2005 SUZUKI JIMNY relay

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-7
Brake warning light
turns on when brake
is appliedBrake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Insufficient amount of brake fluid Add brake fluid.
Faulty P & Differential valve (Differential switch) Replace.
Brake warning light
fails to turn on even
when parking brake is
appliedBulb burnt out Replace bulb.
Brake warning light circuit open Repair circuit.
ABS warning light
does not turn on for 2
sec. after ignition
switch has turned ON.Bulb burnt out Replace bulb.
ABS warning light circuit open, if equipped with
ABS (including check relay)Check system referring to “TABLE-
A” in Section 5E.
ABS warning light
remains on after igni-
tion switch has turned
on for 2 sec.Malfunctioning ABS, if equipped with ABS Check system referring to “TABLE-
B” in Section 5E. Condition Possible Cause Correction

Downloaded from www.Manualslib.com manuals search engine 6-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Precaution on fuel system service
Work must be done with no smoking, in a well-ventilated
area and away from any open flames.
As fuel feed line (between fuel pump and fuel delivery pipe)
is still under high fuel pressure even after engine was
stopped, loosening or disconnecting fuel feed line directly
may cause dangerous spout of fuel to occur where loosened
or disconnected.
Before loosening or disconnecting fuel feed line, make sure
to release fuel pressure according to “FUEL PRESSURE
RELIEF PROCEDURE”. A small amount of fuel may be
released after the fuel line is disconnected. In order to
reduce the chance of personal injury, cover the fitting to be
disconnected with a shop cloth. Put that cloth in an approved
container when disconnection is completed.
Never run engine with fuel pump relay disconnected when
engine and exhaust system are hot.
Fuel or fuel vapor hose connection varies with each type of
pipe. When reconnecting fuel or fuel vapor hose, be sure to
connect and clamp each hose correctly referring to the figure
Hose Connection.
After connecting, make sure that it has no twist or kink.
When installing injector or fuel delivery pipe, lubricate its O-
ring with spindle oil or gasoline.
When connecting fuel pipe flare nut, first tighten flare nut by
hand and then tighten it to specified torque.
[A] : With short pipe, fit hose as far as it reaches pipe joint as shown.
[B] : With following type pipe, fit hose as far as its peripheral projection as shown.
[C] : With bent pipe, fit hose as its bent part as shown or till pipe is about 20 to 30 mm
(0.79 – 1.18 in.) into the hose.
[D] : With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79 – 1.18 in.) into the
hose.
1. Hose
2. Pipe
3. Clamp
4. Clamp securely at a position 3 to 7 mm (0.1 2 – 0.27 in.) from hose end.
5. 20 to 30 mm (0.79 – 1.18 in.)

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-5
Fuel pressure relief procedure
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector
lever to “P” range for A/T model), set parking brake, and
block drive wheels.
2) Remove relay box cover.
3) Disconnect fuel pump relay (1) from its connector.
4) Remove fuel filler cap to release fuel vapor pressure in fuel
tank and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat
cranking engine 2-3 times for about 3 seconds each time to
dissipate fuel pressure in lines. Fuel connections are now
safe for servicing.
6) Upon completion of servicing, connect fuel pump relay (1) to
its connector.
Fuel leakage check procedure
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump)
and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pres-
sure to fuel line. (till fuel pressure is felt by hand placed on
fuel feed hose.)
2) In this state, check to see that there are no fuel leakages
from any part of fuel system. CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.

Downloaded from www.Manualslib.com manuals search engine 6-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Precaution in Diagnosing Trouble
Don’t disconnect couplers from ECM, battery cable at battery, ECM ground wire harness from engine or
main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in ECM memory.
Such disconnection will erase memorized information in ECM memory.
Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan
tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to have
good understanding as to what functions are available and how to use it.
Priorities for diagnosing troubles (Vehicle with Immobilizer indicator lamp).
If multiple diagnostic trouble codes (DTCs) are stored, proceed to the flow table of the DTC which has
detected earliest in the order and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
–Diagnostic trouble codes (DTCs) other than DTC P0171/P0172 (Fuel system too lean / too rich), DTC
P0300/P0301/P0302/P0303/P0304 (Misfire detected) and DTC P0400 (EGR flow malfunction)
–DTC P0171/P0172 (Fuel system too lean / too rich) and DTC P0400 (EGR flow malfunction)
–DTC P0300/P0301/P0302/P0303/P0304 (Misfire detected)
Be sure to read “Precautions for Electrical Circuit Service” in Section 0A before inspection and observe what
is written there.
ECM Replacement
When substituting a known-good ECM, check for following conditions. Neglecting this check may cause
damage to a known-good ECM.
–Resistance value of all relays, actuators is as specified respectively.
–MAP sensor and TP sensor are in good condition and none of power circuits of these sensors is shorted
to ground.AMBIENT TEMPERATURE TIME TO CUT POWER TO
ECM
Over 0 °C (32 °F) 60 sec. or longer
Under 0 °C (32 °F)Not specifiable.
Select a place with higher than
0 °C (32 °F) temperature.

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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 6-31
THROTTLE POS (ABSOLUTE THROTTLE POSITION, %)
When throttle position sensor is fully closed position, throttle opening is indicated as 0% and 100% full open
position.
OXYGEN SENSOR B1 S1 (HEATED OXYGEN SENSOR-1, V)
It indicates output voltage of HO2S-1 installed on exhaust manifold (pre-catalyst).
OXYGEN SENSOR B1 S2 (HEATED OXYGEN SENSOR-2, V)
It indicates output voltage of HO2S-2 installed on exhaust pipe (post-catalyst). It is used to detect catalyst dete-
rioration.
DESIRED IDLE (DESIRED IDLE SPEED, rpm)
The Desired Idle Speed is an ECM internal parameter which indicates the ECM requested idle. If the engine is
not running, this number is not valid.
TP SENSOR VOLT (THROTTLE POSITION SENSOR OUTPUT VOLTAGE, V)
The Throttle Position Sensor reading provides throttle valve opening information in the form of voltage.
INJ PULSE WIDTH (FUEL INJECTION PULSE WIDTH, msec.)
This parameter indicates time of the injector drive (valve opening) pulse which is output from ECM (but injector
drive time of NO.1 cylinder for multiport fuel injection).
IAC FLOW DUTY (IDLE AIR (SPEED) CONTROL DUTY, %)
This parameter indicates current flow time rate within a certain set cycle of IAC valve (valve opening rate) which
controls the amount of bypass air (idle speed).
TOTAL FUEL TRIM (%)
The value of Total Fuel Trim is obtained by putting values of short Term Fuel Trim and Long Term Fuel Trim
together. This value indicates how much correction is necessary to keep the air / fuel mixture stoichiometrical.
BATTERY VOLTAGE (V)
This parameter indicates battery positive voltage inputted from main relay to ECM.
CANIST PURGE DUTY (EVAP CANISTER PURGE FLOW DUTY, %)
This parameter indicates valve ON (valve open) time rate within a certain set cycle of EVAP purge solenoid
valve which controls the amount of EVAP purge.
0% means that the purge valve is completely closed while 100% is a fully open valve.
CLOSED THROTTLE POSITION (ON / OFF)
This parameter will read ON when throttle valve is fully closed, or OFF when the throttle is not fully closed.
FUEL CUT (ON / OFF)
ON : Fuel being cut (output signal to injector is stopped)
OFF : Fuel not being cut
A/C CONDENSER FAN (A/C CONDENSER FAN RELAY, ON / OFF)
ON : Command for condenser fan relay operation being output.
OFF : Command for relay operation not being output.
ELECTRIC LOAD (ON / OFF)
ON : Headlight, small light, heater fan or rear window defogger ON signal inputted.
OFF : Above electric loads all turned OFF.
A/C SWITCH (ON / OFF)
ON : Command for A/C operation being output from ECM to A/C amplifier.
OFF : Command for A/C operation not being output.

Downloaded from www.Manualslib.com manuals search engine 6-36 ENGINE GENERAL INFORMATION AND DIAGNOSIS
For TYPE A (See NOTE)
E1918EGR valve (stepper motor coil 1, if
equipped)10 – 14 VIgnition switch ON position leaving engine
OFF
19 Ignition coil #2––
20 Ignition coil #1––
21 Fuel injector NO.2 10 – 14 V Ignition switch ON
22 Power source for sensors 4.75 – 5.25 V Ignition switch ON
23 Crankshaft position sensor0 – 0.8 or
4 – 5 VIgnition switch ON position
24–– –
25 Knock sensor About 2.5 VAt specified idle speed after engine
warmed up
26 Manifold absolute pressure sensor 3.3 – 4.0 VIgnition switch ON
Barometric pressure : 100 kPa
(760 mmHg)
27–– –
28EGR valve (stepper motor coil 4, if
equipped)10 – 14 VIgnition switch ON position leaving engine
OFF
29EGR valve (stepper motor coil 2, if
equipped)10 – 14 VIgnition switch ON position leaving engine
OFF
30–– –
31 Fuel injector NO.3 10 – 14 V Ignition switch ON TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
NOTE:
See NOTE in “ECM TERMINAL VOLTAGE VALUES TABLE” for applicable model.
TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
E181 A/C compressor clutch 0 V Ignition switch ON
2 Malfunction indicator lamp10 – 14 V Engine running
0 – 1.0 V Ignition switch ON leaving engine OFF
3 Data link connector 10 – 14 V Ignition switch ON
4 Heater of HO2S-2 (if equipped) 10 – 14 V Ignition switch ON
5 Power source 10 – 14 V Ignition switch ON
6 Power source 10 – 14 V Ignition switch ON
7 Power source for buck-up 10 – 14 V Ignition switch ON and OFF
8Immobilizer indicator lamp
(with immobilizer indicator lamp)10 – 14 V Engine running
0 – 1.0 V Ignition switch ON leaving engine OFF
Duty output terminal (without
immobilizer indicator lamp)0 – 1.0 V Ignition switch ON
9–– –
10 Main relay10 – 14 V Ignition switch OFF
0.4 – 1.5 V Ignition switch ON
11 Tachometer––
12 Data link connector 4 – 5 V Ignition switch ON
13 Heated oxygen sensor-2 Refer to DTC P0130 diag. flow table

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-37
For TYPE B (See NOTE)
E1814Diag. Switch terminal (without
immobilizer indicator lamp)4 – 5 V Ignition switch ON
15Test switch terminal (without immo-
bilizer indicator lamp)4 – 5 V Ignition switch ON
16 A/C (input) signal10 – 14 VIgnition switch ON
A/C switch OFF
0 – 2 VIgnition switch ON
A/C switch ON
17 Lighting switch10 – 14 V Lighting switch ON
0 – 1.3 V Lighting switch OFF
18A/C condenser fan motor relay
(if equipped)0 – 1.0 V A/C is operating
10 – 14 V A/C is not operating
19 Fuel pump relay0 – 1 V For 2 seconds after ignition switch ON
10 – 14 V After the above time
20 Sensor ground––
21Throttle opening signal for
TCM (A/T)Indication
deflection
repeated
0 V and
10 – 14 VIgnition switch ON
22Fuel level sensor (gauge)
(with immobilizer indicator lamp)0 – 2 VIgnition switch ON
Fuel tank fully filled
4.5 – 7.5 VIgnition switch ON
Fuel tank emptied
23–– –
24 Heater blower switch0 – 2.0 VIgnition switch ON and heater blower
switch ON
10 – 14 VIgnition switch ON and heater blower
switch OFF TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
NOTE:
See NOTE in “ECM TERMINAL VOLTAGE VALUES TABLE” for applicable model.
TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
E181 A/C compressor clutch 0 V Ignition switch ON
2–– –
3–– –
4–– –
5 Power source 10 – 14 V Ignition switch ON
6 Power source 10 – 14 V Ignition switch ON
7 Power source for buck-up 10 – 14 V Ignition switch ON and OFF
8Immobilizer indicator lamp
(with immobilizer indicator lamp)10 – 14 V Engine running
0 – 1.0 V Ignition switch ON leaving engine OFF
Duty output terminal (without
immobilizer indicator lamp)0 – 1.0 V Ignition switch ON