2005 SUZUKI JIMNY ect

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TAble B-7 A/C Condenser Fan Control System Check
INSPECTION
Step Action Yes No
1 Check Fan Control System.
1) Connect scan tool to DLC with ignition switch OFF. See
Fig. 1.
2) Start engine and select “DATA LIST” mode on scan tool.
3) Warm up engine until coolant temp. is 110 °C, 230 °F or
higher and A/C switch turn OFF. (If engine coolant temp.
does not rise, check engine cooling system or ECT sen-
sor.)
Is A/C condenser fan started when engine coolant temp.
reached above temp.?A/C condenser fan con-
trol system is in good
condition.Go to Step 2.
2 Check A/C Condenser Fan Relay and Its Circuit.
1) Check DTC and pending DTC with scan tool.
Is DTC P0481 displayed?Go to DTC P0481 Diag.
Flow Table.Go to Step 3.
3 Check A/C Condenser Fan Relay (1).
1) Turn ignition switch OFF and remove A/C condenser fan
relay.
2) Check for proper connection to relay at terminals “A”
and “B”.
3) If OK, check that there is continuity between “A” and “B”
when battery is connected to terminals “C” and “D”. See
Fig. 2.
Is check result satisfactory?Go to Step 4. Replace A/C
condenser fan
relay.

Downloaded from www.Manualslib.com manuals search engine 6-122 ENGINE GENERAL INFORMATION AND DIAGNOSIS
[A] Fig. 1 for Step 1 / [B] Fig. 2 for Step 3
Fig. 3 for Step 44 Check A/C Condenser Fan (1).
1) Turn ignition switch OFF.
2) Disconnect fan motor connector (2).
3) Check for proper connection to motor at “R/Bl” and “B”
terminals.
4) If OK, connect battery to motor and check for operation.
See Fig. 3.
Is it in good condition?“R”, “R/Bl” or “B” circuit
open.Replace A/C
condenser fan
motor. Step Action Yes No

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Special Tool
09912-58441 09912-58431 09912-58490 09912-58421
Pressure gauge Pressure hose 3-way joint & hose Checking tool set
(See NOTE “A”.)
09912-57610 09917-47010 09930-88530 09931-76011
Checking tool plate Vacuum pump gauge Injector test lead SUZUKI scan tool (Tech
1A) kit (See NOTE “B”.)
09931-76030
Mass storage cartridge 16 / 14 pin DLC cable Tech 2 kit (SUZUKI scan
tool) (See NOTE “C”.)
NOTE:
“A” : This kit includes the following items.
1. Tool body & washer, 2. Body plug, 3. Body attachment, 4. Holder, 5. Return hose & clamp,
6. Body attachment-2 & washer, 7. Hose attachment-1, 8. Hose attachment-2
“B” : This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead / probe,
6. Power source cable, 7. DLC cable adaptor, 8. Self–test adaptor
“C” : This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply

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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Engine Lubrication
The oil pump is of a trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump
strainer and passed through the pump to the oil filter.
The filtered oil flows into 2 paths in cylinder block.
In one path, oil reaches the crankshaft journal bearings. Oil from the crankshaft journal bearings is supplied to
the connecting rod bearings by means of intersecting passages drilled in the crankshaft, and then injected from
the big end of connecting rod to lubricate piston, rings, and cylinder wall.
In other path oil goes up to the cylinder head and lubricates valves and camshafts, etc., after passing through
the internal oilway of camshafts.
An oil relief valve is provided on the oil pump. This valve starts relieving oil pressure when the pressure exceeds
about 400 kPa (4.0 kg/cm
2, 56.9 psi).

Downloaded from www.Manualslib.com manuals search engine 6A1-4 ENGINE MECHANICAL (M13 ENGINE)
Diagnosis
Diagnosis Table
Refer to “Engine Diagnosis Table” in Section 6.
Compression Check
Check compression pressure on all 4 cylinders as follows:
1) Warm up engine.
2) Stop engine after warming up.
3) Disconnect accelerator cable (1) from clamp (2) (For left
hand steering vehicle only).
4) Remove cylinder head upper cover (3).
5) Disconnect ignition coil couplers (1).
6) Remove ignition coil assemblies (2) with high-tension cord
(3).
7) Remove all spark plugs.
8) Disconnect fuel injector wires (4) at the coupler.
9) Install special tools (Compression gauge) into spark plug
hole.
Special tool
(A) : 09915-64510-001
(B) : 09915-64510-002
(C) : 09915-64530
(D) : 09915-67010 NOTE:
After warming up engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
model), and set parking brake and block drive wheels.

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-5
10) Disengage clutch (1) (to lighten starting load on engine) for
M/T vehicle, and depress accelerator pedal (2) all the way to
make throttle fully open.
11) Crank engine with fully charged battery, and read the highest
pressure on compression gauge.
Compression pressure specification
12) Carry out Steps 9) through 11) on each cylinder to obtain 4
readings.
13) After checking, install spark plugs and ignition coil assem-
blies (1) with high-tension cord (2).
14) Connect ignition coil couplers (3).
15) Connect fuel injector wires (4) at the coupler.
16) Check cylinder head upper cover gasket for deterioration and
then install it into groove of cylinder head upper cover (1)
securely.
17) Install cylinder head upper cover with gasket on to cylinder
head cover.
18) Connect accelerator cable (2) to clamp (3) (For left hand
steering vehicle only).
NOTE:
For measuring compression pressure, crank engine at
least 250 rpm by using fully charged battery.
If check results are below the limit valve, check instal-
lation condition for special tool.
Standard1400 kPa
(14.0 kg/cm
2, 199.0 psi)
Limit1100 kPa
(11.0 kg/cm
2, 156.0 psi)
Max. difference between
any two cylinders100 kPa
(1.0 kg/cm
2, 14.2 psi)

Downloaded from www.Manualslib.com manuals search engine 6A1-6 ENGINE MECHANICAL (M13 ENGINE)
Engine Vacuum Check
The engine vacuum that develops in the intake line is a good indi-
cator of the condition of the engine. The vacuum checking proce-
dure is as follows:
1) Warm up engine to normal operating temperature.
2) Stop engine and turn off the all electric switches.
3) Remove cap (1) from intake manifold.
4) Connect special tool (Vacuum gauge) to intake manifold.
Special tool
(A) : 09915-67310
5) Run engine at specified idle speed and read vacuum gauge.
Vacuum should be within specification.
Vacuum specification (at sea level)
59 – 73 kPa (45 – 55 cm Hg, 17.7 – 21.6 in. Hg)
at specified idle speed
6) After checking, disconnect special tool (Vacuum gauge) from
intake manifold.
7) Install cap to intake manifold.NOTE:
After warming up engine, be sure to place transmission
gear shift lever in “Neutral” (shift selector lever to “P”
range for A/T model), and set parking brake and block
drive wheels.