2005 SUZUKI JIMNY manual transmission

Downloaded from www.Manualslib.com manuals search engine 6A1-94 ENGINE MECHANICAL (M13 ENGINE)
Special Tool
Crankshaft bearing cap No.1 bolts
(for inspection of crankshaft thrust play)50.0 5.0 36.5
Crankshaft bearing cap No.2 bolts 22.0 2.2 16.0
Sensor plate bolts 11.0 1.1 8.0
Crankshaft bearing cap No.1 bolts a) Tighten 50 N·m
b) Turn 60°a) Tighten 5.0 kg-m
b) Turn 60°a) Tighten 36.5 lb-ft
b) Turn 60°
Rear oil seal housing bolts 11.0 1.1 8.0
Flywheel or drive plate bolts 70.0 7.0 51.0
Torque converter bolts 20.0 2.0 14.5
Timing chain tensioner bolt 22.0 2.2 16.0
Knock sensor 23.0 2.3 16.5
Cylinder block and transmission fasten-
ing bolts and nuts (vehicle with M/T)94.0 9.4 68.0
Cylinder block and transmission fasten-
ing bolts and nuts (vehicle with A/T)80.0 8.0 58.0 Fastening partTightening torque
Nm kg-m lb-ft
09911-97720 09911-97820 09913-75520 09915-47330
Oil seal guide Oil seal installer Bearing installer Oil filter wrench
09915-64510-001 09915-64510-002 09915-64530 09915-67010
Compression gauge Connector Hose Attachment

Downloaded from www.Manualslib.com manuals search engine 6B-14 ENGINE COOLING
Radiator
REMOVAL
1) Drain cooling system.
2) Remove radiator shroud.
3) Disconnect water hoses from radiator.
4) With automatic transmission (A/T) vehicle, disconnect addi-
tional two fluid hoses from radiator.
Place some container under radiator to receive A/T fluid
which will flow out when hose is disconnected.
5) Install radiator protection board to between radiator and
cooling fan.
6) Remove radiator after removing two bolts (1).
INSPECTION
If the water side of the radiator is found excessively rusted or cov-
ered with scales, clean it by flushing with the radiator cleaner
compound.
This flushing should be carried out at regular intervals for scale or
rust formation advances with time even where a recommended
type of coolant is used. Periodical flushing will prove more eco-
nomical.
Inspect the radiator cores and straighten the flattened or bent
fins, if any. Clean the cores, removing road grimes and trashes.
Excessive rust or scale formation on the wet side of the radiator
lowers the cooling efficiency.
Flattened or bent fins obstruct the flow of air through the core to
impede heat dissipation.
Radiator flushing interval recommended
Two years
INSTALLATION
Reverse removal procedures.
NOTE:
Refill cooling system with proper coolant referring to
“Coolant” and “Cooling System Flush and Refill” in
this section.
With automatic transmission vehicle, fill A/T fluid up to
specified level. For procedure to check A/T fluid and its
level, refer to “Changing Fluid” in Section 7B.
After installation, check each joint for leakage.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-5
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)

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-7
Electronic Control System
The electronic control system consists of 1) various sensors which detect the state of engine and driving condi-
tions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled
devices.
Functionally, it is divided into the following sub systems:
Fuel injection control system
Idle speed control system
Fuel pump control system
A/C control system (if equipped)
A/C condenser fan control system
EGR system (if equipped)
Evaporative emission control system
Oxygen sensor heater control system
Ignition control system
Also, with A/T model, ECM sends throttle valve opening signal and over drive cut signal to transmission control
module to control A/T.
NOTE:
The figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are installed
at the other side.
1. IAT sensor a : Immobilizer indicator lamp (if equipped) A : ECM
2. TP sensor b : A/C condenser fan motor relay (if equipped) B : A/T control module
3. Monitor connector c : Main relay C : EVAP canister
4. CO adjusting resistor (if equipped) d : Fuel pump relay D : DLC
5. CKP sensor e : IAC valve E : ABS control module (if equipped)
6. MAP sensor f : EVAP canister purge valve
7. CMP sensor g : EGR valve (if equipped)
8. Transmission range switch h : Fuel injector
9. VSS i : Ignition coil assemblies
10. HO2S-1 (if equipped) J : MIL
11. HO2S-2 (if equipped)
12. ECT sensor
13. Knock sensor

Downloaded from www.Manualslib.com manuals search engine 6E-8 ENGINE AND EMISSION CONTROL SYSTEM
Engine & emission control input / output table
INPUTOUTPUT
ELECTRIC CONTROL DEVICE
DIAGNOSIS SWITCH TERMINAL
(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)
BAROMETRIC PRESSURE SENSOR
(VEHICLE WITH IMMOBILIZER INDICATOR LAMP)
STOP LAMP SWITCH
STARTER SWITCH
IGNITION SWITCH
LIGHTING SWITCH
REAR DEFOGGER SWITCH (IF EQUIPPED)
BLOWER SWITCH
A/C SWITCH (IF EQUIPPED)
A/C EVAPORATOR TEMP. SENSOR (IF EQUIPPED)
VSS
HEATED OXYGEN SENSOR-1 (IF EQUIPPED)
HEATED OXYGEN SENSOR-2
(IF EQUIPPED)For detecting deterioration of
three way catalytic converter
IAT SENSOR
ECT SENSOR
TP SENSOR
MAP SENSOR
CMP SENSOR
CKP SENSOR
TEST SWITCH TERMINAL
(VEHICLE WITHOUT IMMOBILIZER INDICATOR LAMP)
KNOCK SENSOR
FUEL PUMP RELAY
FUEL INJECTOR
HO2S HEATER
IAC VALVE
IGNITION COIL WITH IGNITER
EGR VALVE (IF EQUIPPED)
EVAP CANISTER PURGE VALVE
A/C COMPRESSOR CLUTCH
MIL
MAIN RELAY
TRANSMISSION CONTROL MODULE SIGNAL FROM SENSOR, SWITCH AND CONTROL MODULEA/C CONDENSER FAN RELAY

Downloaded from www.Manualslib.com manuals search engine 6E-10 ENGINE AND EMISSION CONTROL SYSTEM
1. CKP sensor 20. Power steering pressure switch
(if equipped)39. Ignition coil assembly (for No.1 and No.4 spark plugs)
2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs)
3. VSS 22. A/C refrigerant pressure switch
(if equipped)41. Stop lamp switch
4. MAP sensor 23. Immobilizer control module (if equipped) 42. Stop lamp
5. Knock sensor 24. Data link connector 43. Lighting switch
6. TP sensor 25. Injector No.1 44. Position lamp
7. ECT sensor 26. Injector No.2 45. Rear defogger switch (if equipped)
8. IAT sensor 27. Injector No.3 46. Rear defogger (if equipped)
9. Heated oxygen sensor-1 (if equipped) 28. Injector No.4 47. A/C compressor clutch (if equipped)
10. Heated oxygen sensor-2 (if equipped) 29. IAC valve 48. Ignition switch
11. A/C evaporator temp. sensor (if equipped) 30. EVAP canister purge valve 49. Main relay
12. Speedometer 31. Fuel pump relay 50. CO adjusting register (if equipped)
13. Fuel level sensor 32. Fuel pump 51. Starting motor
14. TCM (A/T) 33. A/C condenser fan relay (if equipped) 52. 4WD controller (4WD)
15. Transmission range switch (A/T) 34. A/C condenser fan motor (if equipped) 53. ABS control module (if equipped)
16. Shift lock solenoid (A/T, if equipped) 35. EGR valve (if equipped) 54. Engine ground
17. Backup lamp 36. Malfunction indicator lamp 55. Body ground
18. Heater fan motor 37. Immobilizer indicator lamp (if equipped)
19. Heater fan switch 38. Monitor connector (vehicle without immo-
bilizer indicator lamp)

Downloaded from www.Manualslib.com manuals search engine 6E-12 ENGINE AND EMISSION CONTROL SYSTEM
1. CKP sensor 20. Power steering pressure switch
(if equipped)39. Ignition coil assembly (for No.1 and No.4 spark plugs)
2. CMP sensor 21. A/C switch 40. Ignition coil assembly (for No.2 and No.3 spark plugs)
3. VSS 22. A/C refrigerant pressure switch
(if equipped)41. Stop lamp switch
4. MAP sensor 23. Immobilizer control module (if equipped) 42. Stop lamp
5. Knock sensor 24. Data link connector 43. Lighting switch
6. TP sensor 25. Injector No.1 44. Position lamp
7. ECT sensor 26. Injector No.2 45. Rear defogger switch (if equipped)
8. IAT sensor 27. Injector No.3 46. Rear defogger (if equipped)
9. Heated oxygen sensor-1 (if equipped) 28. Injector No.4 47. A/C compressor clutch (if equipped)
10. Heated oxygen sensor-2 (if equipped) 29. IAC valve 48. Ignition switch
11. A/C evaporator temp. sensor (if equipped) 30. EVAP canister purge valve 49. Main relay
12. Speedometer 31. Fuel pump relay 50. CO adjusting register (if equipped)
13. Fuel level sensor 32. Fuel pump 51. Starting motor
14. TCM (A/T) 33. A/C condenser fan relay (if equipped) 52. 4WD controller (4WD)
15. Transmission range switch (A/T) 34. A/C condenser fan motor (if equipped) 53. ABS control module (if equipped)
16. Shift lock solenoid (A/T, if equipped) 35. EGR valve (if equipped) 54. Engine ground
17. Backup lamp 36. Malfunction indicator lamp 55. Body ground
18. Heater fan motor 37. Immobilizer indicator lamp (if equipped)
19. Heater fan switch 38. Monitor connector (vehicle without immo-
bilizer indicator lamp)

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-15
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.