drive train SUZUKI JIMNY 2005 3.G Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine IMPORTANT
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION
and NOTE
have special meanings. Pay special attention to the messages highlighted by
these signal words.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a Supplemental Restraint or 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.
 If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
 Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. Modifications can adversely affect air bag system
performance and lead to injury.
 If the vehicle will be exposed to temperatures over 93°C (200°F), for example, during a paint baking
process, remove the air bag system components, that is air bag or inflator modules, SDM and/or
seat belt with pretensioner, beforehand to avoid component damage or unintended activation.

Downloaded from www.Manualslib.com manuals search engine TABLE OF CONTENTS
GENERAL INFORMATIONGeneral Information0A0A
Maintenance and Lubrication0B
0B
HEATING AND AIR CONDITIONINGHeater and Ventilation1A
1A
Air Conditioning (Optional)1B
1B
STEERING, SUSPENSION, WHEELS AND
TIRESSteering, Suspension, Wheels and Tires3
3
Front Wheel Alignment3A
3A
Steering Gear Box (Manual Type) and Linkage3B
3B
Power Steering (P/S) System (if equipped)3B1
3B1
Steering Wheel and Column3C
3C
Front Suspension3D
3D
Rear Suspension3E
3E
Wheels and Tires3F
3F
DRIVE SHAFT AND PROPELLER SHAFT
Propeller Shafts4B
4B
BRAKE SYSTEMBrakes5
5
Antilock Brake System (ABS)5E
5E
ENGINEEngine General Information and Diagnosis6
6
Engine Mechanical (M13 Engine)6A1
6A1
Engine Cooling6B
6B
Engine Fuel6C
6C
Engine and Emission Control System6E
6E
Ignition System (Electronic Ignition System)6F
6F
Cranking System6G
6G
Charging System6H
6H
Exhaust System6K
6K
TRANSMISSION, CLUTCH AND
DIFFERENTIALManual Transmission7A
7A
Automatic Transmission (4 A/T)7B
7B
Clutch7C
7C
Transfer7D
7D
Front Differential7E
7E
Rear Differential7F
7F
ELECTRICAL SYSTEMBody Electrical System8
8
Immobilizer Control System (if equipped)8G
8G
BODY SERVICE9
9
RESTRAINT SYSTEMRestraint System10
10
Air Bag System10B
10B

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-3
Precautions
Precaution for Vehicles Equipped with a Sup-
plemental Restraint (Air Bag) System
Diagnosis
 When troubleshooting air bag system, be sure to follow “Air
Bag Diagnostic System Check” in Section 10B. Bypassing
these procedures may result in extended diagnostic time,
incorrect diagnosis, and incorrect parts replacement.
 Never use electrical test equipment other than that specified
in this manual. WARNING:
 The configuration of air bag system parts are as shown
in the figure. When it is necessary to service (remove,
reinstall and inspect) these parts, be sure to follow
procedures described in Section 10B. Failure to follow
proper procedures could result in possible air bag sys-
tem activation, personal injury, damage to parts or air
bag system being unable to activate when necessary.
 If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag sys-
tem be repaired first, to help avoid unintended air bag
system activation.
 Do not modify the steering wheel, dashboard, or any
other air bag system components. Modifications can
adversely affect air bag system performance and lead
to injury.
 If the vehicle will be exposed to temperatures over
93°C (200°F) (for example, during a paint baking pro-
cess), remove the air bag system components before-
hand to avoid component damage or unintended air
bag system activation.
1. Air bag wire harness (in instrument panel
wire harness and floor wire harness)5. Contact coil
2. Passenger air bag (inflator) module 6. Driver air bag (inflator) module
3. SDM 7. Seat belt pretensioner (if equipped)
4. DLC
WARNING:
Never attempt to measure the resistance of the air bag
(inflator) modules (driver and passenger) and seat belt
pretensioners (driver and passenger). It is very danger-
ous as the electric current from the tester may deploy the
air bag or activate the pretensioner.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-21
Abbreviations May Be Used In This Manual
Abbreviations
AABC
ATDC
API
ATF
ALR
AC
A/T
A/C
ABDC
A/F
A-ELRAnti-lock Brake System
After Top Dead Center
American Petroleum Institute
Automatic Transmission Fluid
Automatic Locking Retractor
Alternating Current
Automatic Transmission
Air Conditioning
After Bottom Dead Center
Air Fuel Mixture Ratio
Automatic-Emergency
Locking RetractorEEBCM
ECM
ECT Sensor
EGR
EGRT Sensor
EFE Heater
ELR
EPS
EVAP
EVAP CanisterElectronic Brake Control Module,
ABS Control Module
Engine Control Module
Engine Coolant Temperature
Sensor (Water Temp. Sensor,
WTS)
Exhaust Gas Recirculation
EGR Temperature Sensor
(Recirculated Exhaust Gas Temp.
Sensor, REGTS)
Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
Emergency Locking Retractor
Electronic Power Steering
Evaporative Emission
Evaporative Emission Canister
(Charcoal Canister) BB+
BTDC
BBDCBattery Positive Voltage
Before Top Dead Center
Before Bottom Dead Center
CCKT
CMP Sensor
CO
CPP Switch
CPU
CRSCircuit
Camshaft Position Sensor
(Crank Angle Sensor, CAS)
Carbon Monoxide
Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
Central Processing Unit
Child Restraint SystemF 4WD 4 Wheel Drive
GGEN
GNDGenerator
Ground
HHC
HO2SHydrocarbons
Heated Oxygen Sensor
DDC
DLC
DOHC
DOJ
DRL
DTCDirect Current
Data Link Connector
(Assembly Line Diag. Link, ALDL,
Serial Data Link, SDL)
Double Over Head Camshaft
Double Offset Joint
Daytime Running Light
Diagnostic Trouble Code
(Diagnostic Code)IIAC Valve
IAT Sensor
ICM
IG
ISC ActuatorIdle Air Control Valve (Idle Speed
Control Solenoid Valve, ISC
Solenoid Valve)
Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
Immobilizer Control Module
Ignition
Idle Speed Control Actuator
(Motor)

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 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 AIR CONDITIONING (OPTIONAL) 1B-1
6F1
6F2
1B
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 1B
AIR CONDITIONING (OPTIONAL)
CONTENTS
General Description ....................................... 1B-3
Major Components and Location ................. 1B-3
Refrigerant Circulation ................................. 1B-4
Refrigerant Type .......................................... 1B-4
Diagnosis ........................................................ 1B-5
General Diagnosis Table .............................. 1B-5
Abnormal Noise Diagnosis ........................... 1B-7
Abnormal noise from compressor ............ 1B-7
Abnormal noise from magnetic clutch ...... 1B-7
Abnormal noise from tubing ..................... 1B-7
Abnormal noise from condenser .............. 1B-7
Abnormal noise from crankshaft pulley .... 1B-8
Abnormal noise from tension pulley ......... 1B-8
Abnormal noise from A/C evaporator ....... 1B-8
Abnormal noise from blower fan motor .... 1B-8
Quick Checking of Refrigerant Charge......... 1B-9Performance Diagnosis.............................. 1B-10
Performance diagnosis table.................. 1B-12
Detail diagnosis table (Ambient
temperature at 30°C (86°F)) .................. 1B-13
Compressor Drive Belt ............................... 1B-15
Electronical Diagnosis ................................ 1B-16
Wiring Diagram .......................................... 1B-16
A/C System Inspection of ECM and ITS
Circuits ....................................................... 1B-17
Refrigerant Recovery, Evacuating and
Charging ....................................................... 1B-21
Operation Procedure for Refrigerant
Charging .................................................... 1B-21
Recovery .................................................... 1B-22
Replenishing Compressor Oil .................... 1B-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).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to “Refrigerant Type” in this section.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
NOTE:
For basic servicing method of the air conditioning system that is not described in this section, refer to
AIR CONDITIONING BASIC MANUAL (Part number: 99520-02130).

Downloaded from www.Manualslib.com manuals search engine STEERING WHEEL AND COLUMN 3C-1
6F1
6F2
6G
6H
6K
7A
3C
7E
7F
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 3C
STEERING WHEEL AND COLUMN
CONTENTS
General Description ....................................... 3C-2
Diagnosis ........................................................ 3C-3
Inspection and Repair Required
After Accident ............................................... 3C-3
On-Vehicle Service......................................... 3C-3
Service Precautions (For Vehicle with
Air Bag System) ........................................... 3C-3
Diagnosis and servicing ........................... 3C-3
Disabling air bag system .......................... 3C-3
Enabling air bag system ........................... 3C-3
Handling and storage ............................... 3C-3
Disposal.................................................... 3C-3
Drive Air Bag (Inflator) Module (For Vehicle
with Air Bag System) .................................... 3C-4
Steering Wheel ............................................. 3C-5Centering contact coil (for vehicle with
air bag system)......................................... 3C-8
Combination Switch (For Vehicle without
Air Bag System)/Contact Coil and
Combination Switch Assembly (For Vehicle
with Air Bag System).................................... 3C-9
Steering Column Assembly........................ 3C-11
Steering Lock Assembly
(Ignition Switch) ......................................... 3C-15
Steering Lower Shaft ................................. 3C-16
Checking Steering Column for Accident
Damage ......................................................... 3C-18
Tightening Torque Specifications .............. 3C-19
Required Service Material ........................... 3C-19
Special Tool .................................................. 3C-19

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. Please observe all WARNINGS and “Service Precautions” under “On-
Vehicle Service” in air bag system section before performing service on or around the air bag sys-
tem 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.
The procedures in this section must be followed in the order listed to temporarily disable the air
bag system and prevent false diagnostic codes from setting. Failure to follow procedures could
result in possible air bag system activation, personal injury or otherwise unneeded air bag system
repairs.
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application.
If the correct part number fastener is not available, a fastener of equal size and strength (or stronger)
may be used. Fasteners that are not reused, and those requiring thread-locking compound, will be
called out. The correct torque value must be used when installing fasteners that require it. If the above
procedures are not followed, parts or system damage could result.

Downloaded from www.Manualslib.com manuals search engine 3C-2 STEERING WHEEL AND COLUMN
General Description
This double tube type steering column has the following three important features in addition to the steering func-
tion:
The column is energy absorbing, designed to compress in a front-end collision.
The ignition switch and lock are mounted conveniently on this column.
With the column mounted lock, the ignition and steering operations can be locked to inhibit theft of the vehi-
cle.
To insure the energy absorbing action, it is important that only the specified screws, bolts and nuts be used as
designated and that they are tightened to the specified torque.
When the column assembly is removed from the vehicle, special care must be taken in handling it. Use of a
steering wheel puller other than the one recommended in this manual or a sharp blow on the end of the steering
shaft, leaning on the assembly, or dropping the assembly could shear the plastic shear pins which maintain col-
umn length and position.
The driver air bag (inflator) module is one of the supplemental restraint (air bag) system components and is
mounted to the center of the steering wheel. During certain frontal crashes, the air bag system supplements the
restraint of the driver’s and passenger’s seat belts by deploying the air bags.
The air bag (inflator) module should be handled with care to prevent accidental deployment. When servicing, be
sure to observe all WARNINGS and CAUTIONS in this section and “Service Precautions” in Section 10B.
1. Driver air bag (inflator) module 6. Steering column upper cover 11. Steering lower shaft
2. Steering wheel 7. Steering column lower cover [A] : For vehicle with air bag system
3. Steering wheel side cap 8. Steering column assembly [B] : For vehicle without air bag system
4. Steering wheel nut 9. Steering lock assembly (ignition switch)
5. Combination switch or contact coil and com-
bination switch assembly10. Steering column hole cover

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-25
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