catalytic converter SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-1
0A
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 0A
GENERAL INFORMATION
CONTENTS
How to Use This Manual .................................0A-2
Precautions......................................................0A-3
Precaution for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System ..... 0A-3
Diagnosis................................................... 0A-3
Servicing and handling .............................. 0A-4
General Precautions ..................................... 0A-7
Precautions For Catalytic Converter ........... 0A-10
Precautions For Electrical Circuit Service ... 0A-10
Electrical Circuit Inspection Procedure........ 0A-13
Open circuit check ................................... 0A-13
Short circuit check (wire harness to
ground) .................................................... 0A-15
Intermittent and Poor Connection ............... 0A-15
Precaution For Installing Mobile
Communication Equipment ......................... 0A-16Identification Information ............................. 0A-17
Body Number .............................................. 0A-17
Engine Identification Number ...................... 0A-17
Transmission Identification Number............ 0A-17
Warning, Caution and Information
Labels............................................................. 0A-18
Vehicle Lifting Points ................................... 0A-19
When Using Frame Contact Hoist .............. 0A-19
When Using Floor Jack ............................... 0A-20
Abbreviations May Be Used In This
Manual............................................................ 0A-21
Abbreviations .............................................. 0A-21
Fasteners Information .................................. 0A-24
Metric Fasteners ......................................... 0A-24
Fastener Strength Identification .................. 0A-24
Standard Tightening Torque ....................... 0A-24

Downloaded from www.Manualslib.com manuals search engine 0A-10 GENERAL INFORMATION
Precautions For Catalytic Converter
For vehicles equipped with a catalytic converter, use only unleaded gasoline and be careful not to let a
large amount of unburned gasoline enter the converter or it can be damaged.
 Conduct a spark jump test only when necessary, make it as short as possible, and do not open the
throttle.
 Conduct engine compression checks within the shortest possible time.
 Avoid situations which can result in engine misfire (e.g. starting the engine when the fuel tank is
nearly empty.)
Precautions For Electrical Circuit Service
 When replacing a fuse, make sure to use a fuse of the
specified capacity. Use of a fuse with a larger capacity
will cause a damage to the electrical parts and a fire.
 When disconnecting and connecting coupler, make sure
to turn ignition switch OFF, or electronic parts may get
damaged.
 When disconnecting connectors, never pull the wiring
harnesses. Unlock the connector lock first and then pull
them apart by holding connectors themselves.

Downloaded from www.Manualslib.com manuals search engine 0A-22 GENERAL INFORMATION
LLH
LSPVLeft Hand
Load Sensing Proportioning Valve
TTBI
TCC
TCM
TP Sensor
TVV
TWC
2WDThrottle Body Fuel Injection
(Single-Point Fuel Injection, SPI)
Torque Converter Clutch
Transmission Control Module
(A/T Controller, A/T Control Mod-
ule)
Throttle Position Sensor
Thermal Vacuum Valve
(Thermal Vacuum Switching Valve,
TVSV, Bimetal Vacuum Switching
Valve, BVSV)
Three Way Catalytic Converter
(Three Way Catalyst)
2 Wheel Drive MMAF Sensor
MAP Sensor
Max
MFI
Min
MIL
M/TMass Air Flow Sensor
(Air Flow Sensor, AFS, Air Flow
Meter, AFM)
Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Maximum
Multiport Fuel Injection
(Multipoint Fuel Injection)
Minimum
Malfunction Indicator Lamp
(“CHECK ENGINE” Light)
Manual Transmission
N NOx Nitrogen Oxides VVIN
VSSVehicle Identification Number
Vehicle Speed Sensor
OOBD
O/D
OHCOn-Board Diagnostic System
(Self-Diagnosis Function)
Overdrive
Over Head CamshaftWWU-OC
WU-TWCWarm Up Oxidation Catalytic
Converter
Warm Up Three Way Catalytic
Converter
PPNP
P/S
PSP Switch
PCM
PCVPark/Neutral Position
Power Steering
Power Steering Pressure Switch
(P/S Pressure Switch)
Powertrain Control Module
Positive Crankcase Ventilation
R RH Right Hand
SSAE
SDM
SFI
SOHCSociety of Automotive Engineers
Sensing and Diagnostic Module
(Air bag controller, Air bag control
module)
Sequential Multiport Fuel Injection
Single Over Head Camshaft

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 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-27
Condition Possible Cause Reference Item
Excessive hydrocar-
bon (HC) emission or
Excessive carbon mon-
oxide (CO) emissionFaulty ignition coil Ignition coil assembly in Section 6F.
Fuel pressure out of specification Diagnostic Flow Table B-3
Lead contamination of three way catalytic
converterMaintenance in Section 6K.
Malfunctioning PCV system PCV system in Section 6E.
Faulty EVAP control system EVAP control system in Section 6E.
Closed loop system (A/F feed back com-
pensation) fails
–Faulty TP sensor
–Faulty ECT sensor or MAP sensor
–Faulty oxygen sensorCheck oxygen sensor output voltage.
Refer to DTC P0130 (No.14) Table in
this section.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Low compression Previously outlined.
Excessive nitrogen
oxides (NOx) emissionFuel pressure out of specification Diagnostic Flow Table B-3
Lead contamination of three way catalytic
converterMaintenance in Section 6K.
Closed loop system (A/F feed back com-
pensation) fails
–Faulty TP sensor
–Faulty ECT sensor or MAP sensor
–Faulty oxygen sensorCheck oxygen sensor output voltage
Refer to DTC P0130 (No.14) Table in
this section.
Faulty injector Diagnostic Flow Table B-1
Faulty ECM Inspection of ECM and its circuit in
this section.
Faulty EGR system (if equipped) EGR system in Section 6E.

Downloaded from www.Manualslib.com manuals search engine 6-72 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders)
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
CIRCUIT DESCRIPTION
ECM monitors crankshaft revolution speed and engine speed via the crankshaft position sensor and cylinder No.
via the camshaft position sensor. Then it calculates the change in the crankshaft revolution speed and from how
many times such change occurred in every 200 or 1000 engine revolutions, it detects occurrence of misfire.
When ECM detects a misfire (misfire rate per 200 revolutions) which can cause overheat and damage to the
three way catalytic converter, it makes the malfunction indicator lamp (MIL) flash as long as misfire occurs at
that rate.
After that, however, when the misfire rate drops, MIL remains ON until it has been judged as normal 3 times
under the same driving conditions.
Also, when ECM detects a misfire (misfire rate per 1000 revolutions) which will not cause damage to three way
catalytic converter but can cause exhaust emission to be deteriorated, it makes MIL light according to the 2 driv-
ing cycle detection logic.
1. Ignition coil assembly (for No.1 and No.4 cylinder)
2. Ignition coil assembly (for No.2 and No.3 cylinder)
3. Fuel injector
4. CKP sensor
5. CMP sensor

Downloaded from www.Manualslib.com manuals search engine 6-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0420 Catalyst System Efficiency below Threshold
CIRCUIT DESCRIPTION
ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by
HO2S-2.
When the catalyst is functioning properly, the variation cycle of HO2S-2 output voltage (oxygen concentration) is
slower than that of HO2S-1 output voltage because of the amount of oxygen in the exhaust gas which has been
stored in the catalyst.
REFERENCE
1. Heated oxygen sensor-1 3. Three way catalytic converter 5. To the sensor [B] : Case of TYPE B is shown
(See NOTE)
2. Warm up three way catalytic
converter4. Heated oxygen sensor-2 [A] : Case of TYPE A is shown
(See NOTE)
NOTE:
For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable
model.
1. Engine running at closed loop
condition2. Fuel cut 3. Idle after fuel cut [A] : Oscilloscope waveforms

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-89
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 – 110 °C, 158 – 230 °F
2) Start engine and drive vehicle at 35 – 45 mph, 55 – 65 km/h for 8 min. or longer.
While this driving, if “Catalyst Monitoring TEST COMPLETED” is displayed in “READINESS TESTS” mode
and DTC is not displayed in “DTC” mode, confirmation test is completed.
If “TEST NOT COMPLTD” is still being displayed, continue test driving.
3) Decrease vehicle speed at 30 – 40 mph, 50 – 60 km/h, and hold throttle valve at that opening position for 2
min. and confirm that short term fuel trim vary within – 20% – +20% range.
4) Stop vehicle (do not turn ignition switch OFF) and confirm test results according to following “Test Result
Confirmation Flow Table”. DTC DETECTING CONDITION POSSIBLE CAUSE
While vehicle running at constant speed under other than
high load.
Time from rich or lean switching command is output till HO2S-
2 output voltage crosses 0.45 V less than specified value.
✱
✱✱ ✱2 driving cycle detection logic, monitoring once / 1 driving.Exhaust gas leak
Three way catalytic converter malfunction
Fuel system malfunction
HO2S-2 malfunction
HO2S-1 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.

Downloaded from www.Manualslib.com manuals search engine ENGINE FUEL 6C-1
6F1
7A
7A1
7A
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
6G
6C
6K
9
10
10A
10B
SECTION 6C
ENGINE FUEL
CONTENTS
General Description ....................................... 6C-2
Fuel System ................................................. 6C-2
Fuel Tank ..................................................... 6C-2
Fuel Pump Assembly ................................... 6C-3
Fuel Filler Cap .............................................. 6C-3
On-Vehicle Service......................................... 6C-4Fuel Lines .................................................... 6C-4
Fuel Filler Cap.............................................. 6C-4
Fuel Tank ..................................................... 6C-4
Fuel Pump Assembly ................................... 6C-7
Tightening Torque Specification ................ 6C-10
Special Tool .................................................. 6C-10

CAUTION:
For vehicles with a catalytic converter, be sure to use unleaded fuel only. Use of leaded and/or low
lead fuel can result in engine damage and reduce the effectiveness of the emission control system.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-1
6F1
6F2
6G
7C1
7D
7E
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
6H
6E
10
10A
10B
SECTION 6E
ENGINE AND EMISSION CONTROL SYSTEM
CONTENTS
General Description ....................................... 6E-3
Air Intake System ......................................... 6E-5
Fuel Delivery System ................................... 6E-6
Fuel pump ................................................ 6E-6
Electronic Control System ............................ 6E-7
Engine & emission control input / output
table.......................................................... 6E-8
On-Vehicle Service....................................... 6E-15
Accelerator cable adjustment ................. 6E-15
Idle speed / idle air control (IAC) duty
inspection ............................................... 6E-15
Idle mixture inspection / adjustment
(vehicle without heated oxygen
sensor) ................................................... 6E-17
Air Intake System ....................................... 6E-18
Throttle body .......................................... 6E-18
Idle air control valve (IAC valve)............. 6E-21
Fuel Delivery System ................................. 6E-22
Fuel pressure inspection ........................ 6E-22
Fuel pump .............................................. 6E-23
Fuel pressure regulator .......................... 6E-24
Fuel injector ............................................ 6E-25
Electronic Control System .......................... 6E-29Engine control module (ECM) ................ 6E-29
Manifold absolute pressure sensor (MAP
sensor) ................................................... 6E-29
Throttle position sensor (TP sensor) ...... 6E-30
Intake air temperature sensor
(IAT sensor) ........................................... 6E-31
Engine coolant temperature sensor
(ECT sensor) .......................................... 6E-32
Heated oxygen sensor
(Sensor-1 and sensor-2) ........................ 6E-33
Camshaft position sensor....................... 6E-34
Crankshaft position sensor..................... 6E-35
Vehicle speed sensor (VSS) .................. 6E-36
Fuel level sensor (GAUGE).................... 6E-36
Knock sensor ......................................... 6E-36
Main relay, fuel pump relay and A/C
condenser fan control relay .................... 6E-36
Fuel cut operation .................................. 6E-37
A/C condenser fan control system ......... 6E-37
A/C condenser fan ................................. 6E-37
Output signals of throttle valve opening
and engine coolant temp.
(Vehicle with A/T only) ........................... 6E-38
Emission Control System ........................... 6E-38 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 following systems (parts) are used in the particular vehicle or not depends on 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)