fuel pressure SUZUKI JIMNY 2005 3.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 6E-14 ENGINE AND EMISSION CONTROL SYSTEM
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.

Downloaded from www.Manualslib.com manuals search engine 6E-22 ENGINE AND EMISSION CONTROL SYSTEM
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

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-23
6) Start engine and warm it up to normal operating tempera-
ture.
7) Measure fuel pressure at idling.
If measured pressure doesn’t satisfy specification, refer to
“Diagnostic Flow Table B-3” in Section 6 and check each
possibly defective part. Replace if found defective.
8) After checking fuel pressure, remove fuel pressure gauge.
9) Remove special tools from fuel delivery pipe.
10) Connect fuel feed hose to fuel delivery pipe and clamp it
securely.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
Fuel pump
ON-VEHICLE INSPECTION
1) Remove filler cap and turn ON ignition switch (2). Then fuel
pump operating sound should be heard from fuel filler (1) for
about 2 seconds and stop. Be sure to reinstall fuel filler cap
after checking.
If above check result is not satisfactory, advance to “Diag-
nostic Flow Table B-2” in Section 6.
2) Turn OFF ignition switch and leave over 10 minutes as it is.CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following pro-
cedures.
Place fuel container under joint.
Cover joint with rag and loosen joint nut slowly to
release fuel pressure gradually.
CAUTION:
When fuel filler cap is removed in any procedure, work
must be done in a well-ventilated area, keep away from
any open flames and without smoking.
NOTE:
The fuel pressure regulator is the one body with the fuel
pump assembly so individual inspection of it is impossi-
ble.

Downloaded from www.Manualslib.com manuals search engine 6E-24 ENGINE AND EMISSION CONTROL SYSTEM
3) Fuel pressure should be felt at fuel feed hose (1) for 2 sec-
onds after ignition switch ON.
If fuel pressure is not felt, advance to “Diagnostic Flow Table
B-3” in Section 6.
REMOVAL
Remove fuel tank from body according to procedure described in
“Fuel Tank” of Section 6C and remove fuel pump from fuel tank.
INSPECTION
Check fuel pump filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel tank.
INSTALLATION
1) Install fuel pump to its bracket.
2) Install fuel pump to fuel tank and then install fuel tank to
body according to procedure described in “Fuel Tank” of
Section 6C.
Fuel pressure regulator
ON-VEHICLE INSPECTION
Perform fuel pressure inspection according to procedure
described in “Fuel Pressure Inspection” of this section.
REMOVAL
1) Relieve fuel pressure according to procedure described on
“Fuel Pressure Relief Procedure” in Section 6.
2) Disconnect battery negative cable from battery.
3) Disconnect vacuum hose (1) from fuel pressure regulator
(2).
4) Remove fuel pressure regulator from fuel delivery pipe.
5) Disconnect fuel return hose (3) from fuel pressure regulator.
CAUTION:
A small amount of fuel may be released when it is from
delivery pipe.
Place a shop cloth under delivery pipe so that released
fuel is absorbed in it.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-25
INSTALLATION
For installation, reverse removal procedure and note following
precautions.
Use new O-ring (1).
Apply thin coat of gasoline to O-ring to facilitate installation.
Tighten fuel pressure regulator bolts to specified torque.
Tightening torque
Fuel pressure regulator bolts
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
With engine “OFF” and the ignition switch ON position,
check for fuel leaks around fuel line connection.
Fuel injector
ON-VEHICLE INSPECTION
1) Using sound scope (1) or such, check operating sound of
injector (2) when engine is running or cranking.
Cycle of operating sound should vary according to engine
speed.
If no sound or an unusual sound is heard, check injector cir-
cuit (wire or connector) or injector (2).
2) Disconnect connector (1) from injector, connect ohmmeter
between terminals of injector and check resistance.
If resistance is out of specification, replace.
Resistance of injector
11.3 – 13.8
Ω
ΩΩ Ω at 20 °C, 68 °F
3) Connect connector (1) to injector securely.

Downloaded from www.Manualslib.com manuals search engine 6E-26 ENGINE AND EMISSION CONTROL SYSTEM
REMOVAL
1) Relieve fuel pressure according to procedure described in
“Fuel Pressure Relief Procedure” in Section 6.
2) Disconnect battery negative cable at battery.
3) Disconnect fuel injector couplers and release wire harness
from clamps.
4) Remove clamp bolt for fuel feed pipe and return pipe.
5) Remove fuel delivery pipe bolts (2).
6) Remove fuel injector(s) (3).
INSPECTION
1) Install injector (3) and fuel pressure regulator (4) to special
tool (injector checking tool).
Special tool
(A) : 09912-58421
2) Connect special tools (hose and attachment) to fuel feed
hose (1) of vehicle.
Special tool
(B) : 09912-58432
3) Connect special tool (test lead) to injector.
Special tool
(C) : 09930-88530
4) Install suitable vinyl tube onto injector nozzle to prevent fuel
from splashing out when injecting. CAUTION:
A small amount of fuel may come out after removal of
fuel injectors, cover them with shop cloth.
WARNING:
As fuel is injected in this inspection, perform in a well
ventilated area and away from open flames.
Use special care to prevent sparking when connecting
and disconnecting test lead to and from battery.
2. Fuel return line

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-27
5) Put graduated cylinder under injector as shown.
6) Operate fuel pump and apply fuel pressure to injector as fol-
lows:
a) When using SUZUKI scan tool :
i) Connect SUZUKI scan tool to DLC with ignition switch
OFF.
ii) Turn ignition switch ON, clear DTC and select “MISC
TEST” mode on SUZUKI scan tool.
iii) Turn fuel pump ON by using SUZUKI scan tool.
(A) : SUZUKI scan tool
b) Without using SUZUKI scan tool :
i) Remove fuel pump relay from connector.
ii) Connect two terminals of relay connector using service
wire (1) as shown in figure.
iii) Turn ignition switch ON.
7) Apply battery voltage (3) to injector (2) for 15 seconds and
measure injected fuel volume with graduated cylinder.
Test each injector two or three times.
If not within specification, replace injector.
Injected fuel volume
43 – 47 cc/15 sec. (1.45/1.51 – 1.58/1.65 US/Imp. oz/15 sec.)
8) Check fuel leakage from injector nozzle. Do not operate
injector for this check (but fuel pump should be at work).
If fuel leaks (1) more than following specifications, replace.
Fuel leakage (1)
Less than 1 drop/min. CAUTION:
Check to make sure that connection is made between
correct terminals. Wrong connection can cause damage
to ECM, wire harness, etc.
4. Keep as far apart as possible
[A] : When using SUZUKI scan tool
[B] : Without using SUZUKI scan tool

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-43
Tightening Torque Specifications
09931-76030
16/14 pin DLC cable Tech 2 kit (SUZUKI scan
tool) (See NOTE “C”.)
NOTE:
“A”: This kit includes the following items.
1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose & clamp,
6. Body attachment-2 & washer, 7. Hose attachment-1, 8. Hose attachment-2
“B”: 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
“C”: 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
TP sensor mounting screw 2.5 0.25 1.8
IAC valve screw 3.5 0.35 2.5
ECT sensor 15 1.5 11.5
Heated oxygen sensor-1 and -2 45 4.5 32.5
Camshaft position sensor 10 1.0 7.5
Fuel pressure regulator bolt 10 1.0 7.5