2005 SUZUKI JIMNY check engine

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-39
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect EGR valve connector.
3) Remove EGR pipe.
4) Remove EGR valve and gasket from cylinder head.
INSPECTION
1) Check resistance between following terminals of EGR valve
(1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance
2) Remove carbon from EGR valve (1) gas passage.
3) Inspect valve (2), valve seat (3) and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve assembly.
INSTALLATION
Reverse removal procedure noting following.
Clean mating surface of valve and cylinder head.
Use new gaskets.
Evaporative emission (EVAP) control system
EVAP CANISTER PURGE INSPECTION
Terminal Standard resistance
A – B
C – B
F – E
D – E 20 – 24
Ω
ΩΩ Ω
NOTE:
Do not use any sharp-edged tool to remove carbon.
Be careful not to damage or bend EGR valve, valve seat
and rod.
NOTE:
Before inspection, check to make sure that gear shift
lever is in neutral position (with A/T model, selector lever
in “P” range) and that parking brake lever is pulled all the
way up.

Downloaded from www.Manualslib.com manuals search engine 6E-40 ENGINE AND EMISSION CONTROL SYSTEM
1) Disconnect purge hose (1) from EVAP canister.
2) Place finger against the end of disconnected hose and check
that vacuum is not felt there when engine is cool and running
at idle speed.
3) Connect purge hose to EVAP canister and warm up engine
to normal operating temperature.
4) Turn ignition switch OFF.
5) Restart engine and run it at 2000 r/min. for 2 min. or more.
6) Disconnect purge hose from EVAP canister.
7) Also check that vacuum is felt when engine is running at
3000 r/min.
8) If vacuum is not felt in Step 7), run engine at idle for 8 min. or
more and then repeat check in Step 7).
If check result is not satisfactory in Steps 2) and 8), check vac-
uum passage, hoses, EVAP canister purge valve, wire harness
and ECM.
VACUUM PASSAGE INSPECTION
Start engine and run it at idle speed. Disconnect vacuum hose (1)
from EVAP canister purge valve (2). With finger placed against
hose disconnected, check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.
VACUUM HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration.
Replace as necessary.
EVAP CANISTER PURGE VALVE INSPECTION
Check EVAP canister purge valve referring to step 2 of “DTC
P0443 Flow Table” in Section 6.
If found malfunction, replace.NOTE:
ECM detects a change in the purge fuel vapor concentra-
tion and sometimes stops purging for several seconds
but this is nothing abnormal.

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EVAP CANISTER INSPECTION
1) Check outside of EVAP canister visually.
2) Disconnect vacuum hoses from EVAP canister.
3) Check that there should be no restriction of flow through
purge pipe (1) and air pipe (2) when air is blown (4) into tank
pipe (3).
If any faulty condition is found in above inspection replace.
PCV system
PCV HOSE INSPECTION
Check hoses for connection, leakage, clog and deterioration.
Replace as necessary.
PCV VALVE INSPECTION
1) Disconnect PCV valve (1) from cylinder head cover and
install plug to head cover hole.
2) Run engine at idle.
3) Place your finger over end of PCV valve (1) to check for vac-
uum. If there is no vacuum, check for clogged valve.
Replace as necessary. WARNING:
DO NOT SUCK nozzles on EVAP canister. Fuel vapor
inside EVAP canister is harmful.
NOTE:
Be sure to check that there is no obstruction in PCV
valve or its hoses before checking IAC duty, for
obstructed PCV valve or hose hampers its accurate
adjustment.

Downloaded from www.Manualslib.com manuals search engine 6E-42 ENGINE AND EMISSION CONTROL SYSTEM
4) After checking vacuum, stop engine and remove PCV valve
(1).
Shake valve and listen for the rattle of check needle inside
the valve. If valve does not the rattle, replace valve.
5) After checking, remove plug and install PCV valve (1).
Special Tools
09912-57610 09912-58421 09912-58432 09912-58442
Checking tool plate Checking tool set
(See NOTE “A”.)Pressure hose Pressure gauge
09912-58490 09930-88530 09931-76011
3-way joint & hose Injector test lead SUZUKI scan tool
(Tech 1A) kit
(See NOTE “B”.)Mass storage cartridge

Downloaded from www.Manualslib.com manuals search engine IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-3
SYSTEM WIRING DIAGRAM
Diagnosis
1. Ignition switch 7. No.1 spark plug
2. Main relay 8. No.2 spark plug
3. Ignition coil assembly for No.1 and No.4 spark plugs 9. No.3 spark plug
4. Ignition coil assembly for No.2 and No.3 spark plugs 10. No.4 spark plug
5. CMP sensor 11. Sensed information (MAP sensor, ECT sensor, IAT sensor, TP sensor, Knock sensor, VSS, Park/
Neutral position signal, Electric load signal, Engine start signal, Test switch terminal)
6. CKP sensor
Condition Possible Cause Correction
Engine cranks, but will
not start or hard to
start (No spark)Blown fuse for ignition coil Replace.
Loose connection or disconnection of lead wire
or high-tension cord(s)Connect securely.
Faulty high-tension cord(s) Replace.
Faulty spark plug(s) Adjust, clean or replace.
Faulty ignition coil Replace ignition coil assembly.
Faulty CKP sensor or CKP sensor plate Clean, tighten or replace.
Faulty ECM Replace.
Poor fuel economy or
engine performanceIncorrect ignition timing Check related sensors and CKP
sensor plate.
Faulty spark plug(s) or high-tension cord(s) Adjust, clean or replace.
Faulty ignition coil assembly Replace.
Faulty CKP sensor or CKP sensor plate Clean, tighten or replace.
Faulty ECM Replace.

Downloaded from www.Manualslib.com manuals search engine 6F-4 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
IGNITION SYSTEM DIAGNOSTIC FLOW TABLE
Step Action Yes No
1Was “Engine Diagnostic Flow Table” in Section 6 per-
formed?Go to Step 2. Go to “Engine Diag.
Flow Table” in Section
6.
2Ignition Spark Test
1) Check all spark plugs for condition and type refer-
ring to “Spark Plugs” section.
2) If OK, perform ignition spark test, referring to “Igni-
tion Spark Test” section.
Is spark emitted from all spark plugs?Go to Step 11. Go to Step 3.
3Diagnostic Trouble Code (DTC) Check
Is DTC stored in ECM?Go to applicable DTC
Diag. Flow Table in
Section 6.Go to Step 4.
4Electrical Connection Check
1) Check ignition coil assemblies and high-tension
cords for electrical connection.
Are they connected securely?Go to Step 5. Connect securely.
5High-tension Cords Check
1) Check high-tension cord for resistance referring to
“High-Tension Cords” section.
Is check result satisfactory?Go to Step 6. Replace high-tension
cord(s).
6Ignition Coil Assembly Power Supply and Ground Cir-
cuit Check
1) Check ignition coil assembly power supply and
ground circuits for open and short.
Are circuits in good condition?Go to Step 7. Repair or replace.
7Ignition Coil Assembly Check
1) Check ignition coil for resistance referring to “Igni-
tion Coil Assembly” section.
Is check result satisfactory?Go to Step 8. Replace ignition coil
assembly.
8Crankshaft Position (CKP) Sensor Check
1) Check crankshaft position sensor referring to Step
2 and 6 of “DTC P0335 (No.23) CKP Sensor Cir-
cuit Malfunction” in Section 6.
Is check result satisfactory?Go to Step 9. Tighten CKP sensor
bolt, replace CKP sen-
sor or CKP sensor
plate.
9Ignition Trigger Signal Circuit Check
1) Check ignition trigger signal wire for open, short
and poor connection.
Is circuit in good condition?Go to Step 10. Repair or replace.
10A Known-good Ignition Coil Assembly Substitution
1) Substitute a known-good ignition coil assembly
and then repeat Step 2.
Is check result of Step 2 satisfactory?Go to Step 11. Substitute a known-
good ECM and then
repeat Step 2.
11Ignition Timing Check
1) Check initial ignition timing and ignition timing
advance referring to “Ignition Timing” section.
Is check result satisfactory?System is in good con-
dition.Check CKP sensor,
CKP sensor plate and
input signals related to
this system.

Downloaded from www.Manualslib.com manuals search engine IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM 6F-5
On-Vehicle Service
Ignition Spark Test
1) Disconnect all injector connectors (1) from injectors.
2) Remove cylinder head upper cover.
3) Remove spark plug and check it for condition and type refer-
ring to “Spark Plugs” in this section.
4) If OK, connect ignition coil connector to ignition coil assem-
bly and connect spark plug to ignition coil assembly or high-
tension cord. Ground spark plug.
5) Crank engine and check if each spark plug sparks.
6) If no spark is emitted, inspect the related parts as described
under “Diagnosis” earlier in this section.
High-tension Cords
1) Remove cylinder head upper cover and disconnect high-ten-
sion cords (2) from ignition coil assemblies (1) while gripping
each cap.
2) Pull out high-tension cords from spark plugs while gripping
each cap.
3) Measure resistance of high-tension cord (1) by using ohm-
meter.
High-tension cord resistance
4 – 10 k
Ω/m (1.2 – 3.0 kΩ/ft)
4) If resistance exceeds specification, replace high-tension
cord(s). WARNING:
Without disconnection of injector couplers, combustible
gas may come out from spark plug holes during this test
and may get ignited in engine room.
CAUTION:
Removal of high-tension cords together with clamps
will be recommended so as not to damage their inside
wire (resistive conductor).
For the same reason, pull out each connection by grip-
ping cap portion.

Downloaded from www.Manualslib.com manuals search engine 6F-8 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
6) Measure resistance between terminals as follows by using
analog type ohmmeter.
If check result is not satisfactory, replace ignition coil assem-
bly.
Secondary coil resistance
“a” – “b” : 7.5 – 14 k
Ω (at 20°C, 68°F)
7) Install ignition coil assembly.
8) Tighten ignition coil bolts, and then connect ignition coil cou-
pler.
9) Install high-tension cord to ignition coil assembly while grip-
ping its cap.
10) Install cylinder head upper cover.
Crankshaft Position Sensor (CKP Sensor)
Refer to “Crankshaft Position Sensor” in Section 6E for removal,
inspection and installation.
Ignition Timing
INSPECTION
1) When using SUZUKI scan tool (1), connect SUZUKI scan
tool to DLC (2) with ignition switch OFF.
Special tool
(A) : SUZUKI scan tool
2) Start engine and warm it up to normal operating tempera-
ture.
3) Make sure that all of electrical loads except ignition are
switched off.
4) Check to be sure that idle speed is within specification.
(Refer to “Idle Speed/Idle Air Control Duty Inspection” in
Section 6E.)
NOTE:
Ignition timing is not adjustable. If ignition timing is
out of specification, check system related parts.
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for
A/T model), and set parking brake.