Valve lash SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine MAINTENANCE AND LUBRICATION 0B-1
0A 6F1
0B
0B
6G
1A 6H
1B 6K
37A
3A 7A1
3B1 7B1
3C1 7C1
3D 7D
3E 7E
3F 7F
4A2 8A
4B 8B
8C
58D
5A 8E
5B
5C 9
5E
5E1 10
10A
610B
6-1
6A1
6A2
6A4
6B
6C
6E1
6E2
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule .................................. 0B-2
Maintenance Schedule Under Normal
Driving Conditions ........................................ 0B-2
Maintenance Recommended Under Severe
Driving Conditions ........................................ 0B-4
Maintenance Service...................................... 0B-5
Engine .......................................................... 0B-5
Drive Belt .................................................. 0B-5
Valve Lash................................................ 0B-6
Engine Oil and Filter ................................. 0B-6
Engine Coolant ......................................... 0B-8
Exhaust System ....................................... 0B-8
Ignition System ............................................. 0B-9
Spark Plugs .............................................. 0B-9
Fuel System ................................................. 0B-9
Air Cleaner Filter ...................................... 0B-9
Fuel Lines and Connections ................... 0B-10
Fuel Filter ............................................... 0B-10
Fuel Tank ............................................... 0B-10
Emission Control System ........................... 0B-10
Crankcase Ventilation Hoses and
Connections ........................................... 0B-10
PCV (Positive Crankcase Ventilation)
Valve ..................................................... 0B-11Fuel Evaporative Emission Control
System ................................................... 0B-11
Chassis and Body ...................................... 0B-11
Clutch ..................................................... 0B-11
Brake Discs and Pads ............................ 0B-11
Brake Drums and Shoes ........................ 0B-12
Brake Hoses and Pipes.......................... 0B-12
Brake Fluid ............................................. 0B-12
Parking Brake Lever and Cable ............. 0B-13
Tires/Wheels .......................................... 0B-13
Suspension System ............................... 0B-14
Propeller Shafts...................................... 0B-15
Manual Transmission Oil........................ 0B-16
Automatic Transmission Fluid ................ 0B-16
Transfer and Differential Oil ................... 0B-17
Steering System ..................................... 0B-18
Steering Knuckle Seal ............................ 0B-18
Power Steering (P/S) System
(if equipped) ........................................... 0B-19
All Hinges, Latches and Locks ............... 0B-19
Final Inspection............................................ 0B-20
Recommended Fluids and Lubricants ....... 0B-22

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).

Downloaded from www.Manualslib.com manuals search engine 0B-2 MAINTENANCE AND LUBRICATION
Maintenance Schedule
Maintenance Schedule Under Normal Driving Conditions
NOTE:
 This interval should be judged by odometer reading or months, whichever comes first.
 This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.
IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 1827364554
Months 12 24 36 48 60 72
ENGINE
Drive belt V-belt I R I R I R
V-rib belt (Flat type)––I––R
Valve lash (clearance) –I–I–I
Engine oil and oil filter R R R R R R
Engine coolant––R––R
Exhaust system–I–I–I
IGNITION SYSTEM
✱Spark plugs When
unleaded
fuel is usedVehicle without
HO2SNickel spark
plug–R–R–R
Iridium spark
plug––R––R
Vehicle with
HO2SNickel spark
plug––R––R
Iridium spark
plug–––R––
When leaded fuel is used, refer to “Maintenance Recommended Under Severe Driving Condi-
tions” in this section.
FUEL SYSTEM
Air cleaner filter I I R I I R
Fuel lines and connections–I–I–I
Fuel filter Replace every 210,000 km (126,000 miles).
Fuel tank––I––I
EMISSION CONTROL SYSTEM
Crankcase ventilation hoses and connections
(Vehicle without HO2S)––I––I
✱PCV valve Vehicle without HO2S––I––I
Vehicle with HO2S–––––I
✱Fuel evaporative emission
control systemVehicle without HO2S–I–I–I
Vehicle with HO2S–––––I
NOTE:
“R”: Replace or change
“I”: Inspect and correct, replace or lubricate if necessary
 For Sweden, items with
✱
✱✱ ✱ (asterisk) should be performed by odometer reading only.
 For spark plugs, replace every 50,000 km if the local law requires.
 Nickel spark plug: BKR6E-11 (NGK) or K20PR-U11 (DENSO)
 Iridium spark plug: IFR5E11 (NGK) or SK16PR-A11 (DENSO)

Downloaded from www.Manualslib.com manuals search engine 0B-6 MAINTENANCE AND LUBRICATION
3) Check belt for tension.
Power steering pump and/or A/C compressor drive belt
tension
“a”: 6 – 9 mm (0.24 – 0.35 in.) deflection under 100 N
(10 kg, 22 lb) pressure.
4) If belt tension is out of above specification, adjust it referring
to “Compressor Drive Belt” in Section 1B or “Power Steering
Belt Check” in Section 3B1.
5) Connect negative cable to battery.
REPLACEMENT
Replace belt with new one referring to “Compressor Drive Belt” in
Section 1B or “Power Steering Belt Check” in Section 3B1.
Valve Lash
INSPECTION
1) Inspect intake and exhaust valve lash and adjust as neces-
sary.
Refer to “Valve Lash (Clearance)” in Section 6A1 for valve
lash inspection and adjustment procedure.
Engine Oil and Filter
CHANGE
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.
1. P/S pump pulley
2. Camshaft pulley
3. A/C compressor pulley (if equipped)
4. Belt tension pulley
1. Camshaft
2. Thickness gauge
WARNING:
 New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
 Step 1) – 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.

Downloaded from www.Manualslib.com manuals search engine 3D-6 FRONT SUSPENSION
OPERATION
2WD
→ 4WD
When the transfer shift control lever is shifted from the 2WD (2H) position to the 4WD (4H or 4L) position, a 4WD
“ON” signal is transmitted to the 4WD controller which then activates VSV2 to apply vacuum in the intake mani-
fold to the chamber “B” in the hub housing.
When vacuum is applied, the slide gear is separated from the magnet, moves toward the center of the vehicle
body and gets engaged with the outer gear. In this way, the front axle shaft and the front wheel hub rotate as one
unit.
If vacuum in the circuit fails to reach 260 mmHg within 15 seconds after operation of VSV2 due to such trouble
as a hole in the vacuum pipe, the slide gear does not operate and the 4WD indicator light flashes to warn that
the hub is unlocked.
1. ECM 8. Engine speed signal 15. Chamber B 22. Slide gear
2. 4WD controller 9. Intake manifold 16. Piston A 23. Wheel hub
3. 4WD indicator lamp 10. Check valve 17. Magnet 24. Spindle
4.4WD switch 11. Vacuum tank 18. Housing 25. Front axle shaft
5. A/C switch (if equipped) 12. VSV1 19. Spring 26. To opposite side
6. Vacuum switch 13. VSV2 20. Diaphragm 27. A/C controller
7. A/C cut signal (if equipped) 14. Outer gear 21. Sleeve A: Vacuum circuit

Downloaded from www.Manualslib.com manuals search engine 3D-8 FRONT SUSPENSION
Diagnosis
Diagnosis Table
For description not found in the table below, refer to “Diagnosis Table” in Section 3.
4WD CONTROL SYSTEM
4WD CONTROL SYSTEM DIAGNOSTIC FLOW TABLE
Before performing the trouble diagnosis, check that the air locking hub assemblies are in good condition and
there is no air leakage from vacuum hoses and vacuum pipe. Refer to “4WD Control System Check” in this sec-
tion for air leakage.
[NOTES ON SYSTEM CIRCUIT INSPECTION]
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before circuit inspection and
observe what is written there.
For system circuit, refer to the figure of “System Circuit” in this section. Condition Possible Cause Correction
4WD Indicator light
flashingHub locking procedure error
Defective VSV2
Defective vacuum switch
Defective check valve or vacuum tank
Air leak from vacuum circuit
Clogged vacuum hose or pipe
Faulty 4WD controllerShift transfer shift control lever
2WD → 4WD once again
Replace
Replace
Replace
Check and repair
Replace
Check and replace
2WD/4WD switching
errorDefective air locking hub assembly
Abnormality in 4WD control system
Air leakage from vacuum circuit
Clogged vacuum hose or pipe
Defective check valve or vacuum tankReplace
Inspect referring to “4WD Control
System Diagnostic Flow Table”
Check and replace
Replace
Replace
Step Action Yes No
1 Check ground circuit.
1) Disconnect coupler from 4WD controller
with ignition switch OFF.
2) Check for proper connection to 4WD con-
troller at all terminals.
3) If OK, check continuity between A5 terminal
and body ground.
Is there continuity between A5 terminal and
body ground?Go to Step 2.“B” wire is open.
2 Check power circuit.
1) Disconnect coupler from 4WD controller.
2) Turn ignition switch ON.
3) Check voltage between A10 terminal and
ground.
Is it 10 – 14 V?Go to Step 3.“Y/R” circuit is open or
short.

Downloaded from www.Manualslib.com manuals search engine ANTILOCK BRAKE SYSTEM (ABS) 5E-11
Diagnostic Trouble Code (DTC) Table
DTC
(displayed on
SUZUKI scan
tool)DTC
(indicated by
ABS warn-
ing lamp)ABS warning light flashing
patternDIAGNOSTIC ITEMS
–12 Normal
C1015 15 G sensor circuit (for 4WD model only)
C1016 16 Stop lamp switch circuit
C1021 21 RF
Wheel speed sensor circuit and/or sen-
sor ring C1025 25 LF
C1031 31 RR
C1035 35 LR
C1022 22 RF
C1026 26 LF
C1032 32 RR
C1036 36 LR
C1041 41
RFHold solenoid valve circuit
C1042 42 Release solenoid valve circuit
C1045 45
LFHold solenoid valve circuit
C1046 46 Release solenoid valve circuit
C1055 55
RearHold solenoid valve circuit
C1056 56 Release solenoid valve circuit

Downloaded from www.Manualslib.com manuals search engine 5E-12 ANTILOCK BRAKE SYSTEM (ABS)
System Circuit
C1057 57 Power source
C1061 61 ABS pump motor circuit
C1063 63 ABS solenoid valve circuit
C1071 71 ABS control module
1. Battery 5-5. Solenoid valves 14. Stop lamp switch
2. Main fuses 6. Combination meter 15. ECM
3. Ignition switch 7. Right rear wheel speed sensor 16. G sensor
4. Circuit fuses 8. Left rear wheel speed sensor 17. 4WD switch (for 4WD model only)
5. ABS hydraulic unit / control module assem-
bly9. Right front wheel speed sensor 18. 4WD indicator lamp (for 4WD model only)
5-1. Terminal arrangement for ABS hydraulic unit
/ control module assembly10. Left front wheel speed sensor 19. 4WD controller (for 4WD model only)
5-2. ABS fail-safe transistor 11. Data link connector 20.“ABS” warning lamp
5-3. ABS pump motor transistor 12. Monitor connector 21. ABS lamp driver module
5-4. Pump motor 13. Stop lamp
DTC
(displayed on
SUZUKI scan
tool)DTC
(indicated by
ABS warn-
ing lamp)ABS warning light flashing
patternDIAGNOSTIC ITEMS

Downloaded from www.Manualslib.com manuals search engine 6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Diagnostic trouble code (DTC) table ......... 6-16
Fail-safe table............................................ 6-19
Visual inspection ....................................... 6-20
Engine basic inspection ............................ 6-21
Engine diagnosis table .............................. 6-23
Scan Tool Data ............................................. 6-28
Scan tool data definitions .......................... 6-30
Inspection of ECM and Its Circuits ................ 6-33
Component Location ..................................... 6-42
Table A-1 Malfunction Indicator Lamp Circuit
Check - Lamp Does Not Come “ON” at Ignition
Switch ON (But Engine at Stop).................... 6-43
Table A-2 Malfunction Indicator Lamp Circuit
Check - Lamp Remains “ON” after Engine
Starts............................................................. 6-44
Table A-3 Malfunction Indicator Lamp Circuit
Check - Mil Flashes at Ignition Switch ON .... 6-45
Table A-4 Malfunction Indicator Lamp Circuit
Check - MIL Does Not Flash, Just Remains
ON or Just Remains OFF Even with Grounding
Diagnosis Switch Terminal............................ 6-45
Table A-5 ECM Power and Ground Circuit
Check - MIL Doesn’t Light at Ignition Switch
ON and Engine Doesn’t Start Though It Is
Cranked Up ................................................... 6-46
DTC P0105 (DTC No.11) Manifold Absolute
Pressure (MAP) Circuit Malfunction .............. 6-48
DTC P0110 (DTC No.18) Intake Air Temp.
(IAT) Circuit Malfunction ............................... 6-51
DTC P0115 (DTC No.19) Engine Coolant
Temperature (ECT) Circuit Malfunction ........ 6-53
DTC P0120 (DTC No.13) Throttle Position
Circuit Malfunction ........................................ 6-55
DTC P0121 Throttle Position Circuit Range /
Performance Problem ................................... 6-57
DTC P0130 (DTC No.14) Heated Oxygen
Sensor (HO2S) Circuit Malfunction
(Sensor-1) ..................................................... 6-59
DTC P0133 Heated Oxygen Sensor (HO2S)
Circuit Slow Response (Sensor-1) ................ 6-61
DTC P0135 (DTC No.14) Heated Oxygen
Sensor (HO2S) Heater Circuit Malfunction
(Sensor-1) ..................................................... 6-62
DTC P0136 Heated Oxygen Sensor (HO2S)
Circuit Malfunction (Sensor-2) ...................... 6-64
DTC P0141 Heated Oxygen Sensor (HO2S)
Heater Circuit Malfunction (Sensor-2)........... 6-66
DTC P0171 Fuel System Too Lean .............. 6-68
DTC P0172 Fuel System Too Rich ............... 6-68
DTC P0300 Random Misfire Detected
(Misfire Detected at 2 or More Cylinders) ..... 6-72DTC P0301 Cylinder 1 Misfire Detected ........ 6-72
DTC P0302 Cylinder 2 Misfire Detected ........ 6-72
DTC P0303 Cylinder 3 Misfire Detected ........ 6-72
DTC P0304 Cylinder 4 Misfire Detected ........ 6-72
DTC P0325 (DTC No.17) Knock Sensor Circuit
Malfunction .................................................... 6-77
DTC P0335 (DTC No.23) Crankshaft Position
(CKP) Sensor Circuit Malfunction .................. 6-79
DTC P0340 (DTC No.15) Camshaft Position
(CMP) Sensor Circuit Malfunction ................. 6-82
DTC P0400 Exhaust Gas Recirculation Flow
Malfunction .................................................... 6-85
DTC P0420 Catalyst System Efficiency below
Threshold ....................................................... 6-88
DTC P0443 Purge Control Valve Circuit
Malfunction .................................................... 6-91
DTC P0481 A/C Condenser Fan Control
Circuit Malfunction ......................................... 6-92
DTC P0500 (DTC No.16) Vehicle Speed
Sensor (VSS) Malfunction ............................. 6-94
DTC P0505 Idle Control System
Malfunction .................................................... 6-96
DTC P0601 Internal Control Module Memory
Check Sum Error (DTC No.71) ...................... 6-98
DTC P1450 Barometric Pressure Sensor
Low / High Input ............................................. 6-99
DTC P1451 Barometric Pressure Sensor
Performance Problem .................................... 6-99
DTC P1500 Engine Starter Signal Circuit
Malfunction .................................................. 6-101
DTC P1510 ECM Back-up Power Supply
Malfunction .................................................. 6-103
DTC P1570 (DTC No.21) ABS Signal Circuit
Malfunction .................................................. 6-104
DTC P1600 Serial Communication Problem
Between ECM and TCM .............................. 6-105
DTC P1717 A/T Drive Range (Park / Neutral
Position) Signal Circuit Malfunction ............. 6-107
Table B-1 Fuel Injector Circuit Check ..........6-109
Table B-2 Fuel Pump and Its Circuit
Check........................................................... 6-110
Table B-3 Fuel Pressure Check................... 6-112
Table B-4 Idle Air Control System Check ....6-114
Table B-5 A/C Signal Circuits Check
(Vehicle with A/C) ........................................ 6-117
Table B-6 Electric Load Signal Circuit
Check........................................................... 6-119
TAble B-7 A/C Condenser Fan Control
System Check.............................................. 6-121
Special Tool ................................................... 6-123

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-23
[D] Fig. 4 for Step 7 or 8 / [E] Fig. 5 for Step 10 / [F] Fig. 6 for Step 13
Engine diagnosis table
Perform troubleshooting referring to following table when ECM has no DTC and no abnormality found in visual
inspection and engine basic inspection previously.
Condition Possible Cause Reference Item
Hard Starting
(Engine cranks OK)Faulty ignition coil Ignition coil assembly in Section 6F.
Faulty CMP sensing rotor or CKP sensing
rotorCMP sensing rotor or CKP sensing
rotor inspection in Section 6E.
Faulty idle air control system Diagnostic Flow Table B-4
Faulty ECT sensor, TP sensor, CKP sen-
sor, CMP sensor or MAP sensorECT sensor, TP sensor, CKP sensor,
CMP sensor or MAP sensor in Sec-
tion 6E.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty fuel injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning PCV system PCV system in Section 6E.
Low compression Compression check in Section 6A1.
Improper valve lash Valve lash in Section 6A1.
Improper valve timing Timing chain and chain tensioner in
Section 6A1.
Compression leak from valve seat Valves and cylinder head in Section
6A1.
Sticky valve stem Valves and cylinder head in Section
6A1.
Weak or damaged valve springs Valves and cylinder head in Section
6A1.
Compression leak at cylinder head gasket Valves and cylinder head in Section
6A1.
Sticking or damaged piston ring Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn piston, ring or cylinder Pistons, piston rings, connecting rods
and cylinders in Section 6A1.

Downloaded from www.Manualslib.com manuals search engine 6-26 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Excessive engine oil
consumptionSticky piston ring Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn piston and cylinder Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn piston ring groove and ring Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Improper location of piston ring gap Pistons, piston rings, connecting rods
and cylinders in Section 6A1.
Worn or damaged valve stem seal Valves and cylinder head in Section
6A1.
Worn valve stem Valves and cylinder head in Section
6A1.
Low oil pressure
Improper oil viscosity ITEM1-3 Engine oil and oil filter
change in Section 0B.
Malfunctioning oil pressure switch Oil pressure switch in Section 8.
Clogged oil strainer Oil pan and oil pump strainer in Sec-
tion 6A1.
Functional deterioration of oil pump Oil pump in Section 6A1.
Worn oil pump relief valve Oil pump in Section 6A1.
Excessive clearance in various sliding
partsRefer to Section 6A1.
Engine noise
See NOTE below.Improper valve lash Valve lash in Section 6A1.
Worn valve stem and guide Valves and cylinder head in Section
6A1.
Weak or broken valve spring Valve springs in Section 6A1.
Warped or bent valve Valves and cylinder head in Section
6A1.
Loose camshaft housing bolts Camshaft in Section 6A1.
Worn piston, ring and cylinder bore Pistons and cylinders in Section 6A1.
Worn crankpin bearing Crankpin and connecting rod bearing
in Section 6A1.
Worn crankpin Crankpin and connecting rod bearing
in Section 6A1.
Loose connecting rod nuts Connecting rod in Section 6A1.
Low oil pressure Previously outlined.
Worn crankshaft journal bearing Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Worn crankshaft journal Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Loose lower crankcase (bearing cap) bolts Main bearings, Crankshaft and cylin-
der block in Section 6A1.
Excessive crankshaft thrust play Main bearings, Crankshaft and cylin-
der block in Section 6A1. Condition Possible Cause Reference Item
NOTE:
Before checking the mechanical noise, make sure that :
Ignition timing is properly adjusted.
Specified spark plug is used.
Specified fuel is used.