2005 SUZUKI JIMNY ATE

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-21
Abbreviations May Be Used In This Manual
Abbreviations
AABC
ATDC
API
ATF
ALR
AC
A/T
A/C
ABDC
A/F
A-ELRAnti-lock Brake System
After Top Dead Center
American Petroleum Institute
Automatic Transmission Fluid
Automatic Locking Retractor
Alternating Current
Automatic Transmission
Air Conditioning
After Bottom Dead Center
Air Fuel Mixture Ratio
Automatic-Emergency
Locking RetractorEEBCM
ECM
ECT Sensor
EGR
EGRT Sensor
EFE Heater
ELR
EPS
EVAP
EVAP CanisterElectronic Brake Control Module,
ABS Control Module
Engine Control Module
Engine Coolant Temperature
Sensor (Water Temp. Sensor,
WTS)
Exhaust Gas Recirculation
EGR Temperature Sensor
(Recirculated Exhaust Gas Temp.
Sensor, REGTS)
Early Fuel Evaporation
Heater (Positive Temperature
Coefficient, PTC Heater)
Emergency Locking Retractor
Electronic Power Steering
Evaporative Emission
Evaporative Emission Canister
(Charcoal Canister) BB+
BTDC
BBDCBattery Positive Voltage
Before Top Dead Center
Before Bottom Dead Center
CCKT
CMP Sensor
CO
CPP Switch
CPU
CRSCircuit
Camshaft Position Sensor
(Crank Angle Sensor, CAS)
Carbon Monoxide
Clutch Pedal Position Switch
(Clutch Switch, Clutch Start
Switch)
Central Processing Unit
Child Restraint SystemF 4WD 4 Wheel Drive
GGEN
GNDGenerator
Ground
HHC
HO2SHydrocarbons
Heated Oxygen Sensor
DDC
DLC
DOHC
DOJ
DRL
DTCDirect Current
Data Link Connector
(Assembly Line Diag. Link, ALDL,
Serial Data Link, SDL)
Double Over Head Camshaft
Double Offset Joint
Daytime Running Light
Diagnostic Trouble Code
(Diagnostic Code)IIAC Valve
IAT Sensor
ICM
IG
ISC ActuatorIdle Air Control Valve (Idle Speed
Control Solenoid Valve, ISC
Solenoid Valve)
Intake Air Temperature Sensor
(Air temperature Sensor, ATS)
Immobilizer Control Module
Ignition
Idle Speed Control Actuator
(Motor)

Downloaded from www.Manualslib.com manuals search engine 0A-24 GENERAL INFORMATION
Fasteners Information
Metric Fasteners
Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most impor-
tant that replacement fasteners be the correct diameter, thread pitch and strength.
Fastener Strength Identification
Most commonly used metric fastener strength property classes are 4T, 6.8, 7T, 8.8 and radial line with the class
identification embossed on the head of each bolt. Some metric nuts will be marked with punch, 6 or 8 mark
strength identification on the nut face. Figure shows the different strength markings.
When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the origi-
nal fasteners (the same number marking or higher). It is likewise important to select replacement fasteners of
the correct diameter and thread pitch. Correct replacement bolts and nuts are available through the parts divi-
sion.
Metric bolts: Identification class numbers or marks correspond to bolt strength (increasing numbers represent
increasing strength).
Standard Tightening Torque
Each fastener should be tightened to the torque specified in each section of this manual. If no description or
specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener.
When a fastener of greater strength than the original one is used, however, use the torque specified for the orig-
inal fastener.
1. Nuts strength identification
NOTE:
 For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the tightening
torque given in the chart below.
 The chart below is applicable only where the fastened parts are made of steel light alloy.

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0A 6F1
0B
0B
6G
1A 6H
1B 6K
37A
3A 7A1
3B1 7B1
3C1 7C1
3D 7D
3E 7E
3F 7F
4A2 8A
4B 8B
8C
58D
5A 8E
5B
5C 9
5E
5E1 10
10A
610B
6-1
6A1
6A2
6A4
6B
6C
6E1
6E2
SECTION 0B
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule .................................. 0B-2
Maintenance Schedule Under Normal
Driving Conditions ........................................ 0B-2
Maintenance Recommended Under Severe
Driving Conditions ........................................ 0B-4
Maintenance Service...................................... 0B-5
Engine .......................................................... 0B-5
Drive Belt .................................................. 0B-5
Valve Lash................................................ 0B-6
Engine Oil and Filter ................................. 0B-6
Engine Coolant ......................................... 0B-8
Exhaust System ....................................... 0B-8
Ignition System ............................................. 0B-9
Spark Plugs .............................................. 0B-9
Fuel System ................................................. 0B-9
Air Cleaner Filter ...................................... 0B-9
Fuel Lines and Connections ................... 0B-10
Fuel Filter ............................................... 0B-10
Fuel Tank ............................................... 0B-10
Emission Control System ........................... 0B-10
Crankcase Ventilation Hoses and
Connections ........................................... 0B-10
PCV (Positive Crankcase Ventilation)
Valve ..................................................... 0B-11Fuel Evaporative Emission Control
System ................................................... 0B-11
Chassis and Body ...................................... 0B-11
Clutch ..................................................... 0B-11
Brake Discs and Pads ............................ 0B-11
Brake Drums and Shoes ........................ 0B-12
Brake Hoses and Pipes.......................... 0B-12
Brake Fluid ............................................. 0B-12
Parking Brake Lever and Cable ............. 0B-13
Tires/Wheels .......................................... 0B-13
Suspension System ............................... 0B-14
Propeller Shafts...................................... 0B-15
Manual Transmission Oil........................ 0B-16
Automatic Transmission Fluid ................ 0B-16
Transfer and Differential Oil ................... 0B-17
Steering System ..................................... 0B-18
Steering Knuckle Seal ............................ 0B-18
Power Steering (P/S) System
(if equipped) ........................................... 0B-19
All Hinges, Latches and Locks ............... 0B-19
Final Inspection............................................ 0B-20
Recommended Fluids and Lubricants ....... 0B-22

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
 Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
 Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).

Downloaded from www.Manualslib.com manuals search engine 0B-2 MAINTENANCE AND LUBRICATION
Maintenance Schedule
Maintenance Schedule Under Normal Driving Conditions
NOTE:
 This interval should be judged by odometer reading or months, whichever comes first.
 This table includes service as scheduled up to 90,000 km (54,000 miles) mileage. Beyond 90,000 km
(54,000 miles), carry out the same services at the same intervals respectively.
IntervalKm (x 1,000) 15 30 45 60 75 90
Miles (x 1,000) 9 1827364554
Months 12 24 36 48 60 72
ENGINE
Drive belt V-belt I R I R I R
V-rib belt (Flat type)––I––R
Valve lash (clearance) –I–I–I
Engine oil and oil filter R R R R R R
Engine coolant––R––R
Exhaust system–I–I–I
IGNITION SYSTEM
✱Spark plugs When
unleaded
fuel is usedVehicle without
HO2SNickel spark
plug–R–R–R
Iridium spark
plug––R––R
Vehicle with
HO2SNickel spark
plug––R––R
Iridium spark
plug–––R––
When leaded fuel is used, refer to “Maintenance Recommended Under Severe Driving Condi-
tions” in this section.
FUEL SYSTEM
Air cleaner filter I I R I I R
Fuel lines and connections–I–I–I
Fuel filter Replace every 210,000 km (126,000 miles).
Fuel tank––I––I
EMISSION CONTROL SYSTEM
Crankcase ventilation hoses and connections
(Vehicle without HO2S)––I––I
✱PCV valve Vehicle without HO2S––I––I
Vehicle with HO2S–––––I
✱Fuel evaporative emission
control systemVehicle without HO2S–I–I–I
Vehicle with HO2S–––––I
NOTE:
“R”: Replace or change
“I”: Inspect and correct, replace or lubricate if necessary
 For Sweden, items with
✱
✱✱ ✱ (asterisk) should be performed by odometer reading only.
 For spark plugs, replace every 50,000 km if the local law requires.
 Nickel spark plug: BKR6E-11 (NGK) or K20PR-U11 (DENSO)
 Iridium spark plug: IFR5E11 (NGK) or SK16PR-A11 (DENSO)

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IntervalKm (x 1,000) 153045607590
Miles (x 1,000) 9 18 27 36 45 54
Months 12 24 36 48 60 72
CHASSIS AND BODY
Clutch (pedal height and travel)–I–I–I
Brake discs and pads (thickness, wear, damage) I I I I I I
Brake drums and shoes (wear, damage)–I–I–I
Brake hoses and pipes (leakage, damage, clamp)–I–I–I
Brake fluid–R–R–R
Brake lever and cable (damage, stroke, operation) Inspect at first 15,000 km (9,000 miles) only.
Tires (wear, damage, rotation) I I I I I I
Wheel discs (damage) I I I I I I
Suspension system (tightness, damage, rattle, breakage)–I–I–I
Propeller shafts––I––I
Manual transmission oil (leakage, level) (I: 1st 15,000 km only) I–R––R
Automatic transmission Fluid level–I–I–I
Fluid change Replace every 165,000 km (99,000 miles).
Fluid hose–––R––
Transfer oil (leakage, level) I–I–I–
Differential oil (leakage, level) (R: 1st 15,000 km only) R or I–I–I–
Steering system (tightness, damage, breakage, rattle)–I–I–I
Power steering (if equipped) I I I I I I
All latches, hinges and locks–I–I–I
NOTE:
“R”: Replace or change
“I”: Inspect and correct, replace or lubricate if necessary

Downloaded from www.Manualslib.com manuals search engine 0B-4 MAINTENANCE AND LUBRICATION
Maintenance Recommended Under Severe Driving Conditions
If the vehicle is usually used under the conditions corresponding to any severe condition code given below, it is
recommended that applicable maintenance operation be performed at the particular interval as shown in the fol-
lowing table.
Severe condition code
A : Repeated short trips
B : Driving on rough and/or muddy roads
C : Driving on dusty roads
D : Driving in extremely cold weather and/or salted roads
E : Repeated short trips in extremely cold weather
F : Leaded fuel use
G : – – – – –
H : Trailer towing (if admitted)
Severe
Condition CodeMaintenanceMaintenance
OperationMaintenance Interval
– B C D – – – –Drive belt (V-rib belt)IEvery 15,000 km
(9,000 miles) or 12 months
REvery 45,000 km
(27,000 miles) or 36 months
A – C D E F – H Engine oil and oil filter R Every 5,000 km (3,000 miles) or 4 months
– B – – – – – –Exhaust pipe mountings IEvery 15,000 km
(9,000 miles) or 12 months
– – C – – – – –Air cleaner filter ✱1I Every 2,500 km (1,500 miles)
REvery 30,000 km
(18,000 miles) or 24 months
A B C – E F – H Spark plugsNickel spark plug R Every 10,000 km (6,000 miles) or 8 months
Iridium spark plug
REvery 30,000 km
(18,000 miles) or 24 months
– B C D – – – H Wheel bearing IEvery 15,000 km
(9,000 miles) or 12 months
– B – – – – – –Suspension bolts and nuts TEvery 15,000 km
(9,000 miles) or 12 months
– B – D E – – H Propeller shafts IEvery 15,000 km
(9,000 miles) or 12 months
– B – – E – – HManual transmission,
transfer and differential oilRFirst time only:
15,000 km (9,000 miles) or 12 months
Second time and after: Every 30,000 km
(18,000 miles) or 24 months reckoning from
0 km (0 mile) or 0 month
– B – – E – – H Automatic transmission fluid REvery 30,000 km
(18,000 miles) or 24 months
– B C D – – – –Steering knuckle seal IEvery 15,000 km
(9,000 miles) or 12 months
NOTE:
 “I”: Inspect and correct, replace or lubricate if necessary
 “R”: Replace or change
 “T”: Tighten to the specified torque

✱
✱✱ ✱1: Inspect or replace more frequently if necessary

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Maintenance Service
Engine
Drive Belt
WATER PUMP AND GENERATOR DRIVE BELT INSPEC-
TION
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace.
Check belt for tension.
Water pump and generator belt tension
“a”: 4.5 – 5.5 mm (0.18 – 0.22 in.) deflection under 100 N
(10 kg, 22 lb) pressure
3) If belt is too tight or too loose, adjust it to specification by
adjusting alternator position.
4) Tighten alternator adjusting bolts and pivot bolt.
5) Connect negative cable to battery.
REPLACEMENT
Replace belt. Refer to “Water Pump Belt and Cooling Fan” in Sec-
tion 6B for replacement procedure of pump belt.
POWER STEERING PUMP AND/OR A/C COMPRESSOR
DRIVE BELTS INSPECTION (IF EQUIPPED)
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanli-
ness. If any defect exists, replace. WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
NOTE:
When replacing belt with a new one, adjust belt tension
to 3 – 4 mm (0.12 – 0.16 in.).

Downloaded from www.Manualslib.com manuals search engine 0B-6 MAINTENANCE AND LUBRICATION
3) Check belt for tension.
Power steering pump and/or A/C compressor drive belt
tension
“a”: 6 – 9 mm (0.24 – 0.35 in.) deflection under 100 N
(10 kg, 22 lb) pressure.
4) If belt tension is out of above specification, adjust it referring
to “Compressor Drive Belt” in Section 1B or “Power Steering
Belt Check” in Section 3B1.
5) Connect negative cable to battery.
REPLACEMENT
Replace belt with new one referring to “Compressor Drive Belt” in
Section 1B or “Power Steering Belt Check” in Section 3B1.
Valve Lash
INSPECTION
1) Inspect intake and exhaust valve lash and adjust as neces-
sary.
Refer to “Valve Lash (Clearance)” in Section 6A1 for valve
lash inspection and adjustment procedure.
Engine Oil and Filter
CHANGE
Before draining engine oil, check engine for oil leakage. If any evi-
dence of leakage is found, make sure to correct defective part
before proceeding to the following work.
1. P/S pump pulley
2. Camshaft pulley
3. A/C compressor pulley (if equipped)
4. Belt tension pulley
1. Camshaft
2. Thickness gauge
WARNING:
 New and used engine oil can be hazardous.
Be sure to read “WARNING” in General Precaution in
Section 0A and observe what in written there.
 Step 1) – 7) outlined below must be performed with
ENGINE NOT RUNNING. For step 8), be sure to have
adequate ventilation while engine is running.