warning SUZUKI JIMNY 2005 3.G Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 5E-16 ANTILOCK BRAKE SYSTEM (ABS)
Table – C “ABS” Warning Lamp Circuit Check – Lamp Flashes Continuously
While Ignition Switch is ON
CIRCUIT DESCRIPTION
When the diag. switch terminal is shorted or connected to the ground with the ignition switch ON, the diag. trou-
ble code (DTC) is indicated by flashing of the “ABS” warning lamp only in following cases.
Normal DTC (12) is indicated if no malfunction DTC is detected in the ABS.
A history malfunction DTC is indicated by flashing of the lamp if a current malfunction DTC is not detected at
that point although a history malfunction DTC is stored in memory.
INSPECTION
1.“ABS” warning lamp in combination meter 3-1. Diag. switch terminal 5. Pedal bracket
2. ABS hydraulic unit / control module assembly 3-2. Diag. ground terminal
3. Monitor connector 4. Service wire
Step Action Yes No
1 Is diag. switch terminal connected to ground via
service wire?Go to step 3. Go to step 2.
2 1) Ignition switch ON.
2) Measure voltage between diag. switch ter-
minal and ground.
Is it 10 – 14 V?Substitute a known-good
ABS hydraulic unit / con-
trol module assembly and
recheck.“P/B” wire circuit shorted
to ground.
3 1) Ignition switch ON.
2) Does flashing of ABS warning lamp indicate
DTC (DTC 12 or history DTC)?Go to step 7 of “ABS diag-
nostic flow table” in this
section.Substitute a known-good
ABS hydraulic unit / con-
trol module assembly and
recheck.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-17
Table – D Code (DTC) is Not Outputted Even With Diag. Switch Terminal Con-
nected to Ground.
CIRCUIT DESCRIPTION
When the diag. switch terminal is connected to the ground with the ignition switch turned ON, the ABS control
module outputs a diagnostic trouble code by flashing “ABS” warning lamp.
INSPECTION
1.“ABS” warning lamp in combination meter 3-1. Diag. switch terminal 4-1. Lock position
2. ABS hydraulic unit / control module assembly 3-2. Diag. ground terminal 4-2. Unlock position
3. Monitor connector 4. ABS hydraulic unit / control module connector of harness
Step Action Yes No
1 Is it shorted diag. switch terminal and ground
terminal by service wire properly?Go to step 2. Connect service wire
securely.
2 1) Disconnect service wire.
2) Disconnect ABS hydraulic unit / control
module connector.
3) Measure resistance between diag. switch
terminal and connector terminal “A12”.
Is it infinite (∞)?“P/B” circuit open. Go to step 3.
3 1) Measure resistance between ground termi-
nal of monitor connector and body ground.
Is continuity indicated?Go to step 4.“B” circuit open or poor
connection.
4 1) Check for proper connection to ABS hydrau-
lic unit / control module at terminal “A12”
and “A24”.
2) If OK, then check “ABS” warning lamp cir-
cuit referring to TABLE A, B and C.
Is it in good condition?Substitute a known-good
ABS hydraulic unit / con-
trol module assembly and
recheck.Repair “ABS” warning
lamp circuit.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-29
On-Vehicle Service
Precaution
When connectors are connected to ABS hydraulic unit / control
module assembly, do not disconnect connectors of sensors, fuse
etc. and turn ignition switch ON. Then DTC will be set in ABS con-
trol module.
ABS Hydraulic Unit Operation Check
1) Check that basic brake system other than ABS is in good
condition.
2) Check that battery voltage is 11 V or higher.
3) With ABS warning lamp, check that no abnormality is
detected in ABS. Refer to “Diagnostic Trouble Code (DTC)
Check” in this section.
4) Lift up vehicle.
5) Set transmission to neutral and release parking brake.
6) Turn each wheel gradually by hand to check if brake drag-
ging occurs. If it does, correct.
7) With diag. switch terminal (3) of monitor connector (1) con-
nected to ground terminal (2) by using service wire (4), turn
ignition switch ON and check if ABS warning lamp indicates
DTC 12.
When other DTC’s appear on display, refer to “ABS Diagnos-
tic Flow Table” in this section.
8) Turn ignition switch OFF.
9) Perform following checks with help of another person.
Brake pedal (1) should be depressed and then ignition
switch (2) turned ON by one person and wheel (3) should be
turned by another person’s hand. At this time, check that:
Operation sound of solenoid is heard and wheel turns only
about 0.5 sec (Brake force is depressurized).
Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
10) If all 4-wheels cannot be checked during one ignition cycle
(OFF → ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace
hydraulic unit.
11) Turn ignition switch OFF.
12) Remove service wire from monitor connector.

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8B
6
8D
8E
8B
9
10A
10B
SECTION 6
ENGINE GENERAL INFORMATION AND
DIAGNOSIS
GENERAL INFORMATION AND ENGINE DIAGNOSIS ..............................................................................
6-1
ENGINE MECHANICAL ...........................................................................................................................
6A1-1
ENGINE COOLING.....................................................................................................................................
6B-1
ENGINE FUEL ............................................................................................................................................
6C-1
ENGINE AND EMISSION CONTROL SYSTEM ........................................................................................
6E-1
IGNITION SYSTEM ....................................................................................................................................
6F-1
CRANKING SYSTEM .................................................................................................................................
6G-1
CHARGING SYSTEM .................................................................................................................................
6H-1
EXHAUST SYSTEM ...................................................................................................................................
6K-1
CONTENTS
General Information .......................................... 6-3
Statement on Cleanliness and Care ............... 6-3
General Information on Engine Service .......... 6-3
Precaution on fuel system service............... 6-4
Fuel pressure relief procedure .................... 6-5
Fuel leakage check procedure .................... 6-5
Engine Diagnosis .............................................. 6-6
General Description ........................................ 6-6
On-Board Diagnostic System (Vehicle with
Immobilizer Indicator Lamp) ............................ 6-6On-Board Diagnostic System (Vehicle without
Immobilizer Indicator Lamp)............................ 6-9
Precaution in Diagnosing Trouble ................. 6-10
Engine Diagnostic Flow Table ...................... 6-11
Customer problem inspection form
(example) .................................................. 6-13
Malfunction indicator lamp (MIL) check..... 6-14
Diagnostic trouble code (DTC) check ....... 6-14
Diagnostic trouble code (DTC)
clearance................................................... 6-15 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 the following systems (parts) are used in the particular vehicle or not depends on vehicle
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)

Downloaded from www.Manualslib.com manuals search engine 6-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS
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

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-43
Table A-1 Malfunction Indicator Lamp Circuit Check - Lamp Does Not Come
“ON” at Ignition Switch ON (But Engine at Stop)
CIRCUIT DESCRIPTION
When the ignition switch is turned ON, ECM causes the main relay to turn ON (close the contact point). Then,
ECM being supplied with the main power, turns ON the malfunction indicator lamp (MIL). When the engine
starts to run and no malfunction is detected in the system, MIL goes OFF but if a malfunction was or is detected,
MIL remains ON even when the engine is running.
INSPECTION
1. Main fuse 4. Main relay 7.“IG” fuse [A] : Case of TYPE A is shown
(See NOTE)
2. Ignition switch 5. Malfunction indicator lamp in
combination meter8.“IG COIL METER” fuse [B] : Case of TYPE B is shown
(See NOTE)
3. Fuse box 6.“FI” fuse
NOTE:
For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable
model.
Step Action Yes No
1 MIL Power Supply Check
1) Turn ignition switch ON.
Do other indicator / warning lights in combina-
tion meter comes ON?Go to Step 2.“IG” fuse blown, main fuse
blown, ignition switch mal-
function, “B/W” circuit
between “IG” fuse and
combination meter or
poor coupler connection
at combination meter.

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.