drive SUZUKI JIMNY 2005 3.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 6-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Malfunction indicator lamp (MIL) check
1) Turn ON ignition switch (but the engine at stop) and check
that MIL lights.
If MIL does not light up (or MIL dims), go to “Diagnostic Flow
Table A-1” for troubleshooting.
If MIL flushes, go to “Diagnostic Flow Table A-3” for trouble
shooting (vehicle without immobilizer indicator lamp).
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM, go to
“Diagnostic Flow Table A-2” for troubleshooting.
Diagnostic trouble code (DTC) check
[Using SUZUKI Scan Tool]
1) Prepare SUZUKI scan tool.
2) With ignition switch OFF, connect it to data link connector
(DLC) (1) located on underside of instrument panel at
driver’s seat side.
Special tool
(A) : SUZUKI scan tool
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC, pending DTC and freeze frame data according to
instructions displayed on scan tool and print it or write it
down.
Refer to scan tool operator’s manual for further details.
If communication between scan tool and ECM is not possi-
ble, check if scan tool is communicable by connecting it to
ECM in another vehicle. If communication is possible in this
case, scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle with
which communication was not possible.
5) After completing the check, turn ignition switch off and dis-
connect scan tool from data link connector.
[Without Using SUZUKI Scan Tool] (Vehicle Without
Immobilizer Indicator Lamp)
1) Check malfunction indicator lamp referring to “Malfunction
Indicator Lamp Check” in this section.
2) With the ignition switch OFF position, connect diagnosis
switch terminal (3) and ground terminal (2) in monitor con-
nector (1) with service wire (4).
3) With the ignition switch ON position and leaving engine OFF,
read DTC from flashing pattern of malfunction indicator
lamp. Refer to “Diagnostic Trouble Code Table”.
If lamp does not flash or remains ON or OFF, go to “Diag-
nostic Flow Table A-4”.

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-25
Excessive detonation
(The engine makes
sharp metallic knocks
that change with throt-
tle opening.
Sounds like pop corn
popping.)Engine overheating Refer to “Overheating” of this table.
Faulty spark plug Spark plugs in Section 6F.
Clogged fuel filter and fuel lines Diagnostic Flow Table B-3
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
Poor performance of knock sensor, ECT
sensor or MAP sensorKnock sensor in this section, ECT
sensor or MAP sensor in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Excessive combustion chamber deposits Piston and cylinder head in Section
6A1.
Overheating
Inoperative thermostat Thermostat in Section 6B.
Faulty A/C condenser fan motor or its cir-
cuitA/C condenser fan control system
check in Section 6E.
Loose or slip water pump belt ITEM1-1 Drive belt inspection and
change in Section 0B.
Poor water pump performance Water pump in Section 6B.
Clogged or leaky radiator Radiator in Section 6B.
Improper engine oil grade ITEM1-3 Engine oil and oil filter
change in Section 0B.
Clogged oil filter or oil strainer Oil pressure check in Section 6A1.
Poor oil pump performance Oil pressure check in Section 6A1.
Dragging brakes Diagnosis Table in Section 5.
Slipping clutch Diagnosis Table in Section 7C.
Blown cylinder head gasket Valves and cylinder head in Section
6A1.
Poor gasoline mileage
Faulty ignition coil Ignition coil assembly in Section 6F.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty TP sensor, ECT sensor or MAP
sensorTP sensor, ECT sensor or MAP sen-
sor in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
High idle speed Refer to item “Improper Engine Idle
Speed” previously outlined.
Low compression Previously outlined.
Poor valve seating Valves and cylinder head in Section
6A1.
Dragging brakes Diagnosis Table in Section 5.
Slipping clutch Diagnosis Table in Section 7C.
Thermostat out of order Thermostat in Section 6B.
Improper tire pressure Refer to Section 3F. Condition Possible Cause Reference Item

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-31
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.

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For TYPE B (See NOTE)
E174Blank––
5 Overdrive cut signal (A/T)0 – 1.0 VIgnition switch ON and ECT less than
60 °C
10 – 14 VIgnition switch ON and ECT more than
60 °C
6 D-range idle up signal (A/T)10 – 14 VIgnition switch ON and shift select switch
in other than P and N range
0 – 1.6 VIgnition switch ON and shift select switch
in P and N range
7 Stop lamp switch0 VIgnition switch ON
Stop lamp switch OFF
10 – 14 VIgnition switch ON
Stop lamp switch ON
8–– –
9 Ignition switch 10 – 14 V Ignition switch ON
10–– –
11 Vehicle speed sensordeflect
between
0 – 1.6 and
4 – 14 VIgnition switch ON and rear right wheel
turned slowly with rear left wheel locked
12 ABS signal (if equipped) 10 – 14 V Ignition switch ON
13 Engine start signal 6 – 14 V While engine cranking
14–– –
15–– –
16 Rear defogger switch (if equipped)10 – 14 V Ignition switch ON and rear defogger
switch ON
0 – 1.3 V Ignition switch ON and rear defogger
switch OFF
17 A/T failure signal (with immobilizer
indicator lamp) (A/T)–– TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
NOTE:
See NOTE in “ECM TERMINAL VOLTAGE VALUES TABLE” for applicable model.
TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
E171 A/C evaporator temp. sensor 2.0 – 2.3 VIgnition switch ON
A/C evaporator temp. sensor at 25 °C
(77 °F)
2 R-range signal (A/T)10 – 14 VIgnition switch ON and shift select switch
in R range
0 – 1.3 VIgnition switch ON and shift select switch
in other than R range
3Blank––
4Blank––

Downloaded from www.Manualslib.com manuals search engine 6-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS
E175 Overdrive cut signal (A/T)0 – 1.0 VIgnition switch ON and ECT less than
60° C
10 – 14 VIgnition switch ON and ECT more than
60 °C
6 D-range idle up signal (A/T)10 – 14 VIgnition switch ON and shift select switch
in other than P and N range
0 – 1.6 VIgnition switch ON and shift select switch
in P and N range
7 Data link connector 4 – 5 V Ignition switch ON
8–– –
9 Malfunction indicator lamp10 – 14 V Engine running
0 – 1.0 V Ignition switch ON leaving engine OFF
10–– –
11 Data link connector 10 – 14 V Ignition switch ON
12 ABS signal (if equipped) 10 – 14 V Ignition switch ON
13 Heater blower switch0 – 2.0 VIgnition switch ON and heater blower
switch ON
10 – 14 VIgnition switch ON and heater blower
switch OFF
14 Sensor ground––
15Throttle opening signal for
TCM (A/T)Indication
deflection
repeated 0 V
and 10 - 14 VIgnition switch ON
16 Tachometer––
17–– – TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-57
DTC P0121 Throttle Position Circuit Range / Performance Problem
WIRING DIAGRAM
Refer to DTC P0120 section.
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, 158 °F or lower
–Engine coolant temp. : 70 °C, 158 °F or higher
2) Warm up engine to normal operating temperature.
3) Increase vehicle speed to 30 – 40 mph, 50 – 60 km/h in 3rd gear or “D” range and hold throttle valve at that
opening position for 1 min.
4) Stop vehicle.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
After engine warmed up.
Difference between actual throttle opening (detected from TP sensor)
and opening calculated by ECM (Obtained on the basis of engine
speed and intake manifold pressure) in larger than specified value.
✱2 driving cycle detection logic, continuous monitoringTP sensor malfunction
High resistance in the circuit
ECM 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.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Is SUZUKI scan tool available? Go to Step 3. Go to Step 4.
3 Check TP Sensor and Its Circuit.
1) Turn ignition switch OFF and connect
SUZUKI scan tool to DLC. See Fig. 1.
2) Turn ignition switch ON and check TP sen-
sor output voltage when throttle valve is at
idle position and fully opened. See Fig. 3.
Dose voltage vary within specified value linearly
as shown in figure?Substitute a known-good
ECM and recheck.Go to Step 5.

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-59
DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction
(Sensor-1)
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, 158 °F or lower
2) Warm up engine to normal operating temperature.
3) Drive vehicle at 30 – 40 mph, 50 – 60 km/h for 2 min.
4) Stop vehicle and run engine at idle for 2 min.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
1. Heated oxygen sensor-1 (HO2S-1)
DTC DETECTING CONDITION POSSIBLE CAUSE
When running at idle speed after engine warmed up and
running at specified vehicle speed, HO2S-1 output volt-
age does not go below 0.3 V or over 0.6 V.
✱2 driving cycle detection logic, Monitoring once / 1 driving.Heated oxygen sensor-1 malfunction
“B/Bl” or “R” circuit open (poor connection) or
short
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.

Downloaded from www.Manualslib.com manuals search engine 6-62 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Mal-
function (Sensor-1)
CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON, start engine and keep it at idle for 1 min.
3) Start vehicle and depress accelerator pedal fully for 5 sec. or longer.
4) Stop vehicle.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
1. Heated oxygen sensor-1 (HO2S-1) heater
DTC DETECTING CONDITION POSSIBLE CAUSE
DTC will set when A or B condition is met.
A :
Low voltage at terminal E19-7 when engine is running
at high load.
B :
High voltage at terminal E19-7 when engine is running
under condition other than above.
✱
✱✱ ✱2 driving cycle detection logic, Continuous monitoring.HO2S-1 heater circuit open or shorted to ground
ECM 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.

Downloaded from www.Manualslib.com manuals search engine 6-64 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2)
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, 158 °F or lower
–No exhaust gas leakage and loose connection
2) Warm up engine to normal operating temperature.
3) Drive vehicle under usual driving condition for 5 min. and check HO2S-2 output voltage and “short term fuel
trim” with “Data List” mode on scan tool, and write it down.
4) Stop vehicle (don’t turn ignition switch OFF).
5) Increase vehicle speed to higher than 20 mph, 32 km/h and then stop vehicle.
1. Heated oxygen sensor-2 (HO2S-2) [A] : Case of TYPE A is shown (See NOTE) [B] : Case of TYPE B is shown (See NOTE)
NOTE:
For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable
model.
DTC DETECTING CONDITION POSSIBLE CAUSE
Engine is warmed up and HO2S-2 voltage is 4.5 V or more.
(circuit open)
✱
✱✱ ✱2 driving cycle detection logic, monitoring once / 1 driving.Exhaust gas leakage
“W” or “B/Bl” circuit open or short
Heated oxygen sensor-2 malfunction
Fuel system 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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6) Repeat above steps 5) 4 times.
7) Increase vehicle speed to about 50 mph (80 km/h) in 3rd gear or 2 range.
8) Release accelerator pedal and with engine brake applied, keep vehicle coasting (fuel cut condition) for
10sec. or more.
9) Stop vehicle (don’t turn ignition switch OFF) and run engine at idle for 2 min. After this step 9), if “Oxygen
Sensor Monitoring TEST COMPLETED” is displayed in “READINESS TESTS” mode and DTC is not dis-
played in “DTC” mode, confirmation test is completed.
If “TEST NOT COMPLTD” is still being displayed, proceed to next step 10).
10) Drive vehicle under usual driving condition for 10 min. (or vehicle is at a stop and run engine at idle for 10
min. or longer)
11) Stop vehicle (don’t turn ignition switch OFF). Confirm test results according to “Test Result Confirmation
Flow Table” in “DTC CONFIRMATION PROCEDURE” of DTC P0420.
INSPECTION
*Usual driving : Driving at 30 – 40 mph, 50 – 60 km/h including short stop according to traffic signal. (under driving condition other than high-load, high-engine
speed, rapid accelerating and decelerating)
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check exhaust system for leakage, loose con-
nection and damage.
Is it good condition?Go to Step 3. Repair or replace.
3 Check HO2S-2 and Its Circuit.
Was HO2S-2 output voltage indicated on scan
tool in step 3) of DTC confirmation test less
than 1.275 V?Go to Step 4.“B/Bl” or “W” circuit open
or HO2S-2 malfunction.
4 Check Short Term Fuel Trim.
Did short term fuel trim very within –20 – + 20%
range in step 3) of DTC confirmation test?Check “W” and “B/Bl” wire
for open and short, and
connection for poor con-
nection. If wire and con-
nection are OK, replace
HO2S-2.Check fuel system. Go to
DTC P0171 / P0172 Diag.
Flow Table.