engine SUZUKI JIMNY 2005 3.G Service Workshop Manual

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

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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

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INSTALLATION
For installation, reverse removal procedure and note following
precautions.
Replace injector O-ring (1) with new one using care not to
damage it.
Check if cushion (2) is scored or damaged. If it is, replace
with new one.
Apply thin coat of fuel to O-rings (1) and then install injectors
(3) into delivery pipe (4) and intake manifold.
Make sure that injectors (3) rotate smoothly (6). If not, proba-
ble cause is incorrect installation of O-ring (1). Replace O-
ring (1) with new one.
Tighten delivery pipe bolts (5) and make sure that injectors
(3) rotate smoothly (6).
After installation, with engine “OFF” and ignition switch “ON”,
check for fuel leaks around fuel line connection.

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Electronic Control System
Engine control module (ECM)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disable air bag system, refer to “Disabling Air Bag System”
in Section 10B if equipped.
3) Remove glove box.
4) Disconnect ECM (1) and TCM (3) (if equipped) connectors.
5) Loosen 2 nuts (2) and remove ECM and TCM (if equipped).
INSTALLATION
1) Reverse removal procedure noting the following:
Connect connectors to ECM and TCM (if equipped)
securely.
Manifold absolute pressure sensor (MAP sensor)
INSPECTION
Check MAP sensor referring to “MAP Sensor Individual Check” in
DTC P0105 (No.11) Flow Table of Section 6. If malfunction is
found, replace.CAUTION:
As ECM consists of precision parts, be careful not to
expose it to excessive shock.

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Throttle position sensor (TP sensor)
INSPECTION
1) Disconnect negative cable at battery and connector from TP
sensor.
2) Using ohmmeter, check resistance between terminals under
each condition given in table below.
If check result is not satisfactory, replace TP sensor.
TP sensor resistance
3) Connect TP sensor connector securely.
4) Connect negative cable to battery.
REMOVAL
1) Remove throttle body from intake manifold referring to
“Throttle Body” in this section for removal.
2) Remove TP sensor from throttle body.
INSTALLATION
1) Install TP sensor (1) to throttle body.
Fit TP sensor to throttle body in such way that its holes (3)
are a little away from TP sensor screw holes (2) and turn TP
sensor clockwise so that those holes align.
Tightening torque
TP sensor screws (a) : 2.5 N·m (0.25 kg-m, 1.8 lb-ft)
2) Connect connector to TP sensor securely.
3) Connect battery negative cable to battery.TERMINALS RESISTANCE
Between 1 and
3 terminals4.0 – 6.0 k
Ω
ΩΩ Ω
Between 2 and
3 terminals20.0
Ω
ΩΩ Ω – 6.0 k
Ω
ΩΩ Ω, varying according to
throttle valve opening.
NOTE:
There should be more than 2 k
Ω
ΩΩ Ω resistance difference
between when throttle valve is at idle position and when
it is fully open.
1. Reference voltage terminal
2. Output voltage terminal
3. Ground terminal

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Intake air temperature sensor (IAT sensor)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Disconnect connector from IAT sensor (1).
3) Remove IAT sensor (1) from air cleaner case (2).
INSPECTION
Immerse temperature sensing part of IAT sensor in water (or ice)
and measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t show such characteristic as
shown in left figure, replace IAT sensor.
INSTALLATION
Reverse removal procedure noting the following.
Clean mating surfaces of IAT sensor and air cleaner case.
Connect IAT sensor connector (1) securely.

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Engine coolant temperature sensor (ECT sensor)
REMOVAL
1) Disconnect battery negative cable at battery.
2) Drain coolant referring to Step 6) of “Cooling System Flush
and Refill” in Section 6B.
3) Disconnect connector from ECT sensor.
4) Remove ECT sensor (1) from water outlet cap.
INSPECTION
Immerse temperature sensing part of ECT sensor (1) in water (or
ice) and measure resistance between terminal “A” and “B” while
heating water gradually.
If measured resistance doesn’t show such characteristic as
shown in left figure, replace ECT sensor (1).
INSTALLATION
Reverse removal procedure noting the following:
Clean mating surfaces of ECT sensor (1) and water outlet
cap.
Check O-ring for damage and replace if necessary. WARNING:
To help avoid danger of being burned, do not remove
radiator cap while engine and radiator are still hot.
Scalding fluid and steam can be blown out under pres-
sure if cap is taken off too soon.

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Tighten ECT sensor (1) to specified torque.
Tightening torque
ECT sensor (a) : 15 N·m (1.5 kg-m, 11.5 lb-ft)
Connect connector to ECT sensor (1) securely.
Refill coolant referring to “Cooling System Flush and Refill”
in Section 6B.
Heated oxygen sensor (Sensor-1 and sensor-2)
OXYGEN SENSOR HEATER INSPECTION
1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance between terminals
“V
B” and “GND” of sensor connector.
If found faulty, replace oxygen sensor.
Resistance of oxygen sensor heater
HO2S-1 : 5.0 – 6.4
Ω
ΩΩ Ω at 20 °C, 68 °F
HO2S-2 : 11.7 – 14.3
Ω
ΩΩ Ω at 20 °C, 68 °F
3) Connect sensor connector securely.
REMOVAL
NOTE:
Temperature of sensor affects resistance value largely.
Make sure that sensor heater is at correct temperature.
1. Viewed from terminal side
WARNING:
To avoid danger of being burned, do not touch exhaust
system when system is hot. Oxygen sensor removal
should be performed when system is cool.

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1) Disconnect negative cable at battery.
2) For sensor-1, remove exhaust manifold cover (1) and dis-
connect connector of heated oxygen sensor and release its
wire harness from clamps.
3) For sensor-2, disconnect connector of heated oxygen sensor
and release its wire harness from clamp. Hoist vehicle and
then remove exhaust No.1 pipe covers (3).
4) Remove heated oxygen sensor (2) from exhaust manifold or
exhaust No.1 pipe.
INSTALLATION
Reverse removal procedure noting the following.
Tighten heated oxygen sensor (2) to specified torque.
Tightening torque
Heated oxygen sensor (a) : 45 N·m (4.5 kg-m, 32.5 lb-ft)
Connect connector of heated oxygen sensor (2) and clamp
wire harness securely.
After installing heated oxygen sensor (2), start engine and
check that no exhaust gas leakage exists.
Camshaft position sensor
INSPECTION
Check camshaft position sensor referring to “DTC P0340 (No. 15)
Diag. Flow Table” in Section 6. If malfunction is found, replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect connector from camshaft position sensor.
3) Remove camshaft position sensor from cylinder head.
INSTALLATION
1) Check that O-ring is free from damage.
2) Check that camshaft position sensor and signal rotor tooth
are free from any metal particles and damage.
3) Install camshaft position sensor to sensor case.
Tightening torque
Camshaft position sensor bolt
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
4) Connect connector to it securely.
5) Connect negative cable to battery.
[A] : HO2S-1
[B] : HO2S-2

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Crankshaft position sensor
INSPECTION
Check crankshaft position sensor referring to step 2 and 6 of
“DTC P0335 (No.23) Flow Table” in Section 6. If malfunction is
found, replace.
REMOVAL
1) Disconnect negative cable at battery.
2) Remove generator drive belt, loosen pivot bolt and move
generator outward.
3) Disconnect connector from crankshaft position sensor.
4) Remove crankshaft position sensor (1) from cylinder block.
INSTALLATION
1) Check to make sure that crankshaft position sensor and pul-
ley tooth is free from any metal particles and damage.
2) Install crankshaft position sensor to cylinder block.
3) Connect connector to it securely.
4) Adjust generator belt tension, refer to “Water Pump Belt Ten-
sion” in Section 6B.
5) Connect negative cable to battery.