2005 SUZUKI JIMNY Injector

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Throttle Body and Intake Manifold
REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Drain coolant by loosening drain plug (1).
1. Intake manifold 7. EVAP canister purge valve 13. Intake manifold mounting nut 19. Injector assembly
2. Intake manifold gasket 8. TP sensor 14. Intake manifold mounting bolt (short) 20. Cushion
3. Throttle body 9. IAC valve 15. Intake manifold mounting bolt (long) Tightening torque
4. Gasket 10. Fuel delivery pipe 16. EGR pipe gasket Do not reuse
5. EGR pipe 11. Engine hook 17. O-ring
6. MAP sensor 12. Intake manifold stiffener 18. Grommet
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.

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4) Remove air cleaner outlet No.1 (1) and No.2 (2) hoses and
breather hose (3).
5) Remove intake manifold bracket (1) with main harness from
intake manifold.
6) Disconnect the following electric lead wires:
IAC valve (2)
TP sensor (3)
EVAP canister purge valve (4)
MAP sensor (5)
Fuel injector wire harness at couplers (6)
Ground terminal (7) from intake manifold
7) Disconnect accelerator cable (1) from throttle body.
8) Disconnect the following hoses:
Brake booster hose (2) from intake manifold
PCV hose (3) from PCV valve
Fuel pressure regulator vacuum hose (4) from intake mani-
fold
Canister purge hose from EVAP canister purge valve
Water hoses from throttle body
Vacuum hose (5) (to check valve) from throttle body
Fuel feed hose and return hose from each pipe
9) Remove fuel delivery pipe with fuel injectors from cylinder
head and intake manifold.
10) Remove canister purge hose bracket.
11) Disconnect EGR pipe from EGR valve.
12) Remove intake manifold stiffener (1).

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REMOVAL
1) Relieve fuel pressure referring to “Fuel Pressure Relief Pro-
cedure” in Section 6.
2) Disconnect negative cable at battery.
3) Drain engine oil.
4) Drain coolant by loosening drain plug (1).
5) Remove air cleaner outlet No.1 and No.2 hoses and
breather hose.
6) Remove intake manifold bracket (1) with main harness from
intake manifold.
7) Disconnect the following electric lead wires:
EGR valve (if equipped)
IAC valve (2)
TP sensor (3)
MAP sensor (4)
CMP sensor
ECT sensor
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Heated oxygen sensor
Ground terminal (7) from intake manifold
Each wire harness clamps
8) Remove heated oxygen sensor bracket from cylinder head
and detach heated oxygen sensor coupler from its bracket. 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.

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DISASSEMBLY
1) For ease in servicing cylinder head, remove intake manifold,
injectors and exhaust manifold from cylinder head.
2) Using special tools (Valve lifter), compress valve spring and
then remove valve cotters (1) by using special tool (For-
ceps).
Special tool
(A) : 09916-14510
(B) : 09916-14521
(C) : 09916-84511
3) Release special tools and remove spring retainer and valve
spring.
4) Remove valve from combustion chamber side.
5) Remove valve stem seal (1) from valve guide and then valve
spring seat (2).
6) Using special tool (valve guide remover), drive valve guide
out from combustion chamber side to valve spring side.
Special tool
(A) : 09916-44910
7) Place disassembled parts except valve stem seal and valve
guide in order so that they can be installed in their original
position.
NOTE:
Do not reuse seal once disassembled. Be sure to use
new seal when assembling.
NOTE:
Do not reuse valve guide once disassembled. Be sure to
use new valve guide (Oversize) when assembling.

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6) Install valve to valve guide
Before installing valve to valve guide, apply engine oil to
stem seal, valve guide bore and valve stem.
7) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch end (1)) and bot-
tom end (small-pitch end (2)). Be sure to position spring in
place with its bottom end (small-pitch end) facing the bottom
(valve spring seat side).
8) Using special tools (Valve lifter), compress valve spring and
fit two valve cotters (1) into groove in valve stem.
Special tool
(A) : 09916-14510
(B) : 09916-14521
(C) : 09916-84511
9) Install intake manifold, injectors and exhaust manifold to cyl-
inder head.
INSTALLATION
1) Clean mating surface of cylinder head and cylinder block.
Remove oil, old gasket and dust from mating surface.
2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.“TOP”
mark provided on gasket comes to crankshaft pulley side,
facing up (toward cylinder head side).
A : Valve spring retainer side
B : Valve spring seat side
NOTE:
When compressing the valve spring, do not damage
inside face of tappet installing hole.

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a) For right hand steering vehicle:
With hose connected, detach A/C compressor from its
bracket.
b) For left hand steering vehicle:
i) Recover refrigerant from refrigeration system using recov-
ery and recycling equipment.
ii) Disconnect magnet clutch lead wire.
iii) Remove suction pipe and disconnect discharge pipe from
A/C compressor.
iv) Remove A/C compressor from its bracket.
When servicing above steps, refer to “Compressor” in Section 1B.
14) Remove air cleaner outlet No.1 and No.2 hoses.
15) Disconnect the following electric lead wires:
TP sensor (1)
MAP sensor (2)
CKP sensor (if equipped) (3)
CMP sensor
ECT sensor
Heated oxygen sensor
EGR valve (if equipped)
IAC valve (4)
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Generator
Starting motor
Oil pressure switch
Ground terminal from intake manifold and cylinder block
Each wire harness clamps
16) Remove intake manifold bracket (7) with main harness from
intake manifold.
17) Remove starting motor referring to “Dismounting” in Section
6G. NOTE:
Suspend removed A/C compressor at a place where no
damage will be caused during removal and installation of
engine assembly.

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6F1
6F2
6G
7C1
7D
7E
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
6H
6E
10
10A
10B
SECTION 6E
ENGINE AND EMISSION CONTROL SYSTEM
CONTENTS
General Description ....................................... 6E-3
Air Intake System ......................................... 6E-5
Fuel Delivery System ................................... 6E-6
Fuel pump ................................................ 6E-6
Electronic Control System ............................ 6E-7
Engine & emission control input / output
table.......................................................... 6E-8
On-Vehicle Service....................................... 6E-15
Accelerator cable adjustment ................. 6E-15
Idle speed / idle air control (IAC) duty
inspection ............................................... 6E-15
Idle mixture inspection / adjustment
(vehicle without heated oxygen
sensor) ................................................... 6E-17
Air Intake System ....................................... 6E-18
Throttle body .......................................... 6E-18
Idle air control valve (IAC valve)............. 6E-21
Fuel Delivery System ................................. 6E-22
Fuel pressure inspection ........................ 6E-22
Fuel pump .............................................. 6E-23
Fuel pressure regulator .......................... 6E-24
Fuel injector ............................................ 6E-25
Electronic Control System .......................... 6E-29Engine control module (ECM) ................ 6E-29
Manifold absolute pressure sensor (MAP
sensor) ................................................... 6E-29
Throttle position sensor (TP sensor) ...... 6E-30
Intake air temperature sensor
(IAT sensor) ........................................... 6E-31
Engine coolant temperature sensor
(ECT sensor) .......................................... 6E-32
Heated oxygen sensor
(Sensor-1 and sensor-2) ........................ 6E-33
Camshaft position sensor....................... 6E-34
Crankshaft position sensor..................... 6E-35
Vehicle speed sensor (VSS) .................. 6E-36
Fuel level sensor (GAUGE).................... 6E-36
Knock sensor ......................................... 6E-36
Main relay, fuel pump relay and A/C
condenser fan control relay .................... 6E-36
Fuel cut operation .................................. 6E-37
A/C condenser fan control system ......... 6E-37
A/C condenser fan ................................. 6E-37
Output signals of throttle valve opening
and engine coolant temp.
(Vehicle with A/T only) ........................... 6E-38
Emission Control System ........................... 6E-38 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).
NOTE:
Whether following systems (parts) are used in the particular vehicle or not depends on specifications.
Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor (s) or CO adjusting resistor
Three way catalytic converter (TWC) and warm up three-way catalytic converter (WU-TWC)

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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)