Pressure switch SUZUKI JIMNY 2005 3.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 6A1-74 ENGINE MECHANICAL (M13 ENGINE)
a) For right hand steering vehicle:
With hose connected, detach A/C compressor from its
bracket.
b) For left hand steering vehicle:
i) Recover refrigerant from refrigeration system using recov-
ery and recycling equipment.
ii) Disconnect magnet clutch lead wire.
iii) Remove suction pipe and disconnect discharge pipe from
A/C compressor.
iv) Remove A/C compressor from its bracket.
When servicing above steps, refer to “Compressor” in Section 1B.
14) Remove air cleaner outlet No.1 and No.2 hoses.
15) Disconnect the following electric lead wires:
TP sensor (1)
MAP sensor (2)
CKP sensor (if equipped) (3)
CMP sensor
ECT sensor
Heated oxygen sensor
EGR valve (if equipped)
IAC valve (4)
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Generator
Starting motor
Oil pressure switch
Ground terminal from intake manifold and cylinder block
Each wire harness clamps
16) Remove intake manifold bracket (7) with main harness from
intake manifold.
17) Remove starting motor referring to “Dismounting” in Section
6G. NOTE:
Suspend removed A/C compressor at a place where no
damage will be caused during removal and installation of
engine assembly.

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Required Service Material
Tightening Torque Specification
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant SUZUKI BOND NO. 1207C
(99000-31150)To apply to mating surface of cylinder block and oil
pan.
To apply to mating surface of cylinder block and
timing chain cover.
To apply to sealing surface of cylinder head cover.
To apply to mating surface to rear oil seal housing.
SUZUKI BOND NO. 1207B
(99000-31140)To apply to mating surface of cylinder block, cylin-
der head and timing chain cover.
SUZUKI BOND NO. 1215
(99000-31110)To flywheel (M/T) or drive plate (A/T) bolts.
Fastening partTightening torque
Nm kg-m lb-ft
Oil pressure switch 14.0 1.4 10.5
Camshaft housing bolts
(for replacement of shim)8.0 0.8 6.0
Camshaft housing bolts 11.0 1.1 8.0
Cylinder head cover bolts 8.0 0.8 6.0
Intake manifold bolts and nuts 25.0 2.5 18.0
Exhaust manifold bolts and nuts 55.0 5.5 40.0
Exhaust pipe bolts 50.0 5.0 36.5
Exhaust manifold stiffener bolts 50.0 5.0 36.5
Oil pump strainer bolt 11.0 1.1 8.0
Oil pump strainer bracket bolt 11.0 1.1 8.0
Oil pan bolts and nuts 11.0 1.1 8.0
Oil pan drain plug 50.0 5.0 36.5
Timing chain cover bolts and nut 23.0 2.3 17.0
Crankshaft pulley bolt 150.0 15.0 108.5
Oil pump rotor plate bolts 11.0 1.1 8.0
Timing chain No.1 guide bolts 9.0 0.9 6.5
Timing chain tensioner adjuster bolts 11.0 1.1 8.0
Venturi plug 5.0 0.5 3.5
Cylinder head bolt for M8 22.0 2.2 16.0
Cylinder head bolts for M10 a) Tighten 40 N·m
b) Turn 60°
c) Turn 60°a) Tighten 4.0 kg-m
b) Turn 60°
c) Turn 60°a) Tighten 29.0 lb-ft
b) Turn 60°
c) Turn 60°
Connecting rod bearing cap nuts a) Tighten 15 N·m
b) Turn 45°
c) Turn 45°a) Tighten 1.5 kg-m
b) Turn 45°
c) Turn 45°a) Tighten 11.0 lb-ft
b) Turn 45°
c) Turn 45°
Engine mounting bolts 50.0 5.0 36.5

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6F1
6F2
6G
7C1
7D
7E
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
6H
6E
10
10A
10B
SECTION 6E
ENGINE AND EMISSION CONTROL SYSTEM
CONTENTS
General Description ....................................... 6E-3
Air Intake System ......................................... 6E-5
Fuel Delivery System ................................... 6E-6
Fuel pump ................................................ 6E-6
Electronic Control System ............................ 6E-7
Engine & emission control input / output
table.......................................................... 6E-8
On-Vehicle Service....................................... 6E-15
Accelerator cable adjustment ................. 6E-15
Idle speed / idle air control (IAC) duty
inspection ............................................... 6E-15
Idle mixture inspection / adjustment
(vehicle without heated oxygen
sensor) ................................................... 6E-17
Air Intake System ....................................... 6E-18
Throttle body .......................................... 6E-18
Idle air control valve (IAC valve)............. 6E-21
Fuel Delivery System ................................. 6E-22
Fuel pressure inspection ........................ 6E-22
Fuel pump .............................................. 6E-23
Fuel pressure regulator .......................... 6E-24
Fuel injector ............................................ 6E-25
Electronic Control System .......................... 6E-29Engine control module (ECM) ................ 6E-29
Manifold absolute pressure sensor (MAP
sensor) ................................................... 6E-29
Throttle position sensor (TP sensor) ...... 6E-30
Intake air temperature sensor
(IAT sensor) ........................................... 6E-31
Engine coolant temperature sensor
(ECT sensor) .......................................... 6E-32
Heated oxygen sensor
(Sensor-1 and sensor-2) ........................ 6E-33
Camshaft position sensor....................... 6E-34
Crankshaft position sensor..................... 6E-35
Vehicle speed sensor (VSS) .................. 6E-36
Fuel level sensor (GAUGE).................... 6E-36
Knock sensor ......................................... 6E-36
Main relay, fuel pump relay and A/C
condenser fan control relay .................... 6E-36
Fuel cut operation .................................. 6E-37
A/C condenser fan control system ......... 6E-37
A/C condenser fan ................................. 6E-37
Output signals of throttle valve opening
and engine coolant temp.
(Vehicle with A/T only) ........................... 6E-38
Emission Control System ........................... 6E-38 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:
Whether following systems (parts) are used in the particular vehicle or not depends on specifications.
Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor (s) or CO adjusting resistor
Three way catalytic converter (TWC) and warm up three-way catalytic converter (WU-TWC)

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Air Intake System
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3),
idle air control valve (4) and intake manifold (5).
The air (by the amount corresponding to the throttle valve (6) opening and engine speed) is filtered by the air
cleaner (1), passes through the throttle body (3), is distributed by the intake manifold (5) and finally drawn into
each combustion chamber.
When the idle air control valve (4) is opened according to the signal from ECM, the air (7) bypasses the throttle
valve (6) through bypass passage and is finally drawn into the intake manifold (5).
1. Air Cleaner 17. Knock sensor 31-2. Test switch terminal
(vehicle w/o immobilizer indicator lamp)
2. EVAP canister purge valve 18. ECT sensor 31-3. Duty output terminal
(vehicle w/o immobilizer indicator lamp)
3. IAT sensor 19. CMP sensor 32. Immobilizer indicator lamp (if equipped)
4. TP sensor 20. CKP sensor 33. Stop lamp switch
5. IAC valve 21. VSS 34. ECM
6. MAP sensor 22. A/C condenser fan (if equipped) 35. Barometric pressure sensor
(vehicle with immobilizer indicator lamp)
7. EGR valve (if equipped) 23. Malfunction indicator lamp in combination meter 36. Battery
8. EVAP canister 24. Park/Neutral position switch in TR switch (A/T) 37. Immobilizer control module (if equipped)
9. Tank pressure control valve (built-in fuel pump) 25. Ignition switch 38. ABS control module (if equipped)
10. Fuel pump 26. Starter magnetic switch 39. CO adjusting resistor (if equipped)
11. Fuel level sensor 27. TCM (A/T) 40. Power steering pressure switch
(if equipped)
12. Ignition coil assembly 28. Transmission range switch (A/T) 41. A/C compressor clutch (if equipped)
13. Fuel injector 29. DLC 42. A/C EVAP TEMP. sensor (if equipped)
14. Heated Oxygen Sensor (HO2S)-1 (if equipped) 30. Electric load 43. A/C switch (if equipped)
15. Heated Oxygen Sensor (HO2S)-2 (if equipped) 31. Monitor connector (if equipped)
16. Three way catalytic convertor (if equipped) 31-1. Diagnosis switch terminal
(vehicle w/o immobilizer indicator lamp)

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Engine & emission control input / output table
INPUTOUTPUT
ELECTRIC CONTROL DEVICE
DIAGNOSIS SWITCH TERMINAL
(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)
BAROMETRIC PRESSURE SENSOR
(VEHICLE WITH IMMOBILIZER INDICATOR LAMP)
STOP LAMP SWITCH
STARTER SWITCH
IGNITION SWITCH
LIGHTING SWITCH
REAR DEFOGGER SWITCH (IF EQUIPPED)
BLOWER SWITCH
A/C SWITCH (IF EQUIPPED)
A/C EVAPORATOR TEMP. SENSOR (IF EQUIPPED)
VSS
HEATED OXYGEN SENSOR-1 (IF EQUIPPED)
HEATED OXYGEN SENSOR-2
(IF EQUIPPED)For detecting deterioration of
three way catalytic converter
IAT SENSOR
ECT SENSOR
TP SENSOR
MAP SENSOR
CMP SENSOR
CKP SENSOR
TEST SWITCH TERMINAL
(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)
KNOCK SENSOR
FUEL PUMP RELAY
FUEL INJECTOR
HO2S HEATER
IAC VALVE
IGNITION COIL WITH IGNITER
EGR VALVE (IF EQUIPPED)
EVAP CANISTER PURGE VALVE
A/C COMPRESSOR CLUTCH
MIL
MAIN RELAY
TRANSMISSION CONTROL MODULE SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULEA/C CONDENSER FAN RELAY

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1. CKP sensor 20. Power steering pressure switch
(if equipped)39. Ignition coil assembly (for No.1 and No.4 spark plugs)
2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs)
3. VSS 22. A/C refrigerant pressure switch
(if equipped)41. Stop lamp switch
4. MAP sensor 23. Immobilizer control module (if equipped) 42. Stop lamp
5. Knock sensor 24. Data link connector 43. Lighting switch
6. TP sensor 25. Injector No.1 44. Position lamp
7. ECT sensor 26. Injector No.2 45. Rear defogger switch (if equipped)
8. IAT sensor 27. Injector No.3 46. Rear defogger (if equipped)
9. Heated oxygen sensor-1 (if equipped) 28. Injector No.4 47. A/C compressor clutch (if equipped)
10. Heated oxygen sensor-2 (if equipped) 29. IAC valve 48. Ignition switch
11. A/C evaporator temp. sensor (if equipped) 30. EVAP canister purge valve 49. Main relay
12. Speedometer 31. Fuel pump relay 50. CO adjusting register (if equipped)
13. Fuel level sensor 32. Fuel pump 51. Starting motor
14. TCM (A/T) 33. A/C condenser fan relay (if equipped) 52. 4WD controller (4WD)
15. Transmission range switch (A/T) 34. A/C condenser fan motor (if equipped) 53. ABS control module (if equipped)
16. Shift lock solenoid (A/T, if equipped) 35. EGR valve (if equipped) 54. Engine ground
17. Backup lamp 36. Malfunction indicator lamp 55. Body ground
18. Heater fan motor 37. Immobilizer indicator lamp (if equipped)
19. Heater fan switch 38. Monitor connector (vehicle without immo-
bilizer indicator lamp)

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1. CKP sensor 20. Power steering pressure switch
(if equipped)39. Ignition coil assembly (for No.1 and No.4 spark plugs)
2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs)
3. VSS 22. A/C refrigerant pressure switch
(if equipped)41. Stop lamp switch
4. MAP sensor 23. Immobilizer control module (if equipped) 42. Stop lamp
5. Knock sensor 24. Data link connector 43. Lighting switch
6. TP sensor 25. Injector No.1 44. Position lamp
7. ECT sensor 26. Injector No.2 45. Rear defogger switch (if equipped)
8. IAT sensor 27. Injector No.3 46. Rear defogger (if equipped)
9. Heated oxygen sensor-1 (if equipped) 28. Injector No.4 47. A/C compressor clutch (if equipped)
10. Heated oxygen sensor-2 (if equipped) 29. IAC valve 48. Ignition switch
11. A/C evaporator temp. sensor (if equipped) 30. EVAP canister purge valve 49. Main relay
12. Speedometer 31. Fuel pump relay 50. CO adjusting register (if equipped)
13. Fuel level sensor 32. Fuel pump 51. Starting motor
14. TCM (A/T) 33. A/C condenser fan relay (if equipped) 52. 4WD controller (4WD)
15. Transmission range switch (A/T) 34. A/C condenser fan motor (if equipped) 53. ABS control module (if equipped)
16. Shift lock solenoid (A/T, if equipped) 35. EGR valve (if equipped) 54. Engine ground
17. Backup lamp 36. Malfunction indicator lamp 55. Body ground
18. Heater fan motor 37. Immobilizer indicator lamp (if equipped)
19. Heater fan switch 38. Monitor connector (vehicle without immo-
bilizer indicator lamp)

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ECM TERMINAL ARRANGEMENT TABLE
For TYPE A (See NOTE)
CONNEC-
TORTERMINAL WIRE COLOR CIRCUITCONNEC-
TORTERMINAL WIRE COLOR CIRCUIT
E191 B Ground for ECM
E187 W Backup power source
2 B/R Ground for drive circuit
8R/GImmobilizer indicator lamp
(if equipped)
3 B/R Ground for drive circuitDuty output terminal (vehicle without
immobilizer indicator lamp)
4 Bl/G Canister purge valve 9––
5 Bl/OrPower steering pressure switch
(if equipped)10 Bl Main relay
6 G/Y IAC valve 11 Br Tachometer
7 P/B Heater of HO2S-1 (if equipped) 12 Y/B Data link connector (5 V)
8 W/B No.4 fuel injector 13 WHeated oxygen sensor-2
(if equipped)
9 R/W No.1 fuel injector 14 W/BIDiagnosis switch terminal
(vehicle without immobilizer indicator
lamp)
10 B/Bl Ground for sensor circuit 15 PTest switch terminal
(vehicle without immobilizer indicator
lamp)
11 W CMP sensor 16 G/W A/C SW signal (if equipped)
12––17 R/Y Lighting switch
13R
R/BlHeated oxygen sensor-1
(if equipped)
CO adjusting resistor (w/o HO2S)18 P/B A/C condenser fan relay (if equipped)
14 G/B ECT sensor 19 W/G Fuel pump relay
15 Lg/B IAT sensor 20 B/Bl Ground for sensor
16 Lg TP sensor 21 B/RThrottle opening signal output for A/T
(A/T)
17 Gr/BIEGR valve (stepper motor coil 3, if
equipped)22 Y/RFuel level gauge (vehicle with immo-
bilizer indicator lamp)
18 GrEGR valve (stepper motor coil 1, if
equipped)23––
19 Br/BIG coil assembly for No.2 and 3 spark
plugs24 Bl/Y Heater blower switch
20 Br/WIG coil assembly for No.1 and 4 spark
plugs
21 R/G No.2 fuel injector
E171––
22 Lg/R Power supply for sensor 2 R R-range signal (A/T)
23 G/R CKP sensor 3––
24––4––
25 W Knock sensor 5 B/Or Overdrive cut signal (A/T)
26 G MAP sensor 6 G/Y D-range idle-up signal (A/T)
27 W/R A/C evaporator temp. sensor 7 G/W Stop lamp switch
28 Gr/BEGR valve (stepper motor coil 4, if
equipped)8––
29 Gr/REGR valve (stepper motor coil 2, if
equipped)9 B/W Ignition switch
30––10––
31 W/G No.3 fuel injector 11 Y Vehicle speed sensor
12 G ABS signal (if equipped)
E181 P A/C compressor clutch (if equipped) 13B/Y (M/T)
B/R (A/T)Engine start signal
2 V/Y Malfunction indicator lamp 14––
3 P/G Data link connector (12 V) 15––
4 R/BI Heater of HO2S-2 (if equipped) 16 R/W Rear defogger switch (if equipped)
5 Bl/B Power source 17 G/RA/T failure signal (A/T) (vehicle with
immobilizer indicator lamp)
6 Bl/B Power source
NOTE:
See NOTE in “ECM INPUT / OUTPUT CIRCUIT DIAGRAM” for applicable model.

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For TYPE B (See NOTE)
CONNEC-
TORTERMINAL WIRE COLOR CIRCUITCONNEC-
TORTERMINAL WIRE COLOR CIRCUIT
E191 B Ground for ECM
E187 W Backup power source
2 B/R Ground for drive circuit
8R/GImmobilizer indicator lamp
(if equipped)
3 B/R Ground for drive circuitDuty output terminal (vehicle without
immobilizer indicator lamp)
4 Bl/G Canister purge valve 9––
5 Bl/OrPower steering pressure switch
(if equipped)10 Bl Main relay
6 G/Y IAC valve 11 B/W Ignition switch
7 P/B Heater of HO2S-1 (if equipped) 12 R/W Rear defogger switch
8 W/B No.4 fuel injector 13––
9 R/W No.1 fuel injector 14 W/BIDiagnosis switch terminal
(vehicle without immobilizer indicator
lamp)
10 B/Bl Ground for sensor circuit 15 PTest switch terminal
(vehicle without immobilizer indicator
lamp)
11 W CMP sensor 16 G/W A/C SW signal (if equipped)
12––17 R/Y Lighting switch
13R
R/BlHeated oxygen sensor-1
(if equipped)
CO adjusting resistor (w/o HO2S)18 P/B A/C condenser fan relay (if equipped)
14 G/B ECT sensor 19 W/G Fuel pump relay
15 Lg/B IAT sensor 20B/Y (M/T)
B/R (A/T)Engine start signal
16 Lg TP sensor 21 G/W Stop lamp switch
17 Gr/BIEGR valve (stepper motor coil 3, if
equipped)22 Y Vehicle speed sensor
18 GrEGR valve (stepper motor coil 1, if
equipped)23––
19 Br/BIG coil assembly for No.2 and 3 spark
plugs24––
20 Br/WIG coil assembly for No.1 and 4 spark
plugs
21 R/G No.2 fuel injector
E171 W/R A/C evaporator temp. sensor
22 Lg/R Power supply for sensor 2 R R-range signal (A/T)
23 G/R CKP sensor 3––
24––4––
25 W Knock sensor 5 B/Or Overdrive cut signal (A/T)
26 G MAP sensor 6 G/Y D-range idle-up signal (A/T)
27––7 Y/B Data link connector
28 Gr/BEGR valve (stepper motor coil 4, if
equipped)8––
29 Gr/REGR valve (stepper motor coil 2, if
equipped)9 V/Y Malfunction indicator lamp
30––10––
31 W/G No.3 fuel injector 11 P/G Data link connector (12 V)
12 G ABS signal (if equipped)
E181 P A/C compressor clutch (if equipped) 13 Bl/Y Heater blower switch
2––14 B/Bl Ground for sensor
3––15 B/R Throttle opening sensor
4 R/BI Heater of HO2S-2 (if equipped) 16 Br Tachometer
5 Bl/B Power source 17––
6 Bl/B Power source
NOTE:
See NOTE in “ECM INPUT / OUTPUT CIRCUIT DIAGRAM” for applicable model.

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Fuel Delivery System
Fuel pressure inspection
1) Relieve fuel pressure in fuel feed line referring to “Fuel Pres-
sure Relief Procedure” in Section 6.
2) Disconnect fuel feed hose from fuel delivery pipe.
3) Connect special tools and hose between fuel delivery pipe
(1) and fuel feed hose (2) as shown in figure, and clamp
hoses securely to ensure no leaks occur during checking.
Special tool
(A) : 09912-58442
(B) : 09912-58432
(C) : 09912-58490
4) Check that battery voltage is above 11 V.
5) Turn ignition switch ON to operate fuel pump and after 2 sec-
onds turn it OFF. Repeat this 3 or 4 times and then check
fuel pressure.
Fuel pressure specification WARNING:
Be sure to perform work in a well-ventilated area and
away from any open flames, or there is a risk of a fire
breaking out.
CAUTION:
A small amount of fuel may be released when fuel hose is
disconnected. Place container under the joint with a
shop cloth so that released fuel is caught in container or
absorbed in cloth. Place that cloth in an approved con-
tainer.
3. Fuel return pipe
CONDITION FUEL PRESSURE
With fuel pump operating and
engine stopped270 – 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
With 1 min. after engine (fuel
pump) stop (Pressure
reduces as time passes)over 200 kPa
2.0 kg/cm
2, 28.4 psi