2005 SUZUKI JIMNY fuel pump

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Table B-2 Fuel Pump and Its Circuit Check
INSPECTION
1. Ignition switch 3. Main relay 5. Fuel pump relay [A] : Case of TYPE A is shown (See NOTE)
2. Main relay 4. Main fuse 6. Fuel pump [B] : Case of TYPE B is shown (See NOTE)
NOTE:
For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable
model.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check Fuel Pump Control System for Opera-
tion. See Fig. 1.
Is fuel pump heard to operate for 2 sec. after
ignition switch ON?Fuel pump circuit is in
good condition.Go to Step 3.
3 Check Fuel Pump for Operation.
1) Remove fuel pump relay from relay box with
ignition switch OFF.
2) Check for proper connection to relay at each
terminals.
3) If OK, using service wire, connect terminals
“A” and “B” of relay connector. See Fig. 2
and CAUTION.
Is fuel pump heard to operate at ignition switch
ON?Go to Step 4.“P”, “B” or “Bl/B” circuit
open or fuel pump mal-
function.

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[A] Fig. 1 for Step 2 / [B] Fig. 2 for Step 3 / [C] Fig. 3 for Step 44 Check Fuel Pump Relay for Operation.
1) Check resistance between each two termi-
nals of fuel pump relay. See Fig.3.
Fuel pump relay resistance
Between terminals “A” and “B” : Infinity
Between terminals “C” and “D”: 100 – 150
Ω
ΩΩ Ω
2) Check that there is continuity between ter-
minals “A” and “B” when battery is con-
nected to terminals “C” and “D”. See Fig. 3.
Is fuel pump relay in good condition?“W/G” circuit open or poor
E18-19 connection.
If wire and connection are
OK, substitute a known-
good ECM and recheck.Replace fuel pump
relay. Step Action Yes No
CAUTION:
Check to make sure that connection is made between correct terminals. Wrong connection can cause
damage to ECM, wire harness, etc.

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Table B-3 Fuel Pressure Check
INSPECTION
1. Injector 3. Fuel pump (B) : Hose
2. Delivery pipe (A) : Fuel pressure gauge (C) : Attachment
Step Action Yes No
1 Check Fuel Pressure (Refer to Section 6E for
details).
1) Release fuel pressure from fuel feed line.
2) Install fuel pressure gauge. See Fig.1.
3) Check fuel pressure by repeating ignition
switch ON and OFF.
Is fuel pressure then 270 – 310 kPa
(2.7 - 3.1 kg/cm
2, 38.4 – 44.0 psi)?Go to Step 2. Go to Step 4.
2
Is 250 kPa (2.5 kg/cm
2, 35.6 psi) or higher fuel
pressure retained for 1 minute after fuel pump is
stopped at Step 1?Normal fuel pressure. Go to Step 3.
3 Is there fuel leakage from fuel feed line hose,
pipe or their joint?Fuel leakage from hose,
pipe or joint.Faulty fuel pressure regu-
lator.
4 Was fuel pressure higher than spec. in Step 1? Faulty fuel pressure regu-
lator.Clogged fuel filter,
Restricted fuel feed hose
or pipe, Faulty fuel pump
or Fuel leakage from hose
connection in fuel tank.

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9) Disconnect accelerator cable (1) from throttle body.
10) Disconnect the following hoses:
Brake booster hose (2) from intake manifold
Canister purge hose (3) from EVAP canister purge valve
Fuel feed and return hoses (4) from each pipe
Water hose from thermostat case (5)
Heater inlet hose from its pipe
Vacuum hose (to check valve) (6)
11) Remove canister purge hose bracket from intake manifold.
12) Remove intake manifold stiffener (1).
13) Remove oil pan referring to “Oil Pan and Oil Pump Strainer”
in this section.
14) Remove cylinder head cover referring to “Cylinder Head
Cover” in this section.
15) Remove timing chain cover referring to “Timing Chain Cover”
in this section.
16) Remove timing chain referring to “Timing Chain and Chain
Tensioner” in this section.
17) Remove intake and exhaust camshafts referring to “Cam-
shaft, Tappet and Shim” in this section.
18) Disconnect exhaust pipe (1) from exhaust manifold.

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6) Install exhaust manifold stiffener and exhaust pipe referring
to “Exhaust Manifold” in this section.
7) Install camshafts, timing chain and chain cover referring to
“Camshaft, Tappet and Shim”, “Timing Chain and Chain
Tensioner” and “Timing Chain Cover” in this section.
8) Install cylinder head cover and oil pan referring to “Cylinder
Head Cover” and “Oil Pan and Oil Pump Strainer” in this sec-
tion.
9) Install intake manifold stiffener and connect each hoses and
electric lead wires securely.
10) Install air cleaner outlet hoses.
11) Install radiator with cooling fan and connect A/T fluid hoses
(vehicle with A/T), radiator inlet and outlet hoses referring to
“Water Pump Belt and Cooling Fan” and “Radiator” in Sec-
tion 6B.
12) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
13) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
14) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
15) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
16) Refill cooling system with coolant, engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
17) Connect negative cable at battery.
18) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.

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5) Install bearing cap (1):
Point arrow mark (2) on cap to crankshaft pulley side.
After applying oil to rod bolts and tighten cap nuts (3) gradu-
ally as follows.
a) Tighten all cap nuts to 15 N·m (1.5 kg-m, 11.0 lb-ft).
b) Retighten them to 45°.
c) Repeat Step b).
Tightening torque
Connecting rod bearing cap nuts
(a) : 15 N·m (1.5 kg-m, 11.0 lb-ft) and extra tightening 45°
twice.
6) Reverse removal procedure for installation as previously out-
lined.
7) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
8) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
9) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
10) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
11) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
12) Connect negative cable at battery.
13) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection. NOTE:
Before installing bearing cap, make sure to check con-
necting rod bolt diameter.
Refer to “Inspection” of “Connecting Rod” in this sec-
tion.

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Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Remove engine hood after disconnecting windshield washer
hose.
4) Remove A/C compressor and/or P/S pump belt (if
equipped).
5) Remove generator belt.
6) Drain engine oil.
7) Drain coolant.
8) Disconnect radiator inlet and outlet hoses from each pipe.
9) Disconnect A/T fluid hoses (2) (vehicle with A/T) and release
its clamps. Place some container under radiator to receive
A/T fluid which will flow out when hose is disconnected.
10) Remove fan shroud upper bolts and install board (1) or the
like. This prevents damage to radiator fins when removing
and installing radiator.
11) Remove radiator with cooling fan referring to Section 6B.
Then remove water pump pulley.
12) With hose connected, detach P/S pump from its bracket (if
equipped) referring to “Power Steering Pump” in Section
3B1.
13) If vehicle equipped with A/C compressor, work of right hand
steering vehicle differs from its of left hand steering vehicle.
Each work is as follows. WARNING:
To help avoid danger of being burned, do not remove
drain plug (1) and radiator cap while engine and radiator
are still hot. Scalding fluid and steam can be blown out
under pressure if plug and cap are taken off too soon.
NOTE:
Suspend removed P/S pump at a place where no damage
will be caused during removal and installation of engine
assembly.

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Install seal ring and exhaust pipe to exhaust manifold.
Tighten pipe fasteners to specified torque.
Tightening torque
Exhaust pipe bolts (a) : 50 N·m (5.0 kg-m, 36.5 lb-ft)
6) Reverse disconnected hoses, cables and electric wires for
connection.
7) Install air cleaner outlet hoses.
8) Install radiator with cooling fan and connect A/T fluid hoses
(vehicle with A/T), radiator inlet and outlet hoses referring to
“Water Pump Belt and Cooling Fan” and “Radiator” in Sec-
tion 6B.
9) Adjust generator belt tension referring to “Water Pump Belt
Tension” in Section 6B.
10) Adjust A/C compressor and/or P/S pump belt tension (if
equipped) referring to “Compressor Drive Belt” in Section 1B
or “Power Steering Belt” in Section 3B1.
11) Adjust accelerator cable play referring to “Accelerator Cable
Adjustment” in Section 6E.
12) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
13) Refill cooling system with coolant engine with engine oil and
A/T with specified A/T fluid (vehicle with A/T).
14) Connect negative cable at battery.
15) Verify that there is no fuel leakage, coolant leakage, oil leak-
age, A/T fluid leakage (vehicle with A/T) and exhaust gas
leakage at each connection.