check engine SUZUKI JIMNY 2020 Workshop Manual

Refill with oil and oil leakage check
1) Pour oil through the filler hole and install the filler cap. For the approximate capacity of the oil, refer to "Recommended fuel / lubricants and capacities (approx.)" in "SPECIFI­CATIONS" section. 2) Start the engine and carefully check the oil filter and the drain plug for leakage. Run the engine at various speeds for at least 5 minutes. 3) Stop the engine and wait about 5 min­utes. Check the oil level again and add oil if necessary. Check for leakage again.
NOTICE
When replacing the oil filter, it is recommended that you use a genu­ine SUZUKI replacement filter. If you use an aftermarket filter, check that it is of equivalent quality and follow the manufacturer's instruc­tions. • Oil leakage from the periphery of the oil filter or drain plug indicate incorrect installation or gasket damage. If you find any leakage or are not sure that the filter has been properly tightened, have the vehi­cle inspected by a SUZUKI dealer.
Engine coolant
Selection of coolant
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.
To maintain optimum performance and durability of your engine, use SUZUKI gen­uine coolant or equivalent.
NOTE: If you use the engine coolant other than the SUZUKI LLC: Super (Blue) for replace­ment, follow the schedule of SUZUKI LLC: Standard (Green). To see the detail of the maintenance schedule, refer to "Periodic maintenance schedule" in this section.
This type of coolant is the best for cooling system for the following reasons: • The coolant helps maintain proper engine temperature. It gives proper protection against freez­ing and boiling. It gives proper protection against corro­sion and rust.
INSPECTION AND MAINTENANCE
Failure to use the proper coolant can dam­age your cooling system. Your SUZUKI dealer can help you select the proper cool­ant.
NOTICE
To avoid damaging your cooling sys­tem: Always use a high quality ethylene glycol base non-silicate type cool­ant diluted with distilled water at the correct mixture concentration. Check that the proper mix is 50/50 coolant to distilled water and in no case higher than 70/30. Concentra­tions greater than 70/30 coolant to distilled water will cause overheat­ing conditions. Do not use straight coolant nor plain water (except "SUZUKI LLC: Super {Blue)"). . • Do not add extra inhibitors or addi­tives. They may not be compatible with your cooling system. Do not mix different types of base coolants. Doing so may result in accelerated seal wear and/or the possibility of severe overheating and extensive engine/automatic transmission damage.
6-28

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.

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.

(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

Air conditioning system
If you do not use the air conditioner for a long period, such as during winter, it may not give the best performance when you start using it again. To help maintain opti­mum performance and durability of your air conditioner, it needs to be run periodically. Operate the air conditioner at least once a month for one minute with the engine idling. This circulates the refrigerant and oil and helps protect the internal components.
Air conditioner filter replacement
Since special procedures are required, ask a SUZUKI dealer for this job.
78RB07042
1) To approach the air conditioner filter, remove the glove box by pressing both sides of the glove box inward and pull­ing it out.
INSPECTION AND MAINTENANCE
(2)
(1)
78RB07043
2) Remove the cover (1) and pull out the air conditioner filter (2).
NOTE: When you install a new filter, check that the UP mark (3) faces upward.
6-58

Engine trouble: Starter does
not operate
1) Try turning the ignition switch to "START" position with the headlights turned on to determine the lead-acid battery condition. If the headlights go excessively dim or go off, it usually means that either the lead-acid battery is discharged or the battery terminal contact is poor. Recharge the lead-acid battery or correct battery terminal con­tact as necessary. 2) If the headlights remain bright, check the fuses. If the reason for failure of the starter is not obvious, there may be a major electrical problem. Have the vehi­cle inspected by a SUZUKI dealer.
Engine trouble: Does not start
Make sure that your vehicle has enough · fuel and battery. If the engine does not start under very cold condition, press the accelerator pedal all the way to the fioor and hold it while crank­ing the engine. Refer to "Starting engine" in operating your vehicle section. If the engine still does not start have your vehicle inspected at a SUZUKI dealer. Do not operate the starter motor for more than 12 seconds.
EMERGENCY SERVICE
Engine trouble: Overheating
The engine could overheat temporarily under severe driving conditions. If the high engine coolant temperature warning light comes on as overheating or the engine coolant temperature gauge indicates over­heating during driving:
1) Turn off the air conditioner. 2) Take the vehicle to a safe place and park. 3) Run the engine at a normal idle speed for a few minutes until the high engine coolant temperature warning light goes off or the indicator is within the normal, acceptable temperature range between "H" and "C".
A WARNING
If you see or hear escaping steam, stop the vehicle in a safe place and immediately turn off the engine to cool it. Do not open the hood when steam is present. When the steam can no longer be seen or heard, open the hood to see if the coolant is still boiling. If it is, you must wait until it stops boiling before you proceed.
7-10

EMERGENCY SERVICE
If the high engine coolant temperature warning light does not go off or the tem­perature indication does not come down to within the normal, acceptable range:
1) Turn off the engine and check that the water pump belt and pulleys are not damaged or slipping. If any abnormality is found, correct it. 2) Check the coolant level in the reservoir. If it is found to be lower than "LOW" line, check radiator, water pump, radia­tor hoses and heater hoses for leakage. If leakage that may cause overheating is found, do not run the engine until these problems have been corrected. 3) If leakage is not found, carefully add coolant to the reservoir and then the radiator, if necessary. (Refer to "Engine coolant" in "INSPECTION AND MAIN­TENANCE" section.)
NOTE: If engine overheats and you are not sure what to do, contact a SUZUKI dealer.
7-11
650614
A WARNING
• It is hazardous to remove the radia­tor cap when the water temperature is high, because scalding fluid and steam may be blown out under pressure. The cap should only be taken off when the coolant tem­perature has lowered. To help prevent personal injury, keep hands, tools and clothing away from the engine cooling fan and air-conditioner fan. These elec­tric fans can automatically turn on without warning.