starter SUZUKI JIMNY 2005 3.G Service Workshop Manual

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 6-17
P0335
(No.23)Crankshaft position sensor
circuit malfunctionNo signal for 2 sec. During engine crank-
ing1 driving
cycle1 driving
cycle
P0340
(No.15)Camshaft position sensor
circuit malfunctionNo signal during engine running1 driving
cycle1 driving
cycle
P0400Exhaust gas recirculation
flow malfunction detectedExcessive or insufficient EGR flow2 driving
cyclesNot
applicable
P0420Catalyst system efficiency
below thresholdOutput waveforms of HO2S-1 and HO2S-2
are similar.
(Time from output voltage change of
HO2S-1 to that of HO2S-2 is shorter than
specification.)2 driving
cyclesNot
applicable
P0443Purge control valve circuit
malfunctionPurge control valve circuit is open or
shorted to ground2 driving
cyclesNot
applicable
P0481A/C condenser fan control
circuit malfunctionA/C condenser fan relay terminal voltage is
low when fan command is not outputted2 driving
cyclesNot
applicable
P0500
(No.16)Vehicle speed sensor mal-
functionNo signal while running in “D” range or
during fuel cut at decelerating2 driving
cycles1 driving
cycle
P0505 Idle control system malfunc-
tionNo closed signal to IAC valve is detected2 driving
cyclesNot
applicable
P0601
(No.71)Internal control module
memory check sum errorData write error (or check sum error) when
written into ECM2 driving
cyclesNot
applicable
P1450 Barometric pressure sen-
sor circuit malfunctionBarometric pressure is lower or higher
than specification. (or sensor malfunction)1 driving
cycleNot
applicable
P1451Barometric pressure sen-
sor performance problemDifference between manifold absolute
pressure (MAP sensor value) and baro-
metric pressure (barometric pressure sen-
sor value) is larger than specification
during cranking.2 driving
cyclesNot
applicable
P1500Starter signal circuit mal-
functionStarter signal is not inputted from engine
cranking till its start and after or it is always
inputted2 driving
cyclesNot
applicable
P1510ECM backup power source
malfunctionNo backup power after starting engine1 driving
cycleNot
applicable
P1600Serial communication prob-
lem between ECM and
TCMNo signal or check sum error while engine
running1 driving
cycleNot
applicable
P1717AT D-range signal circuit
malfunctionNo “D” range (park / neutral position sig-
nal) is inputted while vehicle running2 driving
cyclesNot
applicable
P1570ABS signal circuit malfunc-
tionABS signal ON (low voltage) when engine
startNot
applicable1 driving
cycle DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-101
DTC P1500 Engine Starter Signal Circuit Malfunction
CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON, crank engine and run it at idle for 3 min.
3) Check pending DTC in “ON BOARD TEST” or “PENDING DTC” mode and DTC in “DTC” mode.
1. Starter 3. Ignition switch (starter switch) [A] : Case of TYPE A is shown (See NOTE) [C] : M/T vehicle
2. Transmission range sensor (switch) 4. Main fuse [B] : Case of TYPE B is shown (See NOTE) [D] : A/T vehicle
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
Low voltage at terminal E17-13 or E18-20 when cranking
engine or
High voltage at terminal E17-13 or E18-20 after starting
engine.
✱
✱✱ ✱2 driving cycle detection logic, continuous monitoring.“B/Y” circuit open
ECM malfunction

Downloaded from www.Manualslib.com manuals search engine 6-102 ENGINE GENERAL INFORMATION AND DIAGNOSIS
INSPECTION
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check for voltage at terminal E17-13 (Case of
TYPE A) (See NOTE) or E18-20 (Case of TYPE
B) (See NOTE) of ECM connector connected,
under following condition.
Engine starter signal specification
While engine cranking : 6 – 10 V
After starting engine : 0 V
Is voltage as specified?Poor E17-13 (Case of
TYPE A) (See NOTE) or
E18-20 (Case of TYPE B)
(See NOTE) connection
or intermittent trouble.
Check for intermittent
referring to “Intermittent
and Poor Connection” in
Section 0A.
If wire and connections
are OK, substitute a
known-good ECM and
recheck.“B/Y” or “B/R” circuit
open.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-5
Air Intake System
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3),
idle air control valve (4) and intake manifold (5).
The air (by the amount corresponding to the throttle valve (6) opening and engine speed) is filtered by the air
cleaner (1), passes through the throttle body (3), is distributed by the intake manifold (5) and finally drawn into
each combustion chamber.
When the idle air control valve (4) is opened according to the signal from ECM, the air (7) bypasses the throttle
valve (6) through bypass passage and is finally drawn into the intake manifold (5).
1. Air Cleaner 17. Knock sensor 31-2. Test switch terminal
(vehicle w/o immobilizer indicator lamp)
2. EVAP canister purge valve 18. ECT sensor 31-3. Duty output terminal
(vehicle w/o immobilizer indicator lamp)
3. IAT sensor 19. CMP sensor 32. Immobilizer indicator lamp (if equipped)
4. TP sensor 20. CKP sensor 33. Stop lamp switch
5. IAC valve 21. VSS 34. ECM
6. MAP sensor 22. A/C condenser fan (if equipped) 35. Barometric pressure sensor
(vehicle with immobilizer indicator lamp)
7. EGR valve (if equipped) 23. Malfunction indicator lamp in combination meter 36. Battery
8. EVAP canister 24. Park/Neutral position switch in TR switch (A/T) 37. Immobilizer control module (if equipped)
9. Tank pressure control valve (built-in fuel pump) 25. Ignition switch 38. ABS control module (if equipped)
10. Fuel pump 26. Starter magnetic switch 39. CO adjusting resistor (if equipped)
11. Fuel level sensor 27. TCM (A/T) 40. Power steering pressure switch
(if equipped)
12. Ignition coil assembly 28. Transmission range switch (A/T) 41. A/C compressor clutch (if equipped)
13. Fuel injector 29. DLC 42. A/C EVAP TEMP. sensor (if equipped)
14. Heated Oxygen Sensor (HO2S)-1 (if equipped) 30. Electric load 43. A/C switch (if equipped)
15. Heated Oxygen Sensor (HO2S)-2 (if equipped) 31. Monitor connector (if equipped)
16. Three way catalytic convertor (if equipped) 31-1. Diagnosis switch terminal
(vehicle w/o immobilizer indicator lamp)

Downloaded from www.Manualslib.com manuals search engine 6E-8 ENGINE AND EMISSION CONTROL SYSTEM
Engine & emission control input / output table
INPUTOUTPUT
ELECTRIC CONTROL DEVICE
DIAGNOSIS SWITCH TERMINAL
(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)
BAROMETRIC PRESSURE SENSOR
(VEHICLE WITH IMMOBILIZER INDICATOR LAMP)
STOP LAMP SWITCH
STARTER SWITCH
IGNITION SWITCH
LIGHTING SWITCH
REAR DEFOGGER SWITCH (IF EQUIPPED)
BLOWER SWITCH
A/C SWITCH (IF EQUIPPED)
A/C EVAPORATOR TEMP. SENSOR (IF EQUIPPED)
VSS
HEATED OXYGEN SENSOR-1 (IF EQUIPPED)
HEATED OXYGEN SENSOR-2
(IF EQUIPPED)For detecting deterioration of
three way catalytic converter
IAT SENSOR
ECT SENSOR
TP SENSOR
MAP SENSOR
CMP SENSOR
CKP SENSOR
TEST SWITCH TERMINAL
(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)
KNOCK SENSOR
FUEL PUMP RELAY
FUEL INJECTOR
HO2S HEATER
IAC VALVE
IGNITION COIL WITH IGNITER
EGR VALVE (IF EQUIPPED)
EVAP CANISTER PURGE VALVE
A/C COMPRESSOR CLUTCH
MIL
MAIN RELAY
TRANSMISSION CONTROL MODULE SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULEA/C CONDENSER FAN RELAY

Downloaded from www.Manualslib.com manuals search engine 6G-2 CRANKING SYSTEM
General Description
Cranking Circuit
Diagnosis
Diagnosis Table
Possible symptoms due to starting system trouble would be as follows:
Starting motor does not run (or runs slowly)
Starting motor runs but fails to crank engine
Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies.....in battery, wiring
harness, (including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check following items and narrow down scope
of possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor termi-
nals
3) Discharge of battery
4) Mounting of starting motor
1. Pinion drive lever 5. Plunger 9. A/T: Transmission range switch (shift lever switch)
2. Pinion & Over-running clutch 6. Magnetic switch contacts 10. Ignition & Starter switch
3. Magnetic switch 7. Pull-in coil 11. Battery
4. Hold-in coil 8. Starting motor

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-5
NO-LOAD PERFORMANCE TEST
Connect battery and ammeter to starter as shown.
Check that starter rotates smoothly and steadily with pinion mov-
ing out. Check that ammeter indicates specified current.
Specified current (No-load performance test)
: 90 A MAX. at 11 V
On-Vehicle Service
Starting Motor
DISMOUNTING
1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (6) and battery cable (7) from starting motor terminals.
3) Remove starting motor mount bolts (4) and nut (5).
4) Remove starting motor (1).
REMOUNTING
Reverse the dismounting procedure.
1. Starting motor 3. Transmission case 5. Starting motor mounting nut 7. Battery cable
2. Clutch housing upper plate 4. Starting motor mounting bolt 6. Magnetic switch lead wire Tightening Torque