engine SUZUKI JIMNY 2020 Owners Manual

INSPECTION AND MAINTENANCE
NOTE: SUZUKI highly recommends the use of ECSTAR brand coolant. ECSTAR has been specially formulated for your SUZUKI product and contributes to the desired vehicle performance and ideal driving experience.
Coolant level check
Check the coolant level at the reservoir tank, not at the radiator. With the engine cool, the coolant level should be between "FULL" and "LOW" marks.
Adding coolant
,A WARNING
Swallowing engine coolant can cause severe injury or death. Inhaling cool­ant mist or vapors or getting coolant in your eyes could result in severe injury. • Do not drink antifreeze or coolant solution. If swallowed, do not induce vomiting. Immediately con­tact a poison control center or a physician. • Avoid inhaling coolant mist or hot vapors. If inhaled, remove to a fresh air area. (Continued)
6-29
,A WARNING
(Continued) • If coolant gets in the eyes, flush with water and seek medical atten­tion. Wash thoroughly after handling coolant. Keep engine coolant out of the reach of children and pets.
NOTICE
SUZUKI LLC: Super (Blue) coolant; This coolant is already diluted to the proper percentage. Do not dilute with distilled water additionally. Doing so may result in the possibility of freez­ing and/or overheating coolant.
NOTICE
SUZUKI LLC: Standard (Green) cool­ant; • The mixture you use should con­tain 50% concentration of anti­freeze. If the lowest ambient temperature in your area is expected lo be -35°C (-31'F) or below, use higher con­centrations up to 60% following the instructions on the antifreeze con­tainer.
78RB07005
If the coolant level is below "LOW" mark, coolant should be added. While the engine is cool, remove the reservoir tank cap and add coolant until the reservoir tank level reaches "FULL" mark. Never fill the reser­voir tank above "FULL" mark.
NOTICE
When putting the cap on the reser­voir tank, line up the mark on the cap and the mark on the tank. Failure to follow this can result in coolant leak­age.
Coolant replacement
Since special procedures are required, ask a SUZUKI dealer for this job.

INSPECTION AND MAINTENANCE
60G160
NOTICE
When installing the spark plugs, screw them in with your fingers to avoid stripping the threads. Tighten the spark plugs with a torque wrench to 17.5 Nm (1.7 kg­m, 12.9 lb-ft). Do not allow contami­nants to enter the engine through the spark plug holes when the plugs are removed. Never use spark plugs with the wrong thread size.
6-31
Spark plug gap "a":
ZXU20PR11 1.0-1.1 mm (0.039-0.043 in.) KR6A-10 0.95-1.0Smm (0.037-0.041 in.)
NOTICE
54G106
When replacing spark plugs, you ".hould use the ~rand and type speci­fied for your vehicle. For the specified plugs, refer to "SPECIFICATIONS" section in the end of this book. If you wish to use a brand of spark plug other than the specified plugs, con­sult a SUZUKI dealer.
Gear oil
Manual transmission oil / transfer
oil/ rear differential oil
When adding gear oil, use gear oil with the appropriate viscosity and grade as shown in the chart below.
We highly recommend you use "SUZUKI GEAR OIL 75W" for manual transmission oil and transfer oil.
Manual transmission oil Transfer oil
<: ==:llil:::======> 75W
°C-30 -20 -10 0 10 20 30 40 °F-22 -4 14 32 50 68 86 104
54P120706
We highly recommend you use "SUZUKI SUPER GEAR OIL 75W-85 SYNTHETIC" for front/rear differential oil.
Front/rear differential oil
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'C-30 -~0 -10 Of.22 4 14 0 ' 32
20 ' 68 83,60 4p 104
78RB07007

Gear oil level check
Manual transmission
(2)
(1) Oil filler and level plug (2) Oil drain plug
78RB07008
Transfer
4)
(3) Oil filter and level plug (4) Oil drain plug
Front/rear differential
(5) Oil filter and level plug (6) Oil drain plug
INSPECTION AND MAINTENANCE
To check the gear oil level, use the fol­lowing procedure:
1) Park the vehicle on a level surface with the parking brake applied. Then, stop the engine. 2) Remove the oil filler and level plug.
For the manual transmission;
3) If gear oil fiows from the plug hole, the oil level is correct. Reinstall the plug. If gear oil does not fiow from the plug hole, add oil through the filler plug hole until oil fiows a little from the plug hole.
78Rs0100, For the transfer and front/rear differential;
78RB07010
3) Check the inside of the hole with your finger. If the oil level comes up to the bottom of the plug hole, the oil level is correct. If so, reinstall the plug. 4) If the oil level is low, add gear oil through the oil filler and level plug hole until the oil level reaches the bottom of the filler hole, and then reinstall the plug.
Tightening torque for oil filler and level plug
Manual transmission (1 )(2): 23 Nm (2.3 kg-m, 16.6 lb-ft)
Transfer (3)(4): 23 Nm (2.3 kg-m, 16.6 lb-ft)
Front/rear differential (5)(6): (5)50 Nm (5.0 kg-m, 36.2 lb-ft) (6)55 Nm (5.6 kg-m, 40.5 lb-ft)
6-32

· INSPECTION AND MAINTENANCE
A CAUTION
After driving the vehicle, the gear oil temperature may be high enough to burn you. Wait until the oil filler and level plug are cool enough to touch with your bare hands before inspect­ing gear oil level.
NOTICE
Be sure to use new plug with new gas­ket to avoid loose·ness of the plug and oil leakage.
Gear oil change
Since special procedures, materials and tools are required, ask a SUZUKI dealer for this job.
6-33
Clutch pedal
Fluid control clutch
78RB07011
Check the clutch pedal for smooth opera­tion and clutch fiuid level from time to time. If clutch dragging is felt with the pedal fully depressed, have the clutch inspected by a SUZUKI dealer. If the clutch fiuid level is near "MIN" line, fill it up to "MAX" line with DOT3 or SAE J1703 brake fiuid.
Brakes
Brake fluid
MAX
MIN
78RB07011
Check the brake fluid level by looking at the reservoir in the engine compartment. Check that the fiuid level is between "MAX" and "MIN" lines.
NOTICE
If your brake fluid level is near the 11MIN" line, there is a possibility of brake pad and/or shoe wear and brake fluid leakage. Consult with a SUZUKI dealer regarding this possi­bility before filling the reservoir.

NOTE: SUZUKI highly recommends the use of ECSTAR brend brake fluid. ECSTAR has been specially formulated for your SUZUKI product and contributes to the desired vehicle performance and ideal driving experience.
A WARNING
Failure to follow the guidelines below can result in personal injury or seri­ous damage to the brake system. . If the brake fluid in the reservoir drops below a certain level, the brake warning light on the instru­ment cluster will come on (the engine must be running with the parking brake fully dise~gaged). Should the light come on, 1mmed1-ately ask a SUZUKI dealer to inspect the brake system. A rapid fluid loss indicates leakage in the brake system which should be inspected by a SUZUKI dealer immediately. Do not use any fluid other than DOT3 or SAE J1703 brake fluid. Do not use reclaimed fluid or fluid that has been stored in old or open con­tainers. It is essential that foreign particles and other liquids are kept out of the brake fluid reservoir.
A CAUTION
Brake fluid can harm your eyes and damage painted surfaces. Be careful when refilling the reservoir.
A WARNING
Brake fluid is harmful or fatal if swal­lowed, and harmful if it comes in con­tact with skin or eyes. If swallowed, do not induce vomiting. Immediately contact a poison control center or a physician. If brake fluid gets in eye~, flush eyes with water and seek medi­cal attention. Wash thoroughly after handling. Solution can be poisonous to animals. Keep out of reach of chil­dren and animals.
NOTE: • The fluid /eve/ can be expected to gredu­ally fall as the brake pad and/or shoe wear. Brake fluid absorbs water over time and brake fluid with high water content may cause vapor lock or breke system mal­function. Replace your breke fluid in accordance with the maintenance schedule m your Owner's Manual.
INSPECTION AND MAINTENANCE
Brake pedal
Check brake pedal stroke. If the stroke is so large, have the brake system inspected by a SUZUKI dealer. If you doubt th_e brake pedal is at its normal height, check 1t as fol­lows:
54G108
Minimum distance between brake pedal and floor carpet "a"
LHD 101 mm (4.0 in)
RHD 89 mm (3.5 in)
6-34

INSPECTION AND MAINTENANCE
With the engine running, measure the dis­tance between the brake pedal and floor carpet when the pedal is depressed with approximately 30 kg (66 lbs) of force. The minimum distance required is as specified. Since your vehicle's brake system is self­adjusting, there is no need for pedal adjustment. If the pedal to floor carpet distance as measured above is less than the minimum distance required, have your vehicle inspected by a SUZUKI dealer.
NOTE: • When measuring the distance between the brake pedal and floor wall, be sure not to include the floor mat or rubber on the floor carpet in your measurement. Measure the distance at the brake pedal's side facing toward the passen­ger's door.
6-35
52RM70500
A WARNING
If you experience any of the following problems with your vehicle's brake system, have the vehicle inspected immediately by a SUZUKI dealer. Poor braking performance Uneven braking (brakes not work­ing uniformly on all wheels.) Excessive pedal travel Brake dragging Excessive noise
Parking brake
~
54G109
Ratchet tooth specification 11b": 4th-9th Lever pull force (1 ): 200 N (20 kg, 45 lbs)
Check the parking brake for proper adjust­ment by counting the number of clicks made by the ratchet teeth as you slowly pull up on the parking brake lever to the point of full engagement. The parking brake lever should stop between the speci­fied ratchet teeth and the rear wheels should be securely locked. If the parking brake is not properly adjusted or the brakes drag is suspected even after the lever has been fully released, have the parking brake inspected and/or adjusted by a SUZUKI dealer.

NOTE: (Battery label) When the battery is disconnected, some i::::-==-=="---------­
of the vehicle's functions will be initial­ized and/or deactivated. These functions must be required to reset after the battery is reconnected. Do not disconnect the battery terminals for at least one minute after the ignition switch is turned off.
A WARNING
Batteries contain toxic substances including sulfuric acid and lead. They could have potential negative conse­quences for the environment and human health. Used batteries must be disposed of or recycled according to applicable rules or regulations and must not be disposed of with ordi­nary household trash. Make sure not to tip over the battery when you remove it from the vehicle. Other­wise, sulfuric acid could run out and you might get injury.
NOTICE
After stopping the engine, controller and system are operated for a while. Therefore, before removing the bat­tery, wait for more than one minute after turning the ignition switch to 110FF".
Pb>----(5)
51KM042
(5) Crossed-out wheeled bin symbol (6) Chemical symbol of "Pb"
The crossed-out wheeled bin symbol (5) located on the battery label indicates that the used battery should be collected sepa­rately from ordinary household trash. The chemical symbol of "Pb" (6) indicates the battery contains more than 0.004% lead.
By ensuring the used battery is disposed of or recycled correctly, you will help pre­vent potential negative consequences for the environment and human health, which could otherwise be caused by inappropri­ate trash handling of the battery. The recy­cling of materials will help to conserve natural resources. For more detailed infor­mation about disposing of or recycling the used battery, consult a SUZUKI dealer.
INSPECTION AND MAINTENANCE
Fuses
Your vehicle has three types of fuses, as described below:
Main fuse The main fuse takes current directly from the lead-acid battery.
Primary fuses These fuses are between the main fuse and individual fuses, and are for electrical load groups.
Individual fuses These fuses are for individual electrical cir­
cuits.
To remove a fuse, use the fuse puller pro­vided in the fuse box cover.
78R807020
6-42

INSPECTION AND MAINTENANCE
Fuses in engine compartment
(1) Main fuse box (2) Relay box
Main fuse box
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6-43
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[N]
78RB07021
78RB07022
Relay box
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~ ~ [@[] [illiJ 8 ;~ ~(32) cc
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78RB07023
MAIN FUSE / PRIMARY FUSE
(1) 120A FL 1
(2) 100A FL2
(3) BOA FL3
(4) 100A FL4
(5) 50A FL5
(6) 50A Ignition switch
(7) 40A ABS motor
(8) -Blank
(9) 30A Blower fan
(10) 30A Starter motor
(11) 30A Headlight cleaner
(12) 15A Headlight (Right)
(13) 15A Headlight (Left)
(14) 25A ABS/ESP® control mod-ule
(15) -Blank
(16) 15A Ignition coil
(17) 25A Headlight high
(18) 30A Back up
(19) -Blank
(20) 15A Fuel injection

(21) 15A Transmission
(22) 50A Ignition sw2
(23) 10 A A/C compressor
(24) 10A 4WD
(25) 20A Front fog light
(26) -Blank
(27) 40A Power steering
(28) -Blank
(29) 40A Radiator fan
(30) -Blank
(31) 5A Starter motor
(32) 15A Headlight high (Left)
(33) 15A Headlight high (Right)
The main fuse, primary fuses and some of the individual fuses are located in the engine compartment. If the main fuse blows, no electrical component will func­tion. If a primary fuse blows, no electrical component in the corresponding load group will function. When replacing the main fuse, a primary fuse or an individual fuse, use a genuine SUZUKI replacement parts or equivalent for individual fuses. To remove a fuse, use the fuse puller pro­vided in the fuse box. The amperage of each fuse is shown in the back of the fuse box cover.
INSPECTION AND MAINTENANCE
IX! OK
BLOWN
60G111
A. WARNING
If the main fuse or a primary fuse blows, have your vehicle inspected by a SUZUKI dealer. Always use a genuine SUZUKI replacement. Never use a substitute such as a wire even for a temporary repair, or extensive electrical damage and a fire can result.
NOTE: Check that the fuse box always carries spare fuses.
6-44

INSPECTION AND MAINTENANCE
Fuses under dashboard
6-45
78RB07024
1 2 3 4 5 6 7 8 9 10 11 12
71819202122232425
80P0185
PRIMARY FUSE
(1) 30A Power window
(2) 10A Meter
(3) 15A Engine Control Module
(4) 5A lgnition-1 signal 2
(5) 20A Blank
(6) -Blank
(7) -Blank
(8) 20A Door lock
(9) 15A Steering lock
(10) 10A Hazard
(11) -Blank
(12) 10A Rear fog lamp
(13) 5A ABS/Esp® control mod-ule
(14) 15A Seat heater
(15) 5A lgnition-1 signal 3
(16) 10A Dome light-2
(17) 5A Dome light
(18) 15A Radio
(19) 5A CONT
(20) 5A Key2
(21) 20A Power window timer
(22) 5A Key
(23) 15A Horn
(24) 5A Tail light (Left)
(25) 10A Tail light
(26) 10A Airbag
(27) 10A lgnition-1 signal
(28) 10A Back-up light
(29) 5A ACC-3
(30) 20A Rear defogger
(31) 10A Heated mirror
(32) 15A ACC-2
(33) 5A ACC
(34) 10A Rear wiper
(35) 5A lgnition-2 signal
(36) 15A Washer
(37) 25A Front wiper
(38) 10A Stop light