2005 SUZUKI JIMNY lamp

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-43
Tightening Torque Specifications
09931-76030
16/14 pin DLC cable Tech 2 kit (SUZUKI scan
tool) (See NOTE “C”.)
NOTE:
“A”: This kit includes the following items.
1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder, 5. Return hose & clamp,
6. Body attachment-2 & washer, 7. Hose attachment-1, 8. Hose attachment-2
“B”: 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 (14/26 pin, 09931-76040),
5. Test lead / probe, 6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
“C”: 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
Fastening partTightening torque
Nm kg-m lb-ft
TP sensor mounting screw 2.5 0.25 1.8
IAC valve screw 3.5 0.35 2.5
ECT sensor 15 1.5 11.5
Heated oxygen sensor-1 and -2 45 4.5 32.5
Camshaft position sensor 10 1.0 7.5
Fuel pressure regulator bolt 10 1.0 7.5

Downloaded from www.Manualslib.com manuals search engine IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-5
On-Vehicle Service
Ignition Spark Test
1) Disconnect all injector connectors (1) from injectors.
2) Remove cylinder head upper cover.
3) Remove spark plug and check it for condition and type refer-
ring to “Spark Plugs” in this section.
4) If OK, connect ignition coil connector to ignition coil assem-
bly and connect spark plug to ignition coil assembly or high-
tension cord. Ground spark plug.
5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as described
under “Diagnosis” earlier in this section.
High-tension Cords
1) Remove cylinder head upper cover and disconnect high-ten-
sion cords (2) from ignition coil assemblies (1) while gripping
each cap.
2) Pull out high-tension cords from spark plugs while gripping
each cap.
3) Measure resistance of high-tension cord (1) by using ohm-
meter.
High-tension cord resistance
4 – 10 k
Ω/m (1.2 – 3.0 kΩ/ft)
4) If resistance exceeds specification, replace high-tension
cord(s). WARNING:
Without disconnection of injector couplers, combustible
gas may come out from spark plug holes during this test
and may get ignited in engine room.
CAUTION:
Removal of high-tension cords together with clamps
will be recommended so as not to damage their inside
wire (resistive conductor).
For the same reason, pull out each connection by grip-
ping cap portion.

Downloaded from www.Manualslib.com manuals search engine IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-9
5) Fix ignition timing to initial one as follows.
a) When using SUZUKI scan tool:
Select “MISC” mode on SUZUKI scan tool and fix ignition
timing to initial one.
b) Without using SUZUKI scan tool: (vehicle without immobi-
lizer indicator lamp)
Disconnect scan tool from DLC, and connect D and E ter-
minals of monitor connector (1) or E to body ground by
using service wire so that ignition timing is fixed on initial
one.
6) Using timing light (1), check that ignition timing is within
specification.
Initial ignition timing (test switch terminal grounded or
fixed with SUZUKI scan tool)
5
± 3° BTDC at idle speed
Ignition order
1-3-4-2
7) If ignition timing is out of specification, check the followings:
CKP sensor
CKP sensor plate
TP sensor
Test switch signal circuit
VSS
Timing chain cover installation
8) After checking Initial Ignition Timing, release ignition timing
fixation by using SUZUKI scan tool or disconnect service
wire from monitor connector.
9) With engine idling (test switch terminal ungrounded, throttle
opening at closed position and car stopped), check that igni-
tion timing is about 7°–17° BTDC. (Constant variation within
a few degrees from 7°–17° indicates no abnormality but
proves operation of electronic timing control system.) Also,
check that increasing engine speed advances ignition timing.
If above check results are not satisfactory, check CKP sen-
sor, test switch terminal circuit and ECM.

Downloaded from www.Manualslib.com manuals search engine 6H-2 CHARGING SYSTEM
General Description
Battery
The battery has three major functions in the electrical system.
It is a source of electrical energy for cranking the engine.
It acts as a voltage stabilizer for the electrical system.
It can, for a limited time, provide energy when the electrical
load exceeds the output of the generator.
CARRIER AND HOLD-DOWN
The battery carrier should be in good condition so that it will sup-
port the battery securely and keep it level.
Before installing the battery, the battery carrier and hold-down
clamp should be clean and free from corrosion and make certain
there are no parts in carrier.
To prevent the battery from shaking in its carrier, the hold-down
bolts should be tight enough but not over-tightened.
ELECTROLYTE FREEZING
The freezing point of electrolyte depends on its specific gravity.
Since freezing may ruin a battery, it should be protected against
freezing by keeping it in a fully charged condition. If a battery is
frozen accidentally, it should not be charged until it is warmed.
SULFATION
If the battery is allowed to stand for a long period in discharged
condition, the lead sulfate becomes converted into a hard, crystal-
line substance, which will not easily turn back to the active mate-
rial again during the subsequent recharging. “Sulfation” means
the result as well as the process of that reaction.
Such a battery can be revived by very slow charging and may be
restored to usable condition but its capacity is lower than before.

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-5
1. Generator with regulator assembly 3. Stator coil 5. Field coil (rotor coil) 7. Main switch
2. I.C. regulator 4. Diode 6. Charge indicator light 8. Battery
1. Pulley 5. Stator core 9. Front housing IG: Ignition terminal
2. Pulley nut 6. Field coil 10. Rear housing L: Lamp terminal
3. Rotor fan 7. Regulator B: Generator output (Battery terminal)
4. Stator coil 8. Brush E: Ground

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM 6H-7
How to use the temperature-corrected state-of-charge
graph
Suppose your S.G. reading is 1.28 and the battery temperature is
–5 °C (23 °F). Locate the intersection of the –5 °C line and the
1.28 S.G. line.
The intersection is within the “A” zone (shaded area in the graph)
and that means CHARGED STATE.
To know how much the battery is charged, draw a line parallel to
the zone demarcation line and extend it to the right till it meets
with the percentage scale. In the present example, the line meets
at about 85% point on the percentage scale. Therefore, the bat-
tery is charged up to the 85% level.
Generator
Trouble in charging system will show up as one or more of follow-
ing conditions:
1) Faulty indicator lamp operation.
2) An undercharged battery as evidenced by slow cranking or
indicator dark.
3) An overcharged battery as evidenced by excessive spewing
of electrolyte from vents.
Noise from generator may be caused by a loose drive pulley,
loose mounting bolts, worn or dirty bearings, defective diode, or
defective stator.
FAULTY INDICATOR LAMP OPERATION
CAUTION:
Do not mistake polarities of IG terminal and L terminal.
Do not make a short circuit between IG and L termi-
nals. Always connect these terminals through a lamp.
Do not connect any load between L and E.
When connecting a charger or a booster battery to
vehicle battery, refer to this section describing battery
charging.
B: Generator output (Battery terminal)
E: Ground
IG: Ignition terminal
L: Lamp terminal
Condition Possible Cause Correction
Charge light does not
light with ignition ON
and engine offFuse blown Check fuse.
Light burned out Replace light.
Wiring connection loose Tighten loose connection.
IC regulator or field coil faulty Check generator.
Charge light does not go
out with engine running
(battery requires fre-
quent recharging)Drive belt loose or worn Adjust or replace drive belt.
IC regulator or generator faulty Check charging system.
Wiring faulty Repair wiring.

Downloaded from www.Manualslib.com manuals search engine 6H-8 CHARGING SYSTEM
UNDERCHARGED BATTERY
This condition, as evidenced by slow cranking or indicator clear
with red dot can be caused by one or more of the following condi-
tions even though indicator lamp may be operating normal.
Following procedure also applies to cars with voltmeter and
ammeter.
1) Make sure that undercharged condition has not been caused
by accessories left on for extended period of time.
2) Check drive belt for proper tension.
3) If battery defect is suspected, refer to BATTERY section.
4) Inspect wiring for defects. Check all connections for tight-
ness and cleanliness, battery cable connections at battery,
starting motor and ignition ground cable.
5) Connect voltmeter and ammeter as shown in the figure.
6) Measure current and voltage.
No-load Check
1) Run engine from idling up to 2,000 rpm and read meters.
Standard current
10 A maximum
Standard voltage
14.4 – 15.0 V (at 20 °C, 68 °F)
Higher Voltage
If voltage is higher than standard value, check ground of brushes.
If brushes are not grounded, replace IC regulator.
Lower Voltage
If voltage is below or in standard value, increase engine speed up
to 2,000 – 2,500 rpm soon after starting engine, and read maxi-
mum value on ammeter immediately.
If current is less than 49 A, repair or replace generator.NOTE:
Use fully charged battery.
1. Generator
2. Ammeter (between generator (B) terminal and battery (+) terminal)
3. Voltmeter (between generator (B) terminal and ground)
4. Battery
5. Load
6. Switch
NOTE:
Turn off switches of all accessories (wiper, heater etc.).
NOTE:
Consideration should be taken that voltage will differ
somewhat with regulator case temperature as shown in
the graph.