2005 SUZUKI JIMNY PCV

Downloaded from www.Manualslib.com manuals search engine 6-68 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0171 Fuel System Too Lean
DTC P0172 Fuel System Too Rich
CIRCUIT DESCRIPTION
[a] : Signal to decrease amount of fuel injection [d] : A/F mixture becomes richer
(Oxygen concentration decreases)1. Injector
[b] : Signal to increase amount of fuel injection [e] : High voltage 2. Heated oxygen sensor-1 (HO2S-1)
[c] : A/F mixture becomes leaner
(Oxygen concentration increases)[f] : Low voltage
DTC DETECTING CONDITION POSSIBLE CAUSE
When following condition occurs while engine running
under closed loop condition.
–Air / fuel ratio too lean
(Total fuel trim (short and long terms added) is more
than 30%)
or
–Air / fuel ratio too rich
(Total fuel trim is less than –30%)
✱
✱✱ ✱2 driving cycle detection logic, continuous monitoring.Vacuum leaks (air drawn in).
Exhaust gas leakage.
Heated oxygen sensor-1 circuit malfunction.
Fuel pressure out of specification.
Fuel injector malfunction (clogged or leakage).
MAP sensor poor performance.
ECT sensor poor performance.
IAT sensor poor performance.
TP sensor poor performance.
EVAP control system malfunction.
PCV valve malfunction.

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5 Check Fuel Injectors and Circuit.
1) Using sound scope (4) or such, check operating
sound of each injector (5) when engine is run-
ning. Cycle of operating sound should vary
according to engine speed. See Fig. 3.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Turn ignition switch OFF and disconnect a fuel
injector connector.
3) Check for proper connection to fuel injector at
each terminal.
4) If OK, then check injector resistance.
See Fig. 4.
Injector resistance
11.3 – 13.8 ohm at 20 °C (68 °F)
5) Carry out steps 1) and 3) on each injector.
6) Check each injector for injected fuel volume
referring to Section 6E. See Fig. 5.
Injected fuel volume
43 – 47 cc/15 sec (1.45/1.51 – 1.58/1.65 US/
Imp.oz/15 sec)
7) Check each injector for fuel leakage after injec-
tor closed.
Fuel leakage
Less than 1 drop / min. (1)
Is check result in step 1) and 3) to 7) satisfactory?Go to Step 6. Check injector circuit or
replace fuel injector(s).
6 Check EVAP Canister Purge Valve.
1) Disconnect purge hose (2) 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. 6.
Is vacuum felt?Check EVAP control
system (See Section
6E).Go to Step 7.
7 Check intake manifold absolute pressure sensor for
performance (See step 4) of DTC P0105 (No.11)
Diag. Flow Table).
Is it in good condition?Go to Step 8. Repair or replace.
8 Check engine coolant temp. sensor for perfor-
mance (See Section 6E).
Is it in good condition?Go to Step 9. Replace engine coolant
temp. sensor.
9 Check intake air temp. sensor for performance
(See Section 6E).
Is it in good condition?Go to Step 10. Replace intake air temp.
sensor.
10 Check throttle position sensor for performance
(See step 5) of DTC P0121 Diag. Flow Table).
Is it in good condition?Go to Step 11. Replace throttle position
sensor.
11 Check PCV valve for valve clogging
(See Section 6E).
Is it good condition?Substitute a known-
good ECM and recheck.Replace PCV valve. Step Action Yes No

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DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
2) Clear DTC with ignition switch ON.
3) Check vehicle and environmental condition for :
–Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Ambient temp. : –10 °C, 14 °F or higher
–Intake air temp. : 70 °C, 158 °F or lower
–Engine coolant temp. : – 10 – 110 °C, 14 – 230 °F
4) Start engine and keep it at idle for 2 min. or more.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
6) If DTC is not detected at idle, consult usual driving based on information obtained in “Customer complaint
analysis” and “Freeze frame data check”.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
Engine under other than high revolution condition
Not on rough road
Engine speed changing rate (below specified value)
Manifold absolute pressure changing rate (below
specified value)
Throttle opening changing rate (below specified
value)
Misfire rate per 200 or 1000 engine revolutions (how
much and how often crankshaft revolution speed
changes) is higher than specified valueEngine overheating
Vacuum leaks (air inhaling) from air intake system
Ignition system malfunction (spark plug(s), high-
tension cord(s), ignition coil assembly)
Fuel pressure out of specification
Fuel injector malfunction (clogged or leakage)
Engine compression out of specification
Valve lash (clearance) out of specification
Manifold absolute pressure sensor malfunction
Engine coolant temp. sensor malfunction
PCV valve malfunction
EVAP control system malfunction
EGR system malfunction
NOTE:
Among different types of random misfire, if misfire occurs at cylinders 1 and 4 or cylinders 3 and 2
simultaneously, it may not possible to reconfirm DTC by using the following DTC confirmation proce-
dure. When diagnosing the trouble of DTC P0300 (Random misfire detected) of the engine which is
apparently misfiring, even if DTC P0300 cannot be reconfirmed by using the following DTC confirma-
tion procedure, proceed to the following Diag. Flow Table.
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine
Diag. Flow Table”.
2 Is there DTC other than Fuel system (DTC P0171/
P0172) and misfire (DTC P0300 – P0304)?Go to applicable DTC
Diag. Flow Table.Go to Step 3.

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3 Check Ignition System.
1) Remove spark plugs and check them for;
Air gap : 1.0 – 1.1 mm (0.040 – 0.043 in.) See Fig. 1.
Carbon deposits / Insulator damage / Plug type
If abnormality is found, adjust, clean or replace by
referring to Section 6F. (See CAUTION)
2) Disconnect all injector connectors. See Fig. 2.
3) Connect spark plugs to high tension cords and then
ground spark plugs.
4) Crank engine and check that each spark plug sparks.
Are above check results satisfactory?Go to Step 4. Check ignition sys-
tem parts (Refer to
Section 6F).
4 Check Fuel Pressure (Refer to Section 6E for details).
1) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge. See Fig. 3.
3) Check fuel pressure.
Fuel pressure specification
With fuel pump operating and engine at stop :
270 – 310 kPa, 2.7 – 3.1 kg/cm
2, 38.4 – 44.0 psi.
At specified idle speed :
210 – 260 kPa, 2.1 – 2.6 kg/cm
2, 29.8 – 37.0 psi.
Is measured value as specified?Go to Step 5. Go to Diag. Flow
Table B-3 fuel pres-
sure check.
5 Check Fuel Injectors and Circuit.
1) sing sound scope (1) or such, check operating sound
of each injector (2) when engine is running. Cycle of
operating sound should very according to engine
speed. See Fig 4.
If no sound or an unusual sound is heard, check
injector circuit (wire or coupler) or injector.
2) Turn ignition switch OFF and disconnect a fuel injec-
tor connector.
3) Check for proper connection to fuel injector at each
terminal.
4) If OK, then check injector resistance. See Fig. 5.
Injector resistance
11.3 – 13.8 ohm at 20 °C (68 °F)
5) Carry out steps 1) and 3) on each injector.
6) Check each injector for injected fuel volume referring
to Section 6E. See Fig. 6.
Injected fuel volume
43 – 47 cc/15 sec (1.45/1.51 – 1.58/1.65 US/Imp. oz/
15 sec)
7) Check each injector for fuel leakage after injector
closed.
Fuel leakage
Less than 1 drop/min.
Is check result in step 1) and 3) to 7) satisfactory?Go to Step 6. Check injector cir-
cuit or replace fuel
injector(s).
6 Check PCV valve for clogging (See Section 6E).
Is it in good condition?Go to Step 7. Replace PCV
valve. Step Action Yes No

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Table B-4 Idle Air Control System Check
INSPECTION
1. Main fuse 2. Fuse box 3. Main relay 4. IAC valve
Step Action Yes No
1 Check engine idle speed and IAC duty referring to
“Idle Speed / IAC Duty Inspection” in Section 6E.
Is idle speed within specification?Go to Step 2. Go to Step 4.
2 Is IAC duty within specification in Step 1? Go to Step 3. Check for followings :
Vacuum leak
EVAP canister purge
control system
Clog of IAC air pas-
sage
Accessory engine
load
Closed throttle posi-
tion (TP sensor)
Stuck of PCV valve

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3 Is engine idle speed kept specified speed even
with headlight ON?System is in good condi-
tion.Check IAC system for
operation referring to
Step 3 or Step 4 of DTC
P0505 Diag. Flow Table.
4 Was idle speed higher than specification in Step
1?Go to Step 5. Go to Step 8.
5 Check A/C (input) signal circuit referring to Step 1
of Table B-5 A/C Signal Circuit Check, if
equipped. (A/C signal can be also checked by
using SUZUKI scan tool.)
Is it in good condition?Go to Step 6. Repair or replace A/C
signal circuit or A/C sys-
tem.
6 Check IAC system referring to Step 2 to Step 4 of
DTC P0505 Diag. Flow Table.
Is check result satisfactory?Go to Step 7. Go to Step 5 of DTC
P0505 Diag. Flow Table.
7 Was IAC duty less than about 3% (or more than
about 97% for OFF duty meter) in Step 1 of this
table?Check abnormal air
inhaling from air intake
system, PCV valve and
EVAP canister purge
control system.Check TP sensor
(closed throttle position)
and ECT sensor for per-
formance.
If sensors are OK, sub-
stitute a known-good
ECM.
8 Is SUZUKI scan tool available? Go to Step 9. Go to Step 10.
9 Check PNP signal (“D” range signal).
1) Connect SUZUKI scan tool to DLC with igni-
tion switch OFF.
2) Turn ignition switch ON and check PNP signal
(“P/N” and “D” range) on display when shifting
selector lever to each range. See Table 1.
Is check result satisfactory?Go to Step 11. Repair or replace.
10 Check PNP signal (“D” range signal).
1) Turn ignition switch ON.
2) Check voltage at terminal E17-6 of ECM con-
nector connected. See Fig. 1 and Table 1.
Is check result satisfactory?Go to Step 11. Repair or replace.
11 Check IAC system referring to Step 2 to Step 4 of
DTC P0505 Diag. Flow Table.
Is check result satisfactory?Go to Step 12. Go to Step 5 of DTC
P0505 Diag. Flow Table.
12 Was IAC duty more than about 30% or ✱40% (or
less than 70% or ✱60% for OFF duty meter) in
Step 1 of this table? See NOTE.Check parts or system
which can cause engine
low idle.
Accessory engine load
Clog of air passage
Etc.Substitute a known-good
ECM and recheck. Step Action Yes No
NOTE:
Duty value with (
✱
✱✱ ✱) are applicable to vehicle used at high altitude (higher than 2000 m or 6560 ft).

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-15
Cylinder Head Cover
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect accelerator cable (1) from clamp (2) (For left
hand steering vehicle only).
3) Remove cylinder head upper cover (3).
4) Disconnect ignition coil couplers (1).
5) Remove ignition coil assemblies (2) with high-tension cord
(3).
6) Remove oil level gauge (1).
7) Disconnect breather hose (2) from cylinder head cover (3)
and PCV hose (4) from PCV valve (5).
8) Remove cylinder head cover mounting bolts in such order as
indicated in figure.
9) Remove cylinder head cover (1) with cylinder head cover
gasket (2) and spark plug hole gasket (3).

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3) Install cylinder head cover to cylinder head.
4) Tighten bolts in such order as indicated in figure a little at a
time till they are tightened to specified torque.
Tightening torque
Cylinder head cover bolts (a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
5) Connect breather hose (1) and PCV hose (2).
6) Install oil level gauge (3).
7) Install ignition coil assemblies with high-tension cord.
8) Connect ignition coil couplers.
9) Install cylinder head upper cover.
10) Connect accelerator cable to clamp (For left hand steering
vehicle only).
11) Connect negative cable at battery.NOTE:
When installing cylinder head cover, use care so that cyl-
inder head cover gasket or spark plug hole gaskets will
not get out of place or fall off.