timing SUZUKI JIMNY 2005 3.G Service Workshop Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2005, Model line: JIMNY, Model: SUZUKI JIMNY 2005 3.GPages: 687, PDF Size: 13.38 MB
Page 378 of 687
Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-21
Engine basic inspection
This check is very important for troubleshooting when ECM has detected no DTC and no abnormality has been
found in visual inspection.
Follow the flow table carefully.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check battery voltage.
Is it 11 V or more?Go to Step 3. Charge or replace battery.
3 Is engine cranked? Go to Step 4. Go to “Diagnosis” in Sec-
tion 6G.
4 Does engine start? Go to Step 5. Go to Step 9.
5 Check idle speed as follows :
1) Warm up engine to normal operating temp.
2) Shift transmission to neutral position for M/T
(“P” position for A/T).
3) All of electrical loads are switched off.
4) Check engine idle speed with scan tool.
See Fig. 1.
Is it 650 – 750 r/min (700 – 800 r/min. for A/T
vehicle)?Go to Step 6. Go to “Engine Diagnosis
Table”.
6 Is SUZUKI scan tool available? Go to Step 8. Go to Step 7.
7 Check ignition timing as follows :
1) Connect test switch terminal (2) of monitor
coupler (1) to ground. See Fig. 2.
2) Remove air cleaner bolt and crips and shift
air cleaner position to observe ignition tim-
ing.
3) Using timing light (1), check initial ignition
timing.
See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “Engine Diagnosis
Table”.Check ignition control
related parts referring to
Section 6F.
8 Check ignition timing as follows :
1) Select “MISC” mode on SUZUKI scan tool
and fix ignition timing to initial one. See Fig.
3.
2) Remove air cleaner bolt and crips and shift
air cleaner position to observe ignition tim-
ing.
3) Using timing light (1), check initial ignition
timing. See Fig. 4.
Is it 5° ± 3° BTDC at specified idle speed?Go to “Engine Diagnosis
Table”.Check ignition control
related parts referring to
Section 6F.
9 Check immobilizer system malfunction as fol-
lows (if equipped) :
1) Check immobilizer indicator lamp or MIL
(malfunction indicator lamp) for flashing.
Is it flashing when ignition switch is turned to
ON position?Go to “Diagnosis” in Sec-
tion 8G.Go to Step 10.
Page 380 of 687
![SUZUKI JIMNY 2005 3.G Service Workshop 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 tab](/img/20/7588/w960_7588-379.png "SUZUKI JIMNY 2005 3.G Service Workshop 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 tab")
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[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.
Page 383 of 687
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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.
Page 385 of 687
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Scan Tool Data
As the data values given below are standard values estimated on the basis of values obtained from the normally
operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condi-
tion, there may be cases where the checked value does not fall within each specified data range. Therefore,
judgment as abnormal should not be made by checking with these data alone.
Also, conditions in the below table that can be checked by the scan tool are those detected by ECM and output
from ECM as commands and there may be cases where the engine or actuator is not operating (in the condi-
tion) as indicated by the scan tool. Be sure to use the timing light to check the ignition timing.
NOTE:
With the generic scan tool, only star (
✱
✱✱ ✱) marked data in the table below can be read.
The triangle (
∆
∆∆ ∆) marked data in the table below can not be read for vehicle without immobilizer indi-
cator lamp at combination meter.
When checking the data with the engine running at idle or racing, be sure to shift M/T gear to the
neutral gear position and A/T gear to the “Park” position and pull the parking brake fully. Also, if
nothing or “no load” is indicated, turn OFF A/C, all electric loads, P/S and all the other necessary
switches.
SCAN TOOL DATA CONDITION REFERENCE VALUES
✱
✱✱ ✱FUEL SYSTEM B1 (FUEL
SYSTEM STATUS)At specified idle speed after warming up CLOSED (closed loop)
✱
✱✱ ✱
CALC LOAD
(CALCULATED LOAD
VALUE)At specified idle speed with no load after
warming up3 – 9 %
At 2500 r/min with no load after warming up 12 – 17 %
✱
✱✱ ✱COOLANT TEMP.
(ENGINE COOLANT
TEMP.)At specified idle speed after warming up 80 – 100 °C, 176 – 212 °F
✱
✱✱ ✱SHORT FT B1 (SHORT
TERM FUEL TRIM)At specified idle speed after warming up– 20 – +20 %
✱
✱✱ ✱LONG FT B1 (LONG TERM
FUEL TRIM)At specified idle speed after warming up– 15 – +15 %
✱
✱✱ ✱MAP (INTAKE MANIFOLD
ABSOLUTE PRESSURE)At specified idle speed with no load after30 – 37 kPa,
220 – 340 mmHg
✱
✱✱ ✱
ENGINE SPEED At idling with no load after warming upDesired idle speed
±50 r/min
✱
✱✱ ✱VEHICLE SPEED At stop 0 km/h, 0 MPH
✱
✱✱ ✱IGNITION ADVANCE
(IGNITION TIMING
ADVANCE FOR NO.1 CYL-
INDER)At specified idle speed with no load after
warming up5 – 16° BTDC
✱
✱✱ ✱
INTAKE AIR TEMP. At specified idle speed after warming upAmbient temp. :
+15 °C (59 °F)
–5 °C (23 °F)
✱
✱✱ ✱MAF (MASS AIR FLOW
RATE)At specified idle speed with no load after
warming up1 – 4 gm/sec
✱
✱✱ ✱
THROTTLE POS
(THROTTLE POSITION)Ignition switch
ON / engine
stoppedThrottle valve fully closed 7 – 18 %
Throttle valve fully open 70 – 90 %
✱
✱✱ ✱O2S B1 S1 (HEATED OXY-
GEN SENSOR-1)At specified idle speed after warming up 0.01 – 0.95 V
Page 387 of 687
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Scan tool data definitions
FUEL SYSTEM (FUEL SYSTEM STATUS)
Air / fuel ratio feedback loop status displayed as either open or closed loop. Open indicates that ECM ignores
feedback from the exhaust oxygen sensor.
Closed indicates final injection duration is corrected for oxygen sensor feedback.
CALC LOAD (CALCULATED LOAD VALUE, %)
Engine load displayed as a percentage of maximum possible load. Value is calculated mathematically using the
formula : actual (current) intake air volume ÷ maximum possible intake air volume x 100%.
COOLANT TEMP. (ENGINE COOLANT TEMPERATURE, °C, °F)
It is detected by engine coolant temp. sensor
SHORT FT B1 (SHORT TERM FUEL TRIM, %)
Short term fuel trim value represents short term corrections to the air / fuel mixture computation. A value of 0
indicates no correction, a value greater than 0 means an enrichment correction, and a value less than 0 implies
an enleanment correction.
LONG FT B1 (LONG TERM FUEL TRIM, %)
Long term fuel trim Value represents long term corrections to the air / fuel mixture computation. A value of 0 indi-
cates no correction, a value greater than 0 means an enrichment correction, and a value less than 0 implies an
enleanment correction.
MAP (INTAKE MANIFOLD ABSOLUTE PRESSURE, kPa, inHg)
It is detected by manifold absolute pressure sensor and used (among other things) to compute engine load.
ENGINE SPEED (rpm)
It is computed by reference pulses from crankshaft position sensor.
VEHICLE SPEED (km/h, MPH)
It is computed based on pulse signals from vehicle speed sensor.
IGNITION ADVANCE (IGNITION TIMING ADVANCE FOR NO.1 CYLINDER, °)
Ignition timing of NO.1 cylinder is commanded by ECM. The actual ignition timing should be checked by using
the timing light.
INTAKE AIR TEMP. (°C, °F)
It is detected by intake air temp. sensor and used to determine the amount of air passing into the intake manifold
as air density varies with temperature.
MAF (MASS AIR FLOW RATE, gm/s, lb/min)
It represents total mass of air entering intake manifold which is computed based on signals from MAP sensor,
IAT sensor, TP sensor, etc.BRAKE SWIgnition switch
ONBrake pedal is depressing ON
Brake pedal is releasing OFF
BLOWER FANIgnition switch
ONBlower fan switch ON ON
Blower fan switch OFF OFF
A/C MAG CLUTCHIgnition switch
ONA/C operating ON
A/C not operating OFF SCAN TOOL DATA CONDITION REFERENCE VALUES
Page 432 of 687
![SUZUKI JIMNY 2005 3.G Service Workshop Manual Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-75
[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 3 / [C] Fig. 3 for Step 4 / [D] Fig. 4 for Step 5 / [](/img/20/7588/w960_7588-431.png "SUZUKI JIMNY 2005 3.G Service Workshop Manual Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-75
[A] Fig. 1 for Step 3 / [B] Fig. 2 for Step 3 / [C] Fig. 3 for Step 4 / [D] Fig. 4 for Step 5 / [")
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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
Page 482 of 687
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).
Page 483 of 687
Downloaded from www.Manualslib.com manuals search engine 6A1-2 ENGINE MECHANICAL (M13 ENGINE)
General Description
Engine
The engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its DOHC (Double overhead
camshaft) valve mechanism arranged for “V” type valve configuration and 16 valves (4 valves / one cylinder).
The double overhead camshaft is mounted over the cylinder head; it is driven from crankshaft through timing
chain, and no push rods are provided in the valve train system.
Page 491 of 687
Downloaded from www.Manualslib.com manuals search engine 6A1-10 ENGINE MECHANICAL (M13 ENGINE)
2) Lift valve by turning crankshaft and then remove camshaft
housing bolts (1) where the shim to be replaced.
3) Install special tool with camshaft housing bolts as shown in
figure.
Special tool
(A) : 09916-67020
Tightening torque
Camshaft housing bolts (for tightening of special tool)
(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
Special tool selection table
4) Turn camshaft by approximately 90° clockwise and remove
shim (3).
2. Plug hole
NOTE:
Check the special tools carved seal as shown, and
then install special tool in accordance with the location
of each camshaft housing.
If special tool is holding down the shim, adjust special
tool position so as not to hold down the shim by loos-
ening camshaft housing bolt.
No. on camshaft housingEmbossed mark
on special tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345
A: I : Intake side or E : Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
WARNING:
Never put in the hand between camshaft and tappet.
1. Special tool
2. Magnet
Page 497 of 687
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INSTALLATION
1) Install new spark plug hole gaskets (1) and new cylinder
head cover gasket (2) to cylinder head cover (3) as shown in
figure.
2) Remove oil, old sealant, and dust from sealing surface on
cylinder head and cover. After cleaning, apply sealant “A” to
the following point.
Cylinder head gasket (1) sealing surface area (2) as shown.
“A” : Sealant 99000-31150
Timing chain cover (1) and cylinder head (2) matching sur-
face as shown.
“A” : Sealant 99000-31150 NOTE:
Be sure to check each of these parts for deterioration or
any damage before installation and replace if found
defective.