 158 °F or lower
–Engine coolant temp. : – 10 – 110 °C, 14 – 230 °F
4) Start engine and keep it at idle for 2 min. or more.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6) If DTC is not detected at idle, consult usual driving based on information obtained in “Customer complaint
analysis” and “Freeze frame data check”.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
Engine under other than high revolution condition
Not on rough road
Engine speed changing rate (below specified value)
Manifold absolute pressure changing rate (below
specified value)
Throttle opening changing rate (below specified
value)
Misfire rate per 200 or 1000 engine revolutions (how
much and how often crankshaft revolution speed
changes) is higher than specified valueEngine overheating
Vacuum leaks (air inhaling) from air intake system
Ignition system malfunction (spark plug(s), high-
tension cord(s), ignition coil assembly)
Fuel pressure out of specification
Fuel injector malfunction (clogged or leakage)
Engine compression out of specification
Valve lash (clearance) out of specification
Manifold absolute pressure sensor malfunction
Engine coolant temp. sensor malfunction
PCV valve malfunction
EVAP control system malfunction
EGR system malfunction
NOTE:
Among different types of random misfire, if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2
simultaneously, it may not possible to reconfirm DTC by using the following DTC confirmation proce-
dure. When diagnosing the trouble of DTC P0300 (Random misfire detected) of the engine which is
apparently misfiring, even if DTC P0300 cannot be reconfirmed by using the following DTC confirma-
tion procedure, proceed to the following Diag. Flow Table.
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine
Diag. Flow Table”.
2 Is there DTC other than Fuel system (DTC P0171/
P0172) and misfire (DTC P0300 – P0304)?Go to applicable DTC
Diag. Flow Table.Go to Step 3.

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DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction
CIRCUIT DESCRIPTION
REFERENCE
Connect oscilloscope between terminals E19-11 of ECM connector connected to ECM and body ground and
check CMP sensor signal.
DTC CONFIRMATION PROCEDURE
1) Clear DTC.
2) Start engine and keep it at idle for 1 min.
3) Select “DTC” mode on scan tool and check DTC.
DTC DETECTING CONDITION POSSIBLE CAUSE
The number of CMP sensor signal pulses is incor-
rect during 8 revolution of crankshaft.CMP sensor circuit open or short.
Signal rotor teeth damaged.
CMP sensor malfunction, foreign material being
attached or improper installation.
ECM malfunction.
CMP sensor phase lag.
1. No.1 cylinder 3. No.3 cylinder [A] : Oscilloscope Waveforms [C] : CKP sensor waveform
2. No.2 cylinder 4. No.4 cylinder [B] : Waveforms at specified idle speed [D] : CMP sensor waveform

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6F1
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8C
6A1
8E
9
9
10B
SECTION 6A1
ENGINE MECHANICAL (M13 ENGINE)
CONTENTS
General Description ......................................6A1-2
Engine ......................................................... 6A1-2
Engine Lubrication ...................................... 6A1-3
Diagnosis .......................................................6A1-4
Diagnosis Table .......................................... 6A1-4
Compression Check .................................... 6A1-4
Engine Vacuum Check ................................ 6A1-6
Oil Pressure Check ..................................... 6A1-7
Valve Lash (Clearance) ............................... 6A1-9
On-Vehicle Service......................................6A1-13
Air Cleaner Element .................................. 6A1-13
Air Cleaner Assembly ................................ 6A1-14
Knock Sensor ............................................ 6A1-14
Cylinder Head Cover ................................. 6A1-15
Throttle Body and Intake Manifold ............ 6A1-18
Exhaust Manifold ....................................... 6A1-21Oil Pan and Oil Pump Strainer .................. 6A1-24
Timing Chain Cover .................................. 6A1-28
Oil Pump ................................................... 6A1-33
Timing Chain and Chain Tensioner .......... 6A1-37
Camshaft, Tappet and Shim ..................... 6A1-42
Valves and Cylinder Head ........................ 6A1-48
Pistons, Piston Rings, Connecting
Rods and Cylinders................................... 6A1-62
Engine Mountings ..................................... 6A1-72
Unit Repair Overhaul .................................. 6A1-73
Engine Assembly ...................................... 6A1-73
Main Bearings, Crankshaft and Cylinder
Block ......................................................... 6A1-79
Required Service Material .......................... 6A1-93
Tightening Torque Specification ............... 6A1-93
Special Tool ................................................. 6A1-94

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 6A1-2 ENGINE MECHANICAL (M13 ENGINE)
General Description
Engine
The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead
camshaft) valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves / one cylinder).
The double overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through timing
chain, and no push rods are provided in the valve train system.

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Engine Lubrication
The oil pump is of a trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump
strainer and passed through the pump to the oil filter.
The filtered oil flows into 2 paths in cylinder block.
In one path, oil reaches the crankshaft journal bearings. Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting passages drilled in the crankshaft, and then injected from
the big end of connecting rod to lubricate piston, rings, and cylinder wall.
In other path oil goes up to the cylinder head and lubricates valves and camshafts, etc., after passing through
the internal oilway of camshafts.
An oil relief valve is provided on the oil pump. This valve starts relieving oil pressure when the pressure exceeds
about 400 kPa (4.0 kg/cm
2, 56.9 psi).

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Diagnosis
Diagnosis Table
Refer to “Engine Diagnosis Table” in Section 6.
Compression Check
Check compression pressure on all 4 cylinders as follows:
1) Warm up engine.
2) Stop engine after warming up.
3) Disconnect accelerator cable (1) from clamp (2) (For left
hand steering vehicle only).
4) Remove cylinder head upper cover (3).
5) Disconnect ignition coil couplers (1).
6) Remove ignition coil assemblies (2) with high-tension cord
(3).
7) Remove all spark plugs.
8) Disconnect fuel injector wires (4) at the coupler.
9) Install special tools (Compression gauge) into spark plug
hole.
Special tool
(A) : 09915-64510-001
(B) : 09915-64510-002
(C) : 09915-64530
(D) : 09915-67010 NOTE:
After warming up engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
model), and set parking brake and block drive wheels.

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10) Disengage clutch (1) (to lighten starting load on engine) for
M/T vehicle, and depress accelerator pedal (2) all the way to
make throttle fully open.
11) Crank engine with fully charged battery, and read the highest
pressure on compression gauge.
Compression pressure specification
12) Carry out Steps 9) through 11) on each cylinder to obtain 4
readings.
13) After checking, install spark plugs and ignition coil assem-
blies (1) with high-tension cord (2).
14) Connect ignition coil couplers (3).
15) Connect fuel injector wires (4) at the coupler.
16) Check cylinder head upper cover gasket for deterioration and
then install it into groove of cylinder head upper cover (1)
securely.
17) Install cylinder head upper cover with gasket on to cylinder
head cover.
18) Connect accelerator cable (2) to clamp (3) (For left hand
steering vehicle only).
NOTE:
For measuring compression pressure, crank engine at
least 250 rpm by using fully charged battery.
If check results are below the limit valve, check instal-
lation condition for special tool.
Standard1400 kPa
(14.0 kg/cm
2, 199.0 psi)
Limit1100 kPa
(11.0 kg/cm
2, 156.0 psi)
Max. difference between
any two cylinders100 kPa
(1.0 kg/cm
2, 14.2 psi)

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Oil Pressure Check
Oil level in oil pan.
If oil level is low, add oil up to Full level mark (hole) (1) on oil
level gauge.
Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in Section 0B.
Oil leaks.
If leak is found, repair it.
1) Disconnect oil pressure switch coupler (1) and remove oil
pressure switch (2) from cylinder block.
2) Install special tools (Oil pressure gauge) to vacated threaded
hole.
Special tool
(A) : 09915-77310
(B) : 09915-78211
3) Start engine and warm it up to normal operating tempera-
ture.
4) After warming up, raise engine speed to 4,000 rpm and mea-
sure oil pressure.
Oil pressure specification
280 – 430 kPa (2.8 – 4.3 kg/cm
2, 39.8 – 61.1 psi) at 4,000
rpm
5) Stop engine and remove oil pressure gauge and attachment.NOTE:
Prior to checking oil pressure, check the following items.
2. Low level mark (hole)
NOTE:
Be sure to place transmission gear shift lever in “Neu-
tral” (shift selector lever to “P” range for A/T model), and
set parking brake and block drive wheels.