compression SUZUKI JIMNY 2005 3.G Service Workshop Manual

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.

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Charging
Charging procedure
The initial charging of the A/C system is performed from the high
pressure side with the engine stopped.
And next, this method must be followed by charging from the low
pressure side with the engine running.
1) Check to make sure that hoses are routed properly after
evacuating the system. CAUTION:
 Always charge through low pressure side of A/C sys-
tem at after the initial charging is performed from the
high pressure side with the engine stopped.
 Never charge to high pressure side of A/C system with
engine running.
 Do not charge while compressor is hot.
 When installing tap valve to refrigerant container to
make a hole there through, carefully follow directions
given by manufacturer.
 A pressure gauge should always be used before and
during charging.
 The refrigerant container should be emptied of refrig-
erant when discarding it.
 The refrigerant container should not be heated up to
40 °C (104 °F) or over.
 Refrigerant container should not be reversed in direc-
tion during charging. Reversing in direction causes liq-
uid refrigerant to enter compressor, causing troubles,
such as compression of liquid refrigerant and the like.
NOTE:
The air conditioning system contains HFC-134a (R-134a).
Described here is a method to charge the air conditioning
system with refrigerant from the refrigerant service con-
tainer.
When charging refrigerant recovered by using the refrig-
erant and recycling equipment (when recycling refriger-
ant), follow the procedure described in the equipment
manufacturer’s instruction manual.

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.

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Engine has no power
Engine overheating Refer to “Overheating” of this table.
Faulty ignition coil Ignition coil assembly in Section 6F.
Faulty knock sensor Knock sensor malfunction in this sec-
tion.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty injector Diagnostic Flow Table B-1
Faulty TP sensor, ECT sensor or MAP
sensorTP sensor, ECT sensor or MAP sen-
sor in Section 6E.
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
Maladjusted accelerator cable play Accelerator cable adjustment in Sec-
tion 6E.
Low compression Previously outlined.
Dragging brakes Diagnosis table in Section 5.
Slipping clutch Diagnosis table in Section 7C.
Improper engine idling
or engine fails to idleFaulty ignition coil Ignition coil assembly in Section 6F.
Engine overheating Refer to “Overheating” of this table.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty idle air control system Diagnostic Flow Table B-4
Faulty evaporative emission control sys-
temEVAP control system in Section 6E.
Faulty injector Diagnostic Flow Table B-1
Faulty ECT sensor, TP sensor or MAP
sensorECT sensor, TP sensor or MAP sen-
sor in Section 6E.
Malfunctioning PCV system PCV system in Section 6F.
Faulty ECM Inspection of ECM and its circuit in
this section.
Faulty EGR system (if equipped) EGR system in Section 6E.
Low compression Previously outlined.
Engine hesitates
(Momentary lack of
response as the accel-
erator is depressed.
Can occur at all vehicle
speeds.
Usually most severe
when first trying to
make the vehicle move,
as from a stop sign.)Faulty ignition coil Ignition coil assembly in Section 6F.
Engine overheating Refer to “Overheating” of this table.
Fuel pressure out of specification Diagnostic Flow Table B-3
Faulty injector Diagnostic Flow Table B-1
Faulty TP sensor, ECT sensor or MAP
sensorTP sensor, ECT sensor or MAP sen-
sor in Section 6E.
Faulty ECM Inspection of ECM and its circuit in
this section.
Malfunctioning EGR valve (if equipped) EGR system in Section 6E.
Low compression Previously outlined.
Surges
(Engine power variation
under steady throttle or
cruise.
Feels like the vehicle
speeds up and down
with no change in the
accelerator pedal.)Faulty ignition coil or high-tension cord Ignition coil assembly or high-tension
cords in Section 6F.
Variable fuel pressure Diagnostic Flow Table B-3
Faulty MAP sensor MAP sensor 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. Condition Possible Cause Reference Item

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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 6-27
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 ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-73
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) 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. : – 10 – 110 °C, 14 – 230 °F
4) Start engine and keep it at idle for 2 min. or more.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6) If DTC is not detected at idle, consult usual driving based on information obtained in “Customer complaint
analysis” and “Freeze frame data check”.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
Engine under other than high revolution condition
Not on rough road
Engine speed changing rate (below specified value)
Manifold absolute pressure changing rate (below
specified value)
Throttle opening changing rate (below specified
value)
Misfire rate per 200 or 1000 engine revolutions (how
much and how often crankshaft revolution speed
changes) is higher than specified valueEngine overheating
Vacuum leaks (air inhaling) from air intake system
Ignition system malfunction (spark plug(s), high-
tension cord(s), ignition coil assembly)
Fuel pressure out of specification
Fuel injector malfunction (clogged or leakage)
Engine compression out of specification
Valve lash (clearance) out of specification
Manifold absolute pressure sensor malfunction
Engine coolant temp. sensor malfunction
PCV valve malfunction
EVAP control system malfunction
EGR system malfunction
NOTE:
Among different types of random misfire, if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2
simultaneously, it may not possible to reconfirm DTC by using the following DTC confirmation proce-
dure. When diagnosing the trouble of DTC P0300 (Random misfire detected) of the engine which is
apparently misfiring, even if DTC P0300 cannot be reconfirmed by using the following DTC confirma-
tion procedure, proceed to the following Diag. Flow Table.
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.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine
Diag. Flow Table”.
2 Is there DTC other than Fuel system (DTC P0171/
P0172) and misfire (DTC P0300 – P0304)?Go to applicable DTC
Diag. Flow Table.Go to Step 3.

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[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 3 / [C] Fig. 3 for Step 4 / [D] Fig. 4 for Step 5 / [E] Fig. 5 for Step 47 Check EVAP Canister Purge Valve for Closing.
1) Disconnect purge hose (1) from EVAP canister.
2) Place finger against the end of disconnected hose.
3) Check that vacuum is not felt there, when engine is
cool and running at idle. See Fig. 7.
Is vacuum felt?Check EVAP control
system
(See Section 6E).Go to Step 8.
8 Check manifold absolute pressure sensor for perfor-
mance (See step 4) DTC P0105 Diag. Flow Table).
Is it in good condition?Go to Step 9. Repair or replace.
9 Check engine coolant temp. sensor for performance
(See Section 6E).
Is it in good condition?Go to Step 10. Replace engine
coolant temp. sen-
sor.
10 Check parts or system which can cause engine rough
idle or poor performance.
Engine compression (See Section 6A1).
Valve lash (See Section 6A1).
Valve timing (Timing belt installation. See Section
6A1).
Are they in good condition?Check wire harness
and connection of
ECM ground, ignition
system and fuel injec-
tor for intermittent
open and short.Repair or replace. Step Action Yes No
CAUTION:
For iridium spark plugs, do not adjust air gap or clean.
3. Fuel delivery pipe
4. Fuel feed hose
3. Fuel pressure gauge & 3 way joint

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[A] Fig. 1 for Step 2 / [B] Fig. 2 for Step 3
Table 13 Check MAP Sensor
1) Remove MAP sensor from intake manifold
and connect vacuum pump gauge to MAP
sensor. See Fig. 2.
2) Connect scan tool to DLC and turn ignition
switch ON.
3) Check intake manifold absolute pressure
displayed on scan tool for specified value.
See Table 1.
Is check result satisfactory?Check air intake system
for air being drawn in and
engine compression.
If OK, then substitute a
known-good ECM and
recheck.Replace MAP sensor. Step Action Yes No
Applying Vacuum Displayed Value on Scan Tool
0 Barometric pressure
(Approx. 100 kPa, 760 mmHg)
027 kPa
200 mmHgBarometric pressure – 27 kPa
(Approx. 73 kPa, 560 mmHg)
67 kPa
500 mmHgBarometric pressure – 67 kPa
(Approx. 33 kPa, 260 mmHg)

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-1
6F1
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8C
6A1
8E
9
9
10B
SECTION 6A1
ENGINE MECHANICAL (M13 ENGINE)
CONTENTS
General Description ......................................6A1-2
Engine ......................................................... 6A1-2
Engine Lubrication ...................................... 6A1-3
Diagnosis .......................................................6A1-4
Diagnosis Table .......................................... 6A1-4
Compression Check .................................... 6A1-4
Engine Vacuum Check ................................ 6A1-6
Oil Pressure Check ..................................... 6A1-7
Valve Lash (Clearance) ............................... 6A1-9
On-Vehicle Service......................................6A1-13
Air Cleaner Element .................................. 6A1-13
Air Cleaner Assembly ................................ 6A1-14
Knock Sensor ............................................ 6A1-14
Cylinder Head Cover ................................. 6A1-15
Throttle Body and Intake Manifold ............ 6A1-18
Exhaust Manifold ....................................... 6A1-21Oil Pan and Oil Pump Strainer .................. 6A1-24
Timing Chain Cover .................................. 6A1-28
Oil Pump ................................................... 6A1-33
Timing Chain and Chain Tensioner .......... 6A1-37
Camshaft, Tappet and Shim ..................... 6A1-42
Valves and Cylinder Head ........................ 6A1-48
Pistons, Piston Rings, Connecting
Rods and Cylinders................................... 6A1-62
Engine Mountings ..................................... 6A1-72
Unit Repair Overhaul .................................. 6A1-73
Engine Assembly ...................................... 6A1-73
Main Bearings, Crankshaft and Cylinder
Block ......................................................... 6A1-79
Required Service Material .......................... 6A1-93
Tightening Torque Specification ............... 6A1-93
Special Tool ................................................. 6A1-94

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).