2005 SUZUKI JIMNY start

Downloaded from www.Manualslib.com manuals search engine 6-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Diagnostic trouble code (DTC) table ......... 6-16
Fail-safe table............................................ 6-19
Visual inspection ....................................... 6-20
Engine basic inspection ............................ 6-21
Engine diagnosis table .............................. 6-23
Scan Tool Data ............................................. 6-28
Scan tool data definitions .......................... 6-30
Inspection of ECM and Its Circuits ................ 6-33
Component Location ..................................... 6-42
Table A-1 Malfunction Indicator Lamp Circuit
Check - Lamp Does Not Come “ON” at Ignition
Switch ON (But Engine at Stop).................... 6-43
Table A-2 Malfunction Indicator Lamp Circuit
Check - Lamp Remains “ON” after Engine
Starts............................................................. 6-44
Table A-3 Malfunction Indicator Lamp Circuit
Check - Mil Flashes at Ignition Switch ON .... 6-45
Table A-4 Malfunction Indicator Lamp Circuit
Check - MIL Does Not Flash, Just Remains
ON or Just Remains OFF Even with Grounding
Diagnosis Switch Terminal............................ 6-45
Table A-5 ECM Power and Ground Circuit
Check - MIL Doesn’t Light at Ignition Switch
ON and Engine Doesn’t Start Though It Is
Cranked Up ................................................... 6-46
DTC P0105 (DTC No.11) Manifold Absolute
Pressure (MAP) Circuit Malfunction .............. 6-48
DTC P0110 (DTC No.18) Intake Air Temp.
(IAT) Circuit Malfunction ............................... 6-51
DTC P0115 (DTC No.19) Engine Coolant
Temperature (ECT) Circuit Malfunction ........ 6-53
DTC P0120 (DTC No.13) Throttle Position
Circuit Malfunction ........................................ 6-55
DTC P0121 Throttle Position Circuit Range /
Performance Problem ................................... 6-57
DTC P0130 (DTC No.14) Heated Oxygen
Sensor (HO2S) Circuit Malfunction
(Sensor-1) ..................................................... 6-59
DTC P0133 Heated Oxygen Sensor (HO2S)
Circuit Slow Response (Sensor-1) ................ 6-61
DTC P0135 (DTC No.14) Heated Oxygen
Sensor (HO2S) Heater Circuit Malfunction
(Sensor-1) ..................................................... 6-62
DTC P0136 Heated Oxygen Sensor (HO2S)
Circuit Malfunction (Sensor-2) ...................... 6-64
DTC P0141 Heated Oxygen Sensor (HO2S)
Heater Circuit Malfunction (Sensor-2)........... 6-66
DTC P0171 Fuel System Too Lean .............. 6-68
DTC P0172 Fuel System Too Rich ............... 6-68
DTC P0300 Random Misfire Detected
(Misfire Detected at 2 or More Cylinders) ..... 6-72DTC P0301 Cylinder 1 Misfire Detected ........ 6-72
DTC P0302 Cylinder 2 Misfire Detected ........ 6-72
DTC P0303 Cylinder 3 Misfire Detected ........ 6-72
DTC P0304 Cylinder 4 Misfire Detected ........ 6-72
DTC P0325 (DTC No.17) Knock Sensor Circuit
Malfunction .................................................... 6-77
DTC P0335 (DTC No.23) Crankshaft Position
(CKP) Sensor Circuit Malfunction .................. 6-79
DTC P0340 (DTC No.15) Camshaft Position
(CMP) Sensor Circuit Malfunction ................. 6-82
DTC P0400 Exhaust Gas Recirculation Flow
Malfunction .................................................... 6-85
DTC P0420 Catalyst System Efficiency below
Threshold ....................................................... 6-88
DTC P0443 Purge Control Valve Circuit
Malfunction .................................................... 6-91
DTC P0481 A/C Condenser Fan Control
Circuit Malfunction ......................................... 6-92
DTC P0500 (DTC No.16) Vehicle Speed
Sensor (VSS) Malfunction ............................. 6-94
DTC P0505 Idle Control System
Malfunction .................................................... 6-96
DTC P0601 Internal Control Module Memory
Check Sum Error (DTC No.71) ...................... 6-98
DTC P1450 Barometric Pressure Sensor
Low / High Input ............................................. 6-99
DTC P1451 Barometric Pressure Sensor
Performance Problem .................................... 6-99
DTC P1500 Engine Starter Signal Circuit
Malfunction .................................................. 6-101
DTC P1510 ECM Back-up Power Supply
Malfunction .................................................. 6-103
DTC P1570 (DTC No.21) ABS Signal Circuit
Malfunction .................................................. 6-104
DTC P1600 Serial Communication Problem
Between ECM and TCM .............................. 6-105
DTC P1717 A/T Drive Range (Park / Neutral
Position) Signal Circuit Malfunction ............. 6-107
Table B-1 Fuel Injector Circuit Check ..........6-109
Table B-2 Fuel Pump and Its Circuit
Check........................................................... 6-110
Table B-3 Fuel Pressure Check................... 6-112
Table B-4 Idle Air Control System Check ....6-114
Table B-5 A/C Signal Circuits Check
(Vehicle with A/C) ........................................ 6-117
Table B-6 Electric Load Signal Circuit
Check........................................................... 6-119
TAble B-7 A/C Condenser Fan Control
System Check.............................................. 6-121
Special Tool ................................................... 6-123

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-3
General Information
Statement on Cleanliness and Care
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the thousands of an millimeter (ten thousands of an inch).
Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and
friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically
stated.
A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the
surfaces on initial operation.
Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft jour-
nal bearings are removed for service, they should be retained in order.
At the time of installation, they should be installed in the same locations and with the same mating surfaces
as when removed.
Battery cables should be disconnected before any major work is performed on the engine.
Failure to disconnect cables may result in damage to wire harness or other electrical parts.
Throughout this manual, the four cylinders of the engine are
identified by numbers; No.1 (1), No.2 (2), No.3 (3) and No.4
(4) counted from crankshaft pulley side to flywheel side.
General Information on Engine Service
THE FOLLOWING INFORMATION ON ENGINE SERVICE SHOULD BE NOTED CAREFULLY, AS IT IS
IMPORTANT IN PREVENTING DAMAGE, AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE.
When raising or supporting engine for any reason, do not use a jack under oil pan. Due to small clearance
between oil pan and oil pump strainer, jacking against oil pan may cause it to be bent against strainer result-
ing in damaged oil pick-up unit.
It should be kept in mind, while working on engine, that 12-volt electrical system is capable of violent and
damaging short circuits.
When performing any work where electrical terminals can be grounded, ground cable of the battery should
be disconnected at battery.
Any time the air cleaner, throttle body or intake manifold is removed, the intake opening should be covered.
This will protect against accidental entrance of foreign material which could follow intake passage into cylin-
der and cause extensive damage when engine is started.

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Fuel pressure relief procedure
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector
lever to “P” range for A/T model), set parking brake, and
block drive wheels.
2) Remove relay box cover.
3) Disconnect fuel pump relay (1) from its connector.
4) Remove fuel filler cap to release fuel vapor pressure in fuel
tank and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat
cranking engine 2-3 times for about 3 seconds each time to
dissipate fuel pressure in lines. Fuel connections are now
safe for servicing.
6) Upon completion of servicing, connect fuel pump relay (1) to
its connector.
Fuel leakage check procedure
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump)
and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pres-
sure to fuel line. (till fuel pressure is felt by hand placed on
fuel feed hose.)
2) In this state, check to see that there are no fuel leakages
from any part of fuel system. CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.

Downloaded from www.Manualslib.com manuals search engine 6-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Engine Diagnosis
General Description
This vehicle is equipped with an engine and emission control system which are under control of ECM.
The engine and emission control system in this vehicle are controlled by ECM. ECM has an On-Board Diagnos-
tic system which detects a malfunction in this system and abnormality of those parts that influence the engine
exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the outline of “On-
Board Diagnostic System” and each item in “Precaution in Diagnosing Trouble” and execute diagnosis accord-
ing to “ENGINE DIAGNOSTIC FLOW TABLE”.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust
system, etc. and the engine and emission control system in their structure and operation. In case of an engine
trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to
this flow table.
On-Board Diagnostic System (Vehicle with
Immobilizer Indicator Lamp)
ECM in this vehicle has following functions.
When the ignition switch is turned ON with the engine at a
stop, malfunction indicator lamp (MIL) (1) turns ON to check
the bulb of the malfunction indicator lamp (1).
When ECM detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it
makes the malfunction indicator lamp (1) in the meter cluster
of the instrument panel turn ON or flash (flashing only when
detecting a misfire which can cause damage to the catalyst)
and stores the malfunction area in its memory.
(If it detects that continuously 3 driving cycles are normal
after detecting a malfunction, however, it makes MIL (1) turn
OFF although DTC stored in its memory will remain.)
As a condition for detecting a malfunction in some areas in
the system being monitored by ECM and turning ON the
malfunction indicator lamp (1) due to that malfunction, 2 driv-
ing cycle detection logic is adopted to prevent erroneous
detection.
When a malfunction is detected, engine and driving condi-
tions then are stored in ECM memory as freeze frame data.
(For the details, refer to description on Freeze frame data.)
It is possible to communicate by using not only SUZUKI scan
tool (2) but also generic scan tool. (Diagnostic information
can be accessed by using a scan tool.)
WARM-UP CYCLE
A warm-up cycle means sufficient vehicle operation such that the
coolant temperature has risen by at least 22 °C (40 °F) from
engine starting and reaches a minimum temperature of 70 °C
(160 °F).

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DRIVING CYCLE
A “Driving Cycle” consists of engine startup and engine shutoff.
2 DRIVING CYCLES DETECTION LOGIC
The malfunction detected in the first driving cycle is stored in
ECM memory (in the form of pending DTC and freeze frame data)
but the malfunction indicator lamp does not light at this time. It
lights up at the second detection of same malfunction also in the
next driving cycle.
PENDING DTC
Pending DTC means a DTC detected and stored temporarily at 1
driving cycle of the DTC which is detected in the 2 driving cycle
detection logic.
FREEZE FRAME DATA
ECM stores the engine and driving conditions (in the from of data
as shown in the figure) at the moment of the detection of a mal-
function in its memory. This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving conditions
(e.g., whether the engine was warm or not, where the vehicle was
running or stopped, where air / fuel mixture was lean or rich)
when a malfunction was detected by checking the freeze frame
data. Also, ECM has a function to store each freeze frame data
for three different malfunctions in the order as the malfunction is
detected. Utilizing this function, it is possible to know the order of
malfunctions that have been detected. Its use is helpful when
rechecking or diagnosing a trouble.
Priority of freeze frame data :
ECM has 4 frames where the freeze frame data can be stored.
The first frame stores the freeze frame data of the malfunction
which was detected first. However, the freeze frame data stored
in this frame is updated according to the priority described below.
(If malfunction as described in the upper square “1” below is
detected while the freeze frame data in the lower square “2” has
been stored, the freeze frame data “2” will be updated by the
freeze frame data “1”.)
[A] : An Example of Freeze Frame Data
[B] : 1st, 2nd or 3rd in parentheses here represents which position in the order
the malfunction is detected.
PRIORITY FREEZE FRAME DATA IN FRAME 1
1Freeze frame data at initial detection of mal-
function among misfire detected (P0300 –
P0304), fuel system too lean (P0171) and fuel
system too rich (P0172)
2Freeze frame data when a malfunction other
than those in “1” above is detected

Downloaded from www.Manualslib.com manuals search engine ENGINE GENERAL INFORMATION AND DIAGNOSIS 6-9
On-Board Diagnostic System (Vehicle without
Immobilizer Indicator Lamp)
ECM diagnosis troubles which may occur in the area including
the following parts when the ignition switch is ON and the engine
is running, and indicates the result by turning on or flashing mal-
function indicator lamp (1).
Heated oxygen sensor (if equipped)
ECT sensor
TP sensor
IAT sensor
MAP sensor
CMP sensor
CKP sensor
Knock sensor
VSS
CPU (Central Processing Unit) of ECM
ECM and malfunction indicator lamp (1) operate as follows.
Malfunction indicator lamp (1) lights when the ignition switch
is turned ON (but the engine at stop) with the diagnosis
switch terminal ungrounded regardless of the condition of
Engine and Emission Control system. This is only to check
the malfunction indicator lamp (1) bulb and its circuit.
If the above areas of Engine and Emission Control system is
free from any trouble after the engine start (while engine is
running), malfunction indicator lamp (1) turns OFF.
When ECM detects a trouble which has occurred in the
above areas, it makes malfunction indicator lamp (1) turn ON
while the engine is running to warn the driver of such occur-
rence of trouble and at the same time it stores the trouble
area in ECM back-up memory. (The memory is kept as it is
even if the trouble was only temporary and disappeared
immediately. And it is not erased unless the power to ECM is
shut off for specified time below.)
ECM also indicates trouble area in memory by means of
flashing of malfunction indicator lamp (1) at the time of
inspection. (i.e. when connecting diagnosis switch terminal
(2) and ground terminal (4) of monitor connector (3) with a
service wire (5) and ignition switch is turned ON.)
NOTE:
When a trouble occurs in the above areas and disap-
pears soon while the diagnosis switch terminal is
ungrounded and the engine is running, malfunction
indicator lamp (1) lights and remains ON as long as the
trouble exists but it turns OFF when the normal condi-
tion is restored.
Time required to erase diagnostic trouble code mem-
ory thoroughly varies depending on ambient tempera-
ture as follows.

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Malfunction indicator lamp (MIL) check
1) Turn ON ignition switch (but the engine at stop) and check
that MIL lights.
If MIL does not light up (or MIL dims), go to “Diagnostic Flow
Table A-1” for troubleshooting.
If MIL flushes, go to “Diagnostic Flow Table A-3” for trouble
shooting (vehicle without immobilizer indicator lamp).
2) Start engine and check that MIL turns OFF.
If MIL remains ON and no DTC is stored in ECM, go to
“Diagnostic Flow Table A-2” for troubleshooting.
Diagnostic trouble code (DTC) check
[Using SUZUKI Scan Tool]
1) Prepare SUZUKI scan tool.
2) With ignition switch OFF, connect it to data link connector
(DLC) (1) located on underside of instrument panel at
driver’s seat side.
Special tool
(A) : SUZUKI scan tool
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC, pending DTC and freeze frame data according to
instructions displayed on scan tool and print it or write it
down.
Refer to scan tool operator’s manual for further details.
If communication between scan tool and ECM is not possi-
ble, check if scan tool is communicable by connecting it to
ECM in another vehicle. If communication is possible in this
case, scan tool is in good condition. Then check data link
connector and serial data line (circuit) in the vehicle with
which communication was not possible.
5) After completing the check, turn ignition switch off and dis-
connect scan tool from data link connector.
[Without Using SUZUKI Scan Tool] (Vehicle Without
Immobilizer Indicator Lamp)
1) Check malfunction indicator lamp referring to “Malfunction
Indicator Lamp Check” in this section.
2) With the ignition switch OFF position, connect diagnosis
switch terminal (3) and ground terminal (2) in monitor con-
nector (1) with service wire (4).
3) With the ignition switch ON position and leaving engine OFF,
read DTC from flashing pattern of malfunction indicator
lamp. Refer to “Diagnostic Trouble Code Table”.
If lamp does not flash or remains ON or OFF, go to “Diag-
nostic Flow Table A-4”.

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P0335
(No.23)Crankshaft position sensor
circuit malfunctionNo signal for 2 sec. During engine crank-
ing1 driving
cycle1 driving
cycle
P0340
(No.15)Camshaft position sensor
circuit malfunctionNo signal during engine running1 driving
cycle1 driving
cycle
P0400Exhaust gas recirculation
flow malfunction detectedExcessive or insufficient EGR flow2 driving
cyclesNot
applicable
P0420Catalyst system efficiency
below thresholdOutput waveforms of HO2S-1 and HO2S-2
are similar.
(Time from output voltage change of
HO2S-1 to that of HO2S-2 is shorter than
specification.)2 driving
cyclesNot
applicable
P0443Purge control valve circuit
malfunctionPurge control valve circuit is open or
shorted to ground2 driving
cyclesNot
applicable
P0481A/C condenser fan control
circuit malfunctionA/C condenser fan relay terminal voltage is
low when fan command is not outputted2 driving
cyclesNot
applicable
P0500
(No.16)Vehicle speed sensor mal-
functionNo signal while running in “D” range or
during fuel cut at decelerating2 driving
cycles1 driving
cycle
P0505 Idle control system malfunc-
tionNo closed signal to IAC valve is detected2 driving
cyclesNot
applicable
P0601
(No.71)Internal control module
memory check sum errorData write error (or check sum error) when
written into ECM2 driving
cyclesNot
applicable
P1450 Barometric pressure sen-
sor circuit malfunctionBarometric pressure is lower or higher
than specification. (or sensor malfunction)1 driving
cycleNot
applicable
P1451Barometric pressure sen-
sor performance problemDifference between manifold absolute
pressure (MAP sensor value) and baro-
metric pressure (barometric pressure sen-
sor value) is larger than specification
during cranking.2 driving
cyclesNot
applicable
P1500Starter signal circuit mal-
functionStarter signal is not inputted from engine
cranking till its start and after or it is always
inputted2 driving
cyclesNot
applicable
P1510ECM backup power source
malfunctionNo backup power after starting engine1 driving
cycleNot
applicable
P1600Serial communication prob-
lem between ECM and
TCMNo signal or check sum error while engine
running1 driving
cycleNot
applicable
P1717AT D-range signal circuit
malfunctionNo “D” range (park / neutral position sig-
nal) is inputted while vehicle running2 driving
cyclesNot
applicable
P1570ABS signal circuit malfunc-
tionABS signal ON (low voltage) when engine
startNot
applicable1 driving
cycle DTC
NO.DETECTING ITEM DETECTING CONDITION
(DTC will set when detecting :)MIL
(vehicle
with immo-
bilizer indi-
cator lamp)MIL
(vehicle
without
immobi-
lizer indica-
tor lamp)