lamp SUZUKI JIMNY 2005 3.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-9
On-Board Diagnostic System (Vehicle without
Immobilizer Indicator Lamp)
ECM diagnosis troubles which may occur in the area including
the following parts when the ignition switch is ON and the engine
is running, and indicates the result by turning on or flashing mal-
function indicator lamp (1).
Heated oxygen sensor (if equipped)
ECT sensor
TP sensor
IAT sensor
MAP sensor
CMP sensor
CKP sensor
Knock sensor
VSS
CPU (Central Processing Unit) of ECM
ECM and malfunction indicator lamp (1) operate as follows.
Malfunction indicator lamp (1) lights when the ignition switch
is turned ON (but the engine at stop) with the diagnosis
switch terminal ungrounded regardless of the condition of
Engine and Emission Control system. This is only to check
the malfunction indicator lamp (1) bulb and its circuit.
If the above areas of Engine and Emission Control system is
free from any trouble after the engine start (while engine is
running), malfunction indicator lamp (1) turns OFF.
When ECM detects a trouble which has occurred in the
above areas, it makes malfunction indicator lamp (1) turn ON
while the engine is running to warn the driver of such occur-
rence of trouble and at the same time it stores the trouble
area in ECM back-up memory. (The memory is kept as it is
even if the trouble was only temporary and disappeared
immediately. And it is not erased unless the power to ECM is
shut off for specified time below.)
ECM also indicates trouble area in memory by means of
flashing of malfunction indicator lamp (1) at the time of
inspection. (i.e. when connecting diagnosis switch terminal
(2) and ground terminal (4) of monitor connector (3) with a
service wire (5) and ignition switch is turned ON.)
NOTE:
When a trouble occurs in the above areas and disap-
pears soon while the diagnosis switch terminal is
ungrounded and the engine is running, malfunction
indicator lamp (1) lights and remains ON as long as the
trouble exists but it turns OFF when the normal condi-
tion is restored.
Time required to erase diagnostic trouble code mem-
ory thoroughly varies depending on ambient tempera-
ture as follows.

Downloaded from www.Manualslib.com manuals search engine 6-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Precaution in Diagnosing Trouble
Don’t disconnect couplers from ECM, battery cable at battery, ECM ground wire harness from engine or
main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in ECM memory.
Such disconnection will erase memorized information in ECM memory.
Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have
good understanding as to what functions are available and how to use it.
Priorities for diagnosing troubles (Vehicle with Immobilizer indicator lamp).
If multiple diagnostic trouble codes (DTCs) are stored, proceed to the flow table of the DTC which has
detected earliest in the order and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
–Diagnostic trouble codes (DTCs) other than DTC P0171/P0172 (Fuel system too lean / too rich), DTC
P0300/P0301/P0302/P0303/P0304 (Misfire detected) and DTC P0400 (EGR flow malfunction)
–DTC P0171/P0172 (Fuel system too lean / too rich) and DTC P0400 (EGR flow malfunction)
–DTC P0300/P0301/P0302/P0303/P0304 (Misfire detected)
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before inspection and observe what
is written there.
ECM Replacement
When substituting a known-good ECM, check for following conditions. Neglecting this check may cause
damage to a known-good ECM.
–Resistance value of all relays, actuators is as specified respectively.
–MAP sensor and TP sensor are in good condition and none of power circuits of these sensors is shorted
to ground.AMBIENT TEMPERATURE TIME TO CUT POWER TO
ECM
Over 0 °C (32 °F) 60 sec. or longer
Under 0 °C (32 °F)Not specifiable.
Select a place with higher than
0 °C (32 °F) temperature.

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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”.

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4) After completing the check, turn the ignition switch OFF posi-
tion and disconnect service wire from monitor coupler.
Diagnostic trouble code (DTC) clearance
[Using SUZUKI Scan Tool]
1) Connect SUZUKI scan tool to data link connector in the
same manner as when making this connection for DTC
check.
2) Turn ignition switch ON.
3) Erase DTC and pending DTC according to instructions dis-
played on scan tool. Refer to scan tool operator’s manual for
further details.
4) After completing the clearance, turn ignition switch off and
disconnect scan tool from data link connector.
[Without Using SUZUKI Scan Tool]
1) Turn the ignition switch OFF position.
2) Disconnect battery negative cable for specified time below to
erase diagnostic trouble code stored in ECM memory and
reconnect it.
Time required to erase DTC NOTE:
If abnormality or malfunction lies in two or more areas,
malfunction indicator lamp indicates applicable codes
three times each.
And flashing of these codes is repeated as long as
diagnosis terminal is grounded and ignition switch is
held at ON position.
Take a note of diagnostic trouble code indicated first.
NOTE:
DTC and freeze frame data stored in ECM memory are
also cleared in following cases. Be careful not to clear
them before keeping their record.
When power to ECM is cut off (by disconnecting bat-
tery cable, removing fuse or disconnecting ECM con-
nectors)
When the same malfunction (DTC) is not detected
again during 40 engine warm-up cycles.
Ambient temperature Time to cut power to ECM
Over 0 °C (32 °F) 30 sec. or longer
Under 0 °C (32 °F)Not specifiable.
Select a place with higher than
0 °C (32 °F) temperature.

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Diagnostic trouble code (DTC) table
DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)
P0105
(No.11)Manifold absolute pressure
circuit malfunctionLow pressure-high vacuum-low voltage
(or MAP sensor circuit shorted to ground)
High pressure-low vacuum-high voltage
(or MAP sensor circuit open)1 driving
cycle1 driving
cycle
P0110
(No.18)Intake air temp. circuit mal-
functionIntake air temp. circuit low input
Intake air temp. circuit high input1 driving
cycle1 driving
cycle
P0115
(No.19)Engine coolant temp. cir-
cuit malfunctionEngine coolant temp. circuit low input
Engine coolant temp. circuit high input1 driving
cycle1 driving
cycle
P0120
(No.13)Throttle position circuit mal-
functionThrottle position circuit low input
Throttle position circuit high input1 driving
cycle1 driving
cycle
P0121Throttle position circuit per-
formance problemPoor performance of TP sensor 2 driving
cyclesNot
applicable
P0130
(No.14)HO2S circuit malfunction
(Sensor-1)Min. output voltage of HO2S-higher than
specification
Max. output voltage of HO2S-lower than
specification2 driving
cycles1 driving
cycle
P0133HO2S circuit slow response
(Sensor-1)Response time of HO2S-1 output voltage
between rich and lean is longer than spec-
ification.2 driving
cyclesNot
applicable
P0135
(No.14)HO2S heater circuit mal-
function (Sensor-1)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.2 driving
cycles1 driving
cycle
P0136HO2S circuit malfunction
(Sensor-2)HO2S-2 voltage is higher than specifica-
tion2 driving
cyclesNot
applicable
P0141HO2S heater circuit mal-
function (Sensor-2)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.
(or heater circuit or short)2 driving
cyclesNot
applicable
P0171 Fuel system too leanShort term fuel trim or total fuel trim (short
and long terms added) is larger than spec-
ification for specified time or longer.
(fuel trim toward rich side is large.)2 driving
cyclesNot
applicable
P0172 Fuel system too richShort term fuel trim or total fuel trim (short
and long term added) is smaller than spec-
ification for specified time or longer.
(fuel trim toward lean side is large.)2 driving
cyclesNot
applicable
P0300
P0301
P0302
P0303
P0304Random misfire detected
Cylinder 1 misfire detected
Cylinder 2 misfire detected
Cylinder 3 misfire detected
Cylinder 4 misfire detectedMisfire of such level as to cause damage
to three way catalystMIL flashing
during mis-
fire detec-
tionNot
applicable
Misfire of such level as to deteriorate emis-
sion but not to cause damage to three way
catalyst2 driving
cyclesNot
applicable
P0325
(No.17)Knock sensor circuit mal-
functionKnock sensor circuit low input
Knock sensor circuit high input1 driving
cycle1 driving
cycle

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P0335
(No.23)Crankshaft position sensor
circuit malfunctionNo signal for 2 sec. During engine crank-
ing1 driving
cycle1 driving
cycle
P0340
(No.15)Camshaft position sensor
circuit malfunctionNo signal during engine running1 driving
cycle1 driving
cycle
P0400Exhaust gas recirculation
flow malfunction detectedExcessive or insufficient EGR flow2 driving
cyclesNot
applicable
P0420Catalyst system efficiency
below thresholdOutput waveforms of HO2S-1 and HO2S-2
are similar.
(Time from output voltage change of
HO2S-1 to that of HO2S-2 is shorter than
specification.)2 driving
cyclesNot
applicable
P0443Purge control valve circuit
malfunctionPurge control valve circuit is open or
shorted to ground2 driving
cyclesNot
applicable
P0481A/C condenser fan control
circuit malfunctionA/C condenser fan relay terminal voltage is
low when fan command is not outputted2 driving
cyclesNot
applicable
P0500
(No.16)Vehicle speed sensor mal-
functionNo signal while running in “D” range or
during fuel cut at decelerating2 driving
cycles1 driving
cycle
P0505 Idle control system malfunc-
tionNo closed signal to IAC valve is detected2 driving
cyclesNot
applicable
P0601
(No.71)Internal control module
memory check sum errorData write error (or check sum error) when
written into ECM2 driving
cyclesNot
applicable
P1450 Barometric pressure sen-
sor circuit malfunctionBarometric pressure is lower or higher
than specification. (or sensor malfunction)1 driving
cycleNot
applicable
P1451Barometric pressure sen-
sor performance problemDifference between manifold absolute
pressure (MAP sensor value) and baro-
metric pressure (barometric pressure sen-
sor value) is larger than specification
during cranking.2 driving
cyclesNot
applicable
P1500Starter signal circuit mal-
functionStarter signal is not inputted from engine
cranking till its start and after or it is always
inputted2 driving
cyclesNot
applicable
P1510ECM backup power source
malfunctionNo backup power after starting engine1 driving
cycleNot
applicable
P1600Serial communication prob-
lem between ECM and
TCMNo signal or check sum error while engine
running1 driving
cycleNot
applicable
P1717AT D-range signal circuit
malfunctionNo “D” range (park / neutral position sig-
nal) is inputted while vehicle running2 driving
cyclesNot
applicable
P1570ABS signal circuit malfunc-
tionABS signal ON (low voltage) when engine
startNot
applicable1 driving
cycle DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)

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DTC NO. DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
P0702 Transmission Control System Electrical
Refer to Section 7B.
These DTCs can not be read on vehicle without
Immobilizer indicator lamp (by ECM application of
SUZUKI scan tool). P0705 Temperature Sensor Circuit Malfunction
P0710Transmission Temperature Sensor Circuit Mal-
function
P0715Input / Turbine Speed Sensor Circuit Malfunc-
tion
P0720Output Shaft Speed Sensor Circuit Malfunc-
tion
P0725 Engine Speed Input Circuit Malfunction
P0730 Incorrect Gear Ratio
P0743 Torque Converter Clutch Circuit Electrical
P0753 Shift Solenoid A Electrical
P0758 Shift Solenoid B Electrical
P0763 Shift Solenoid C Electrical
P0768 Shift Solenoid D Electrical
P1700 Throttle Position Signal Input Malfunction
P1702Internal Control Module Memory Check Some
Error
P1709Engine Coolant Temperature Signal Input
Malfunction
P1887 Transfer Signal
P1620
(No.84)ECU code not registered
Refer to Section 8G. P1621
(No.83)No ECU code transmitted from Immobilizer
Control Module
P1622
(No.82)Faulty in ECM
P1623
(No.81)ECU code not matched
NOTE:
For ( ) marked No. in DTC column, it is used for vehicle without Immobilizer indicator lamp.
DTC No.12 appears when none of the other codes is identified (vehicle without Immobilizer indica-
tor lamp).

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Visual inspection
Visually check following parts and systems.
INSPECTION ITEM REFERRING SECTION
Engine oil – level, leakage Section 0B
Engine coolant – level, leakage Section 0B
Fuel – level, leakage Section 0B
A/T fluid – level, leakage Section 0B
Air cleaner element – dirt, clogging Section 0B
Battery – fluid level, corrosion of terminal
Water pump belt – tension, damage Section 0B
Throttle cable – play, installation
Section 6E Vacuum hoses of air intake system – disconnection, looseness,
deterioration, bend
Connectors of electric wire harness – disconnection, friction
Fuses – burning Section 8
Parts – installation, bolt – looseness
Parts – deformation
Other parts that can be checked visually
Also check following items at engine start, if possible
Malfunction indicator lamp – operation Section 6
Charge warning lamp – operation Section 6H
Engine oil pressure warning lamp – operation Section 8 (Section 6 for pressure check)
Engine coolant temp. meter – operation Section 8
Fuel level meter – operation Section 8
Tachometer, if equipped – operation
Abnormal air being inhaled from air intake system
Exhaust system – leakage of exhaust gas, noise
Other parts that can be checked visually

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Engine basic inspection
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been
found in visual inspection.
Follow the flow table carefully.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check battery voltage.
Is it 11 V or more?Go to Step 3. Charge or replace battery.
3 Is engine cranked? Go to Step 4. Go to “Diagnosis” in Sec-
tion 6G.
4 Does engine start? Go to Step 5. Go to Step 9.
5 Check idle speed as follows :
1) Warm up engine to normal operating temp.
2) Shift transmission to neutral position for M/T
(“P” position for A/T).
3) All of electrical loads are switched off.
4) Check engine idle speed with scan tool.
See Fig. 1.
Is it 650 – 750 r/min (700 – 800 r/min. for A/T
vehicle)?Go to Step 6. Go to “Engine Diagnosis
Table”.
6 Is SUZUKI scan tool available? Go to Step 8. Go to Step 7.
7 Check ignition timing as follows :
1) Connect test switch terminal (2) of monitor
coupler (1) to ground. See Fig. 2.
2) Remove air cleaner bolt and crips and shift
air cleaner position to observe ignition tim-
ing.
3) Using timing light (1), check initial ignition
timing.
See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “Engine Diagnosis
Table”.Check ignition control
related parts referring to
Section 6F.
8 Check ignition timing as follows :
1) Select “MISC” mode on SUZUKI scan tool
and fix ignition timing to initial one. See Fig.
3.
2) Remove air cleaner bolt and crips and shift
air cleaner position to observe ignition tim-
ing.
3) Using timing light (1), check initial ignition
timing. See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “Engine Diagnosis
Table”.Check ignition control
related parts referring to
Section 6F.
9 Check immobilizer system malfunction as fol-
lows (if equipped) :
1) Check immobilizer indicator lamp or MIL
(malfunction indicator lamp) for flashing.
Is it flashing when ignition switch is turned to
ON position?Go to “Diagnosis” in Sec-
tion 8G.Go to Step 10.

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Scan Tool Data
As the data values given below are standard values estimated on the basis of values obtained from the normally
operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condi-
tion, there may be cases where the checked value does not fall within each specified data range. Therefore,
judgment as abnormal should not be made by checking with these data alone.
Also, conditions in the below table that can be checked by the scan tool are those detected by ECM and output
from ECM as commands and there may be cases where the engine or actuator is not operating (in the condi-
tion) as indicated by the scan tool. Be sure to use the timing light to check the ignition timing.
NOTE:
With the generic scan tool, only star (
✱
✱✱ ✱) marked data in the table below can be read.
The triangle (
∆
∆∆ ∆) marked data in the table below can not be read for vehicle without immobilizer indi-
cator lamp at combination meter.
When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the
neutral gear position and A/T gear to the “Park” position and pull the parking brake fully. Also, if
nothing or “no load” is indicated, turn OFF A/C, all electric loads, P/S and all the other necessary
switches.
SCAN TOOL DATA CONDITION REFERENCE VALUES
✱
✱✱ ✱FUEL SYSTEM B1 (FUEL
SYSTEM STATUS)At specified idle speed after warming up CLOSED (closed loop)
✱
✱✱ ✱
CALC LOAD
(CALCULATED LOAD
VALUE)At specified idle speed with no load after
warming up3 – 9 %
At 2500 r/min with no load after warming up 12 – 17 %
✱
✱✱ ✱COOLANT TEMP.
(ENGINE COOLANT
TEMP.)At specified idle speed after warming up 80 – 100 °C, 176 – 212 °F
✱
✱✱ ✱SHORT FT B1 (SHORT
TERM FUEL TRIM)At specified idle speed after warming up– 20 – +20 %
✱
✱✱ ✱LONG FT B1 (LONG TERM
FUEL TRIM)At specified idle speed after warming up– 15 – +15 %
✱
✱✱ ✱MAP (INTAKE MANIFOLD
ABSOLUTE PRESSURE)At specified idle speed with no load after30 – 37 kPa,
220 – 340 mmHg
✱
✱✱ ✱
ENGINE SPEED At idling with no load after warming upDesired idle speed
±50 r/min
✱
✱✱ ✱VEHICLE SPEED At stop 0 km/h, 0 MPH
✱
✱✱ ✱IGNITION ADVANCE
(IGNITION TIMING
ADVANCE FOR NO.1 CYL-
INDER)At specified idle speed with no load after
warming up5 – 16° BTDC
✱
✱✱ ✱
INTAKE AIR TEMP. At specified idle speed after warming upAmbient temp. :
+15 °C (59 °F)
–5 °C (23 °F)
✱
✱✱ ✱MAF (MASS AIR FLOW
RATE)At specified idle speed with no load after
warming up1 – 4 gm/sec
✱
✱✱ ✱
THROTTLE POS
(THROTTLE POSITION)Ignition switch
ON / engine
stoppedThrottle valve fully closed 7 – 18 %
Throttle valve fully open 70 – 90 %
✱
✱✱ ✱O2S B1 S1 (HEATED OXY-
GEN SENSOR-1)At specified idle speed after warming up 0.01 – 0.95 V