2005 SUZUKI JIMNY ABS

Downloaded from www.Manualslib.com manuals search engine 5E-40 ANTILOCK BRAKE SYSTEM (ABS)
Tightening Torque Specification
Special Tool
Fastening partTightening torque
Nm kg-m lb-ft
Brake pipe flare nuts 16 1.6 11.6
ABS hydraulic unit / control module assembly bracket bolts 11 1.1 8.0
ABS hydraulic unit / control module assembly bolts 9 0.9 6.5
Front wheel speed sensor bolt 10 1.0 7.2
Front wheel speed sensor harness clamp bolts 10 1.0 7.2
Rear wheel speed sensor bolt 10 1.0 7.2
Rear wheel speed sensor harness clamp bolts 10 1.0 7.2
G sensor bolts 23 2.3 17.0
09950-78220 09931-76011 09931-76030
Flare nut wrench (10 mm) Tech 1A kit (SUZUKI scan
tool) See NOTE “A” belowMass storage cartridge for
Tech 1A16/14 pin DLC cable for
Tech 1A
Tech 2 kit (SUZUKI scan
tool) See NOTE “B”
below.
NOTE:
“A” : This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead / probe,
6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
“B” : This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply

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 6-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS
In the 2nd through the 4th frames, the freeze frame data of each
malfunction is stored in the order as the malfunction is detected.
These data are not updated.
Shown in the table below are examples of how freeze frame data
are stored when two or more malfunctions are detected.
Freeze Frame Data Clearance :
The freeze frame data is cleared at the same time as clearance of
diagnostic trouble code (DTC).
DATA LINK CONNECTOR (DLC)
DLC (1) is in compliance with SAEJ1962 in its installation posi-
tion, the shape of connector and pin assignment.
Serial data line (K line of ISO 9141) (3) is used for SUZUKI scan
tool or generic scan tool to communicate with ECM, TCM, Air Bag
SDM and ABS control module.
SUZUKI serial data line (6) is used for SUZUKI scan tool to com-
municate with immobilizer control module.FRAME
FRAME 1 FRAME 2 FRAME 3 FRAME4
FREEZE FRAME
DATA to be updated1st FREEZE
FRAME DATA2nd FREEZE
FRAME DATA3rd FREEZE
FRAME DATA
MALFUNCTION
DETECTED
ORDERNo malfunction No freeze frame data
1 P0400 (EGR)
detectedData at P0400
detectionData at P0400
detection––
2 P0171 (Fuel sys-
tem) detectedData at P0171
detectionData at P0400
detectionData at P0171
detection–
3 P0300 (Misfire)
detectedData at P0171
detectionData at P0400
detectionData at P0171
detectionData at P0300
detection
4 P0301 (Misfire)
detectedData at P0171
detectionData at P0400
detectionData at P0171
detectionData at P0300
detection
2. B+
4. ECM ground
5. Body ground

Downloaded from www.Manualslib.com manuals search engine 6-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Diagnostic trouble code (DTC) table
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)
P0105
(No.11)Manifold absolute pressure
circuit malfunctionLow pressure-high vacuum-low voltage
(or MAP sensor circuit shorted to ground)
High pressure-low vacuum-high voltage
(or MAP sensor circuit open)1 driving
cycle1 driving
cycle
P0110
(No.18)Intake air temp. circuit mal-
functionIntake air temp. circuit low input
Intake air temp. circuit high input1 driving
cycle1 driving
cycle
P0115
(No.19)Engine coolant temp. cir-
cuit malfunctionEngine coolant temp. circuit low input
Engine coolant temp. circuit high input1 driving
cycle1 driving
cycle
P0120
(No.13)Throttle position circuit mal-
functionThrottle position circuit low input
Throttle position circuit high input1 driving
cycle1 driving
cycle
P0121Throttle position circuit per-
formance problemPoor performance of TP sensor 2 driving
cyclesNot
applicable
P0130
(No.14)HO2S circuit malfunction
(Sensor-1)Min. output voltage of HO2S-higher than
specification
Max. output voltage of HO2S-lower than
specification2 driving
cycles1 driving
cycle
P0133HO2S circuit slow response
(Sensor-1)Response time of HO2S-1 output voltage
between rich and lean is longer than spec-
ification.2 driving
cyclesNot
applicable
P0135
(No.14)HO2S heater circuit mal-
function (Sensor-1)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.2 driving
cycles1 driving
cycle
P0136HO2S circuit malfunction
(Sensor-2)HO2S-2 voltage is higher than specifica-
tion2 driving
cyclesNot
applicable
P0141HO2S heater circuit mal-
function (Sensor-2)Terminal voltage is lower than specification
at heater OFF or it is higher at heater ON.
(or heater circuit or short)2 driving
cyclesNot
applicable
P0171 Fuel system too leanShort term fuel trim or total fuel trim (short
and long terms added) is larger than spec-
ification for specified time or longer.
(fuel trim toward rich side is large.)2 driving
cyclesNot
applicable
P0172 Fuel system too richShort term fuel trim or total fuel trim (short
and long term added) is smaller than spec-
ification for specified time or longer.
(fuel trim toward lean side is large.)2 driving
cyclesNot
applicable
P0300
P0301
P0302
P0303
P0304Random misfire detected
Cylinder 1 misfire detected
Cylinder 2 misfire detected
Cylinder 3 misfire detected
Cylinder 4 misfire detectedMisfire of such level as to cause damage
to three way catalystMIL flashing
during mis-
fire detec-
tionNot
applicable
Misfire of such level as to deteriorate emis-
sion but not to cause damage to three way
catalyst2 driving
cyclesNot
applicable
P0325
(No.17)Knock sensor circuit mal-
functionKnock sensor circuit low input
Knock sensor circuit high input1 driving
cycle1 driving
cycle

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 6-19
Fail-safe table
When any of the following DTCs is detected, ECM enters fail-safe mode as long as malfunction continues to
exist but that mode is canceled when ECM detects normal condition after that.
DTC NO. DETECTED ITEM FAIL-SAFE OPERATION (SYMPTOM)
P0105
(No.11)Manifold absolute pressure sensor circuit
malfunctionECM uses value determined by throttle opening and
engine speed.
P0110
(No.18)Intake air temp. sensor circuit malfunctionECM controls actuators assuming that intake air tem-
perature is 20 °C (68 °F).
P0115
(No.19)Engine coolant temp. sensor circuit mal-
functionECM controls actuators assuming that engine coolant
temperature is 80 °C (176 °F).
P0120
(No.13)Throttle position sensor circuit malfunc-
tionECM controls actuators assuming that throttle opening
is 20°. (High idle speed)
P0335
(No.23)Crankshaft position sensor circuit mal-
functionECM controls injection system sequential injection to
synchronous injection. (Cranking for a few seconds to
start engine)
P0340
(No.15)Camshaft position sensor circuit malfunc-
tionECM controls injection system sequential injection to
synchronous injection. (Cranking for a few seconds to
start engine)
P0500
(No.16)Vehicle speed sensor malfunction ECM stops idle air control.
P1450Barometric pressure sensor low / high
inputECM controls actuators assuming that barometric
pressure is 100 kPa (760 mmHg).
P1570
(No.21)ABS signal circuit malfunctionECM controls actuators assuming that ABS signal is
OFF.

Downloaded from www.Manualslib.com manuals search engine 6-28 ENGINE GENERAL INFORMATION AND DIAGNOSIS
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

Downloaded from www.Manualslib.com manuals search engine 6-30 ENGINE GENERAL INFORMATION AND DIAGNOSIS
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