2005 SUZUKI JIMNY exhaust

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DTC P0400 Exhaust Gas Recirculation Flow Malfunction
CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
Clear DTC with ignition switch ON, check vehicle and environmental condition for :
–Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Ambient temp. : –10 °C, 14 °F or higher
–Intake air temp. : 70 °C, 122 °F or lower
1. EGR valve
DTC DETECTING CONDITION POSSIBLE CAUSE
While running at specified vehicle speed after engine warm-up
During deceleration (engine speed high with closed throttle position
ON) in which fuel cut is involved, difference in intake manifold absolute
pressure between when EGR valve is opened at specified value and
when it is closed is larger or smaller than specified value.
✱
✱✱ ✱2 driving cycle detection logic, monitoring once / 1 drivingEGR valve or its circuit
EGR passage
ECM
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.

Downloaded from www.Manualslib.com manuals search engine 6-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS
DTC P0420 Catalyst System Efficiency below Threshold
CIRCUIT DESCRIPTION
ECM monitors oxygen concentration in the exhaust gas which has passed the three way catalytic converter by
HO2S-2.
When the catalyst is functioning properly, the variation cycle of HO2S-2 output voltage (oxygen concentration) is
slower than that of HO2S-1 output voltage because of the amount of oxygen in the exhaust gas which has been
stored in the catalyst.
REFERENCE
1. Heated oxygen sensor-1 3. Three way catalytic converter 5. To the sensor [B] : Case of TYPE B is shown
(See NOTE)
2. Warm up three way catalytic
converter4. Heated oxygen sensor-2 [A] : Case of TYPE A is shown
(See NOTE)
NOTE:
For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable
model.
1. Engine running at closed loop
condition2. Fuel cut 3. Idle after fuel cut [A] : Oscilloscope waveforms

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DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF.
Clear DTC with ignition switch ON, check vehicle and environmental condition for :
–Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Ambient temp. : –10 °C, 14 °F or higher
–Intake air temp. : 70 °C, 158 °F or lower
–Engine coolant temp. : 70 – 110 °C, 158 – 230 °F
2) Start engine and drive vehicle at 35 – 45 mph, 55 – 65 km/h for 8 min. or longer.
While this driving, if “Catalyst Monitoring TEST COMPLETED” is displayed in “READINESS TESTS” mode
and DTC is not displayed in “DTC” mode, confirmation test is completed.
If “TEST NOT COMPLTD” is still being displayed, continue test driving.
3) Decrease vehicle speed at 30 – 40 mph, 50 – 60 km/h, and hold throttle valve at that opening position for 2
min. and confirm that short term fuel trim vary within – 20% – +20% range.
4) Stop vehicle (do not turn ignition switch OFF) and confirm test results according to following “Test Result
Confirmation Flow Table”. DTC DETECTING CONDITION POSSIBLE CAUSE
While vehicle running at constant speed under other than
high load.
Time from rich or lean switching command is output till HO2S-
2 output voltage crosses 0.45 V less than specified value.
✱
✱✱ ✱2 driving cycle detection logic, monitoring once / 1 driving.Exhaust gas leak
Three way catalytic converter malfunction
Fuel system malfunction
HO2S-2 malfunction
HO2S-1 malfunction
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-1
6F1
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8C
6A1
8E
9
9
10B
SECTION 6A1
ENGINE MECHANICAL (M13 ENGINE)
CONTENTS
General Description ......................................6A1-2
Engine ......................................................... 6A1-2
Engine Lubrication ...................................... 6A1-3
Diagnosis .......................................................6A1-4
Diagnosis Table .......................................... 6A1-4
Compression Check .................................... 6A1-4
Engine Vacuum Check ................................ 6A1-6
Oil Pressure Check ..................................... 6A1-7
Valve Lash (Clearance) ............................... 6A1-9
On-Vehicle Service......................................6A1-13
Air Cleaner Element .................................. 6A1-13
Air Cleaner Assembly ................................ 6A1-14
Knock Sensor ............................................ 6A1-14
Cylinder Head Cover ................................. 6A1-15
Throttle Body and Intake Manifold ............ 6A1-18
Exhaust Manifold ....................................... 6A1-21Oil Pan and Oil Pump Strainer .................. 6A1-24
Timing Chain Cover .................................. 6A1-28
Oil Pump ................................................... 6A1-33
Timing Chain and Chain Tensioner .......... 6A1-37
Camshaft, Tappet and Shim ..................... 6A1-42
Valves and Cylinder Head ........................ 6A1-48
Pistons, Piston Rings, Connecting
Rods and Cylinders................................... 6A1-62
Engine Mountings ..................................... 6A1-72
Unit Repair Overhaul .................................. 6A1-73
Engine Assembly ...................................... 6A1-73
Main Bearings, Crankshaft and Cylinder
Block ......................................................... 6A1-79
Required Service Material .......................... 6A1-93
Tightening Torque Specification ............... 6A1-93
Special Tool ................................................. 6A1-94

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).

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Valve Lash (Clearance)
1) Remove negative cable at battery.
2) Remove cylinder head cover referring to “Cylinder Head
Cover” in this section.
3) Using 17 mm wrench, turn crankshaft pulley (1) clockwise
until cam lobes (2) become perpendicular to shim faces (3)
at valves “1” and “7” as shown in figure.
4) Check valve lashes with thickness gauge (4) according to
the following procedure.
If valve lash is out of specification, record valve lash and
adjust it to specification by replacing shim.
a) Check valve lashes at valves “1” and “7”.
b) Turn camshafts by 90° (by turning crankshaft with wrench).
c) Make sure that cam lobes are perpendicular to shim faces
at valves to be checked (in this case, “3” and “8”), if not,
adjust it by turning crankshaft. Check valve lashes.
d) In the same manner as b) – c), check valve lashes at valves
“4” and “6”.
e) In the same manner as b) – c) again, check valve lashes at
valves “2” and “5”.
Valve clearance specification
REPLACEMENT OF SHIM
1) Close the valve whose shim (2) is to be replaced by turning
crankshaft, then turn tappet (3) till its cut section (1) faces
inside as shown in figure.When cold
(Coolant temperature
is 15 – 25°C or
59 –77°F)When hot
(Coolant temperature
is 60 – 68°C or
140 – 154°F)
Intake0.18 – 0.22 mm
(0.007 – 0.009 in.)0.21 – 0.27 mm
(0.008 – 0.011 in.)
Exhaust0.28 – 0.32 mm
(0.011 – 0.013 in.)0.30 – 0.36 mm
(0.012 – 0.014 in.)

Downloaded from www.Manualslib.com manuals search engine 6A1-10 ENGINE MECHANICAL (M13 ENGINE)
2) Lift valve by turning crankshaft and then remove camshaft
housing bolts (1) where the shim to be replaced.
3) Install special tool with camshaft housing bolts as shown in
figure.
Special tool
(A) : 09916-67020
Tightening torque
Camshaft housing bolts (for tightening of special tool)
(a) : 8 N·m (0.8 kg-m, 6.0 lb-ft)
Special tool selection table
4) Turn camshaft by approximately 90° clockwise and remove
shim (3).
2. Plug hole
NOTE:
Check the special tools carved seal as shown, and
then install special tool in accordance with the location
of each camshaft housing.
If special tool is holding down the shim, adjust special
tool position so as not to hold down the shim by loos-
ening camshaft housing bolt.
No. on camshaft housingEmbossed mark
on special tool
I2 IN2
I3, I4, I5 IN345
E2 EX2
E3, E4, E5 EX345
A: I : Intake side or E : Exhaust side
B: Position from timing chain side
C: Pointing to timing chain side
WARNING:
Never put in the hand between camshaft and tappet.
1. Special tool
2. Magnet

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5) Using a micrometer (2), measure the thickness of the
removed shim (1), and determine replacement shim by cal-
culating the thickness of new shim with the following formula
and table.
Intake side
A = B + C – 0.20 mm (0.008 in.)
Exhaust side
A = B + C – 0.30 mm (0.012 in.)
A : Thickness of new shim
B : Thickness of removed shim
C : Measured valve clearance
Example of intake side :
When thickness of removed shim is 2.40 mm (0.094 in.), and
measured valve clearance is 0.45 mm (0.018 in.).
A = 2.40 mm (0.094 in.) + 0.45 mm (0.018 in.) – 0.20 mm (0.008
in.) = 2.65 mm (0.104 in.)
Calculated thickness of new shim = 2.65 mm (0.104 in.)
6) Select new shim No. (1) with a thickness as close as possi-
ble to calculated value.
Available new shims No.
7) Install new shim facing shim No. side with tappet.
Thickness
mm (in.)Shim
No.Thickness
mm (in.)Shim
No.
2.175 (0.0856) 218 2.675 (0.1053) 268
2.200 (0.0866) 220 2.700 (0.1063) 270
2.225 (0.0876) 223 2.725 (0.1073) 273
2.250 (0.0886) 225 2.750 (0.1083) 275
2.275 (0.0896) 228 2.775 (0.1093) 278
2.300 (0.0906) 230 2.800 (0.1102) 280
2.325 (0.0915) 233 2.825 (0.1112) 283
2.350 (0.0925) 235 2.850 (0.1122) 285
2.375 (0.0935) 238 2.875 (0.1132) 288
2.400 (0.0945) 240 2.900 (0.1142) 290
2.425 (0.0955) 243 2.925 (0.1152) 293
2.450 (0.0965) 245 2.950 (0.1161) 295
2.475 (0.0974) 248 2.975 (0.1171) 298
2.500 (0.0984) 250 3.000 (0.1181) 300
2.525 (0.0994) 253
2.550 (0.1004) 255
2.575 (0.1014) 258
2.600 (0.1024) 260
2.625 (0.1033) 263
2.650 (0.1043) 265

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Exhaust Manifold
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect heated oxygen sensor coupler (1) (if equipped)
and detach it from its stay.
3) Remove exhaust manifold cover (2).
4) Remove exhaust manifold stiffener (1).
1. Exhaust manifold 4. Exhaust manifold cover Tightening torque
2. Exhaust manifold gasket 5. Engine hook Do not reuse.
3. Heated oxygen sensor (if equipped) 6. Exhaust manifold mounting nut
WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system cools down.