Engine fuel SUZUKI JIMNY 2005 3.G Service Repair Manual
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![SUZUKI JIMNY 2005 3.G Service Repair Manual Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-71
[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 4 / [C] Fig. 3 for Step 5
[D] Fig. 4 for Step 5 / [E]](/img/20/7588/w960_7588-427.png "SUZUKI JIMNY 2005 3.G Service Repair Manual Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-71
[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 4 / [C] Fig. 3 for Step 5
[D] Fig. 4 for Step 5 / [E]")
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[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 4 / [C] Fig. 3 for Step 5
[D] Fig. 4 for Step 5 / [E] Fig. 5 for Step 5 / [F] Fig. 6 for Step 6
1. Fuel delivery pipe
2. Fuel feed hose
3. Fuel pressure gauge & 3 way joint
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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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3 Check Ignition System.
1) Remove spark plugs and check them for;
Air gap : 1.0 – 1.1 mm (0.040 – 0.043 in.) See Fig. 1.
Carbon deposits / Insulator damage / Plug type
If abnormality is found, adjust, clean or replace by
referring to Section 6F. (See CAUTION)
2) Disconnect all injector connectors. See Fig. 2.
3) Connect spark plugs to high tension cords and then
ground spark plugs.
4) Crank engine and check that each spark plug sparks.
Are above check results satisfactory?Go to Step 4. Check ignition sys-
tem parts (Refer to
Section 6F).
4 Check Fuel Pressure (Refer to Section 6E for details).
1) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge. See Fig. 3.
3) Check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine at stop :
270 – 310 kPa, 2.7 – 3.1 kg/cm
2, 38.4 – 44.0 psi.
At specified idle speed :
210 – 260 kPa, 2.1 – 2.6 kg/cm
2, 29.8 – 37.0 psi.
Is measured value as specified?Go to Step 5. Go to Diag. Flow
Table B-3 fuel pres-
sure check.
5 Check Fuel Injectors and Circuit.
1) sing sound scope (1) or such, check operating sound
of each injector (2) when engine is running. Cycle of
operating sound should very according to engine
speed. See Fig 4.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Turn ignition switch OFF and disconnect a fuel injec-
tor connector.
3) Check for proper connection to fuel injector at each
terminal.
4) If OK, then check injector resistance. See Fig. 5.
Injector resistance
11.3 – 13.8 ohm at 20 °C (68 °F)
5) Carry out steps 1) and 3) on each injector.
6) Check each injector for injected fuel volume referring
to Section 6E. See Fig. 6.
Injected fuel volume
43 – 47 cc/15 sec (1.45/1.51 – 1.58/1.65 US/Imp. oz/
15 sec)
7) Check each injector for fuel leakage after injector
closed.
Fuel leakage
Less than 1 drop/min.
Is check result in step 1) and 3) to 7) satisfactory?Go to Step 6. Check injector cir-
cuit or replace fuel
injector(s).
6 Check PCV valve for clogging (See Section 6E).
Is it in good condition?Go to Step 7. Replace PCV
valve. Step Action Yes No
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![SUZUKI JIMNY 2005 3.G Service Repair Manual Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-75
[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 3 / [C] Fig. 3 for Step 4 / [D] Fig. 4 for Step 5 / [](/img/20/7588/w960_7588-431.png "SUZUKI JIMNY 2005 3.G Service Repair Manual Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-75
[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 3 / [C] Fig. 3 for Step 4 / [D] Fig. 4 for Step 5 / [")
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[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 3 / [C] Fig. 3 for Step 4 / [D] Fig. 4 for Step 5 / [E] Fig. 5 for Step 47 Check EVAP Canister Purge Valve for Closing.
1) Disconnect purge hose (1) from EVAP canister.
2) Place finger against the end of disconnected hose.
3) Check that vacuum is not felt there, when engine is
cool and running at idle. See Fig. 7.
Is vacuum felt?Check EVAP control
system
(See Section 6E).Go to Step 8.
8 Check manifold absolute pressure sensor for perfor-
mance (See step 4) DTC P0105 Diag. Flow Table).
Is it in good condition?Go to Step 9. Repair or replace.
9 Check engine coolant temp. sensor for performance
(See Section 6E).
Is it in good condition?Go to Step 10. Replace engine
coolant temp. sen-
sor.
10 Check parts or system which can cause engine rough
idle or poor performance.
Engine compression (See Section 6A1).
Valve lash (See Section 6A1).
Valve timing (Timing belt installation. See Section
6A1).
Are they in good condition?Check wire harness
and connection of
ECM ground, ignition
system and fuel injec-
tor for intermittent
open and short.Repair or replace. Step Action Yes No
CAUTION:
For iridium spark plugs, do not adjust air gap or clean.
3. Fuel delivery pipe
4. Fuel feed hose
3. Fuel pressure gauge & 3 way joint
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DTC P0400 Exhaust Gas Recirculation Flow Malfunction
CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
Clear DTC with ignition switch ON, 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, 122 °F or lower
1. EGR valve
DTC DETECTING CONDITION POSSIBLE CAUSE
While running at specified vehicle speed after engine warm-up
During deceleration (engine speed high with closed throttle position
ON) in which fuel cut is involved, difference in intake manifold absolute
pressure between when EGR valve is opened at specified value and
when it is closed is larger or smaller than specified value.
✱
✱✱ ✱2 driving cycle detection logic, monitoring once / 1 drivingEGR valve or its circuit
EGR passage
ECM
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, on a level road.
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2) Start engine and warm it up to normal operating temperature (70 – 110 °C, 158 – 230 °F) and run it at idle
for 5 min.
3) Increase vehicle speed to 50 – 55 mph, 80 – 88 km/h in 5th gear or in “D” range.
4) Hold throttle valve at that opening position for 2 min. or longer.
5) Increase engine speed to 4000 r/min. in 3rd gear or in “2” range.
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting (fuel cut condition) till
engine speed reaches 1500 r/min.
7) Stop vehicle (don’t turn ignition switch OFF) and confirm test results according to following “Test Result Con-
firmation Flow Table.”
Test Result Confirmation Flow Table
INSPECTION
Step Action Yes No
1 Check DTC in “DTC” mode and pending DTC in
“ON BOARD TEST”.
Is DTC or pending DTC displayed?Proceed to applicable
DTC flow table.Go to Step 2.
2 Set scan tool to “READINESS TESTS” mode
and check if testing has been completed.
Is test completed?No DTC is detected.
(Confirmation test is com-
pleted)Repeat DTC confirmation
procedure.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 1) Turn ignition switch ON.
2) Does EGR stepper motor operation for 0.6
second after ignition switch OFF?Go to Step 3. Go to Step 6.
3 With ignition switch at OFF, check voltage
between E19-28, 17, 29, 18 terminals of ECM
and body ground. See Fig. 2.
Is voltage about 0 V?Go to Step 4. Go to Step 8.
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DTC P0420 Catalyst System Efficiency below Threshold
CIRCUIT DESCRIPTION
ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by
HO2S-2.
When the catalyst is functioning properly, the variation cycle of HO2S-2 output voltage (oxygen concentration) is
slower than that of HO2S-1 output voltage because of the amount of oxygen in the exhaust gas which has been
stored in the catalyst.
REFERENCE
1. Heated oxygen sensor-1 3. Three way catalytic converter 5. To the sensor [B] : Case of TYPE B is shown
(See NOTE)
2. Warm up three way catalytic
converter4. Heated oxygen sensor-2 [A] : Case of TYPE A is shown
(See NOTE)
NOTE:
For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable
model.
1. Engine running at closed loop
condition2. Fuel cut 3. Idle after fuel cut [A] : Oscilloscope waveforms
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DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
Clear DTC with ignition switch ON, 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. : 70 – 110 °C, 158 – 230 °F
2) Start engine and drive vehicle at 35 – 45 mph, 55 – 65 km/h for 8 min. or longer.
While this driving, if “Catalyst Monitoring TEST COMPLETED” is displayed in “READINESS TESTS” mode
and DTC is not displayed in “DTC” mode, confirmation test is completed.
If “TEST NOT COMPLTD” is still being displayed, continue test driving.
3) Decrease vehicle speed at 30 – 40 mph, 50 – 60 km/h, and hold throttle valve at that opening position for 2
min. and confirm that short term fuel trim vary within – 20% – +20% range.
4) Stop vehicle (do not turn ignition switch OFF) and confirm test results according to following “Test Result
Confirmation Flow Table”. DTC DETECTING CONDITION POSSIBLE CAUSE
While vehicle running at constant speed under other than
high load.
Time from rich or lean switching command is output till HO2S-
2 output voltage crosses 0.45 V less than specified value.
✱
✱✱ ✱2 driving cycle detection logic, monitoring once / 1 driving.Exhaust gas leak
Three way catalytic converter malfunction
Fuel system malfunction
HO2S-2 malfunction
HO2S-1 malfunction
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, on a level road.
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Test Result Confirmation Flow Table
INSPECTION
Step Action Yes No
1 Check DTC in “DTC” mode and pending DTC in
“ON BOARD TEST” or “PENDING DTC” mode.
Is DTC or pending DTC displayed?Proceed to applicable
DTC Diag. Flow Table.Go to Step 2.
2 Set scan tool to “READINESS TESTS” mode
and check if testing has been completed.
Is test completed?No DTC is detected (con-
firmation test is com-
pleted).Repeat DTC confirmation
procedure.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check Short Term Fuel Trim.
Did short term fuel trim vary within –20 % –
+20 % range in step 3) of DTC confirmation
test?Go to Step 3. Check fuel system.
Go to DTC P0171/P0172
Diag. Flow Table.
3 Check HO2S-2 for Output Voltage.
Perform steps 1) through 9) of DTC confirma-
tion procedure for DTC P0136 (HO2S-2 mal-
function) and check output voltage of HO2S-2
then.
Is over 0.6 V and below 0.3 V indicated?Replace three way cata-
lytic converter.Check “W” and “B/Bl”
wires for open and short,
and connections for poor
connection.
If wires and connections
are OK, replace HO2S-2.