2005 SUZUKI JIMNY throttle body

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Air Intake System
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), throttle body (3),
idle air control valve (4) and intake manifold (5).
The air (by the amount corresponding to the throttle valve (6) opening and engine speed) is filtered by the air
cleaner (1), passes through the throttle body (3), is distributed by the intake manifold (5) and finally drawn into
each combustion chamber.
When the idle air control valve (4) is opened according to the signal from ECM, the air (7) bypasses the throttle
valve (6) through bypass passage and is finally drawn into the intake manifold (5).
1. Air Cleaner 17. Knock sensor 31-2. Test switch terminal
(vehicle w/o immobilizer indicator lamp)
2. EVAP canister purge valve 18. ECT sensor 31-3. Duty output terminal
(vehicle w/o immobilizer indicator lamp)
3. IAT sensor 19. CMP sensor 32. Immobilizer indicator lamp (if equipped)
4. TP sensor 20. CKP sensor 33. Stop lamp switch
5. IAC valve 21. VSS 34. ECM
6. MAP sensor 22. A/C condenser fan (if equipped) 35. Barometric pressure sensor
(vehicle with immobilizer indicator lamp)
7. EGR valve (if equipped) 23. Malfunction indicator lamp in combination meter 36. Battery
8. EVAP canister 24. Park/Neutral position switch in TR switch (A/T) 37. Immobilizer control module (if equipped)
9. Tank pressure control valve (built-in fuel pump) 25. Ignition switch 38. ABS control module (if equipped)
10. Fuel pump 26. Starter magnetic switch 39. CO adjusting resistor (if equipped)
11. Fuel level sensor 27. TCM (A/T) 40. Power steering pressure switch
(if equipped)
12. Ignition coil assembly 28. Transmission range switch (A/T) 41. A/C compressor clutch (if equipped)
13. Fuel injector 29. DLC 42. A/C EVAP TEMP. sensor (if equipped)
14. Heated Oxygen Sensor (HO2S)-1 (if equipped) 30. Electric load 43. A/C switch (if equipped)
15. Heated Oxygen Sensor (HO2S)-2 (if equipped) 31. Monitor connector (if equipped)
16. Three way catalytic convertor (if equipped) 31-1. Diagnosis switch terminal
(vehicle w/o immobilizer indicator lamp)

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On-Vehicle Service
Accelerator cable adjustment
1) With throttle valve closed, check accelerator pedal play
which should be within following specification.
If measured value is out of specification, adjust it to specifi-
cation with cable adjusting nut (1).
Accelerator pedal play
“a” : 2 – 7 mm (0.08 – 0.27 in.)
2) With accelerator pedal depressed fully, check clearance
between throttle lever (2) and lever stopper (3) (throttle
body) which should be within following specification.
If measured value is out of specification, adjust it to specifi-
cation by changing height of pedal stopper bolt (1).
Accelerator cable adjustment clearance
(With pedal depressed fully)
“a” : 0.5 – 2.0 mm (0.02 – 0.07 in.)
Idle speed / idle air control (IAC) duty inspection
Before idle speed / IAC duty check, make sure of the following.
Lead wires and hoses of Electronic Fuel Injection and engine
emission control systems are connected securely.
Accelerator cable has some play, that is, it is not tight.
Valve lash is checked and adjusted according to mainte-
nance schedule.
Ignition timing is within specification.
All accessories (wipers, heater, lights, A/C, etc.) are out of
service.
Air cleaner has been properly installed and is in good condi-
tion.
No abnormal air inhaling from air intake system.
After above items are all confirmed, check idle speed and IAC
duty as follows.
NOTE:
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
vehicle), and set parking brake and block drive wheels.

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Air Intake System
Throttle body
ON-VEHICLE INSPECTION
Check that throttle valve lever (1) moves smoothly.
REMOVAL
1) Disconnect negative cable at battery.
2) Drain cooling system.
3) Disconnect accelerator cable (1) from throttle valve lever.
1. Throttle body 4. Gasket 7. TP sensor screws
2. Throttle body gasket 5. Idle air control valve Tightening torque
3. TP sensor 6. IAC valve screws Do not reuse

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4) Disconnect air cleaner outlet NO.2 hose (1) from throttle
body.
5) Disconnect electric connector from TP sensor (1) and IAC
valve (2).
6) Remove throttle body from intake manifold.
7) Disconnect engine coolant hoses from throttle body.
DISASSEMBLY
1) Remove TP sensor and IAC valve from throttle body.
CLEANING
Clean throttle body bore (1) and idle air passage (2) by blowing
compressed air.
REASSEMBLY
1) Install IAC valve to throttle body referring to “Idle Air Control
Valve” in this section.
2) Install TP sensor to throttle body referring to “Throttle Posi-
tion Sensor” in this section for installation.
NOTE:
While disassembling and assembling throttle body, use
special care not to deform levers on throttle valve shaft
or cause damage to any other parts.
NOTE:
TP sensor, idle air control valve or other components
containing rubber must not be placed in a solvent or
cleaner bath. A chemical reaction will cause these parts
to swell, harden or get distorted.

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INSTALLATION
1) Clean mating surfaces and install throttle body gasket to
intake manifold.
Use new gasket.
2) Connect engine coolant hoses.
3) Install throttle body (1) to intake manifold.
4) Connect connectors to TP sensor (2) and IAC valve (3)
securely.
5) Install air cleaner outlet No.2 hose (1) and pipe.
6) Connect accelerator cable and adjust cable play to specifica-
tion.
7) Refill cooling system.
8) Connect negative cable at battery.

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Idle air control valve (IAC valve)
REMOVAL
1) Remove throttle body from intake manifold referring to
“Throttle Body” in this section for removal.
2) Remove IAC valve from throttle body.
INSPECTION
1) Connect each connector to IAC valve (1), TP sensor and IAT
sensor.
2) Check that rotary valve (2) of lAC valve opens and closes
once and then stops in about 60 ms as soon as ignition
switch is turned ON.
INSTALLATION
1) Install new O-ring (2) to IAC valve (1).
2) Install IAC valve (1) to throttle body (3).
Tighten IAC valve screws to specified torque.
Tightening torque
IAC valve screws (a) : 3.5 N·m (0.35 kg-m, 2.5 lb-ft)
3) Install throttle body to intake manifold referring to “Throttle
Body” in this section for installation. NOTE:
This check should be performed by two people, one
person turns on ignition switch while the other checks
valve operation.
As valve operation is momentary, it may be over-
looked. To prevent this, perform this operation check 3
times or more continuously.
If rotary valve of lAC valve does not operate at all,
check wire harness for open and short. If wire harness
is in good condition, replace lAC valve and recheck.

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Throttle position sensor (TP sensor)
INSPECTION
1) Disconnect negative cable at battery and connector from TP
sensor.
2) Using ohmmeter, check resistance between terminals under
each condition given in table below.
If check result is not satisfactory, replace TP sensor.
TP sensor resistance
3) Connect TP sensor connector securely.
4) Connect negative cable to battery.
REMOVAL
1) Remove throttle body from intake manifold referring to
“Throttle Body” in this section for removal.
2) Remove TP sensor from throttle body.
INSTALLATION
1) Install TP sensor (1) to throttle body.
Fit TP sensor to throttle body in such way that its holes (3)
are a little away from TP sensor screw holes (2) and turn TP
sensor clockwise so that those holes align.
Tightening torque
TP sensor screws (a) : 2.5 N·m (0.25 kg-m, 1.8 lb-ft)
2) Connect connector to TP sensor securely.
3) Connect battery negative cable to battery.TERMINALS RESISTANCE
Between 1 and
3 terminals4.0 – 6.0 k
Ω
ΩΩ Ω
Between 2 and
3 terminals20.0
Ω
ΩΩ Ω – 6.0 k
Ω
ΩΩ Ω, varying according to
throttle valve opening.
NOTE:
There should be more than 2 k
Ω
ΩΩ Ω resistance difference
between when throttle valve is at idle position and when
it is fully open.
1. Reference voltage terminal
2. Output voltage terminal
3. Ground terminal

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.