2005 SUZUKI JIMNY Clutch

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-13
ECM TERMINAL ARRANGEMENT TABLE
For TYPE A (See NOTE)
CONNEC-
TORTERMINAL WIRE COLOR CIRCUITCONNEC-
TORTERMINAL WIRE COLOR CIRCUIT
E191 B Ground for ECM
E187 W Backup power source
2 B/R Ground for drive circuit
8R/GImmobilizer indicator lamp
(if equipped)
3 B/R Ground for drive circuitDuty output terminal (vehicle without
immobilizer indicator lamp)
4 Bl/G Canister purge valve 9––
5 Bl/OrPower steering pressure switch
(if equipped)10 Bl Main relay
6 G/Y IAC valve 11 Br Tachometer
7 P/B Heater of HO2S-1 (if equipped) 12 Y/B Data link connector (5 V)
8 W/B No.4 fuel injector 13 WHeated oxygen sensor-2
(if equipped)
9 R/W No.1 fuel injector 14 W/BIDiagnosis switch terminal
(vehicle without immobilizer indicator
lamp)
10 B/Bl Ground for sensor circuit 15 PTest switch terminal
(vehicle without immobilizer indicator
lamp)
11 W CMP sensor 16 G/W A/C SW signal (if equipped)
12––17 R/Y Lighting switch
13R
R/BlHeated oxygen sensor-1
(if equipped)
CO adjusting resistor (w/o HO2S)18 P/B A/C condenser fan relay (if equipped)
14 G/B ECT sensor 19 W/G Fuel pump relay
15 Lg/B IAT sensor 20 B/Bl Ground for sensor
16 Lg TP sensor 21 B/RThrottle opening signal output for A/T
(A/T)
17 Gr/BIEGR valve (stepper motor coil 3, if
equipped)22 Y/RFuel level gauge (vehicle with immo-
bilizer indicator lamp)
18 GrEGR valve (stepper motor coil 1, if
equipped)23––
19 Br/BIG coil assembly for No.2 and 3 spark
plugs24 Bl/Y Heater blower switch
20 Br/WIG coil assembly for No.1 and 4 spark
plugs
21 R/G No.2 fuel injector
E171––
22 Lg/R Power supply for sensor 2 R R-range signal (A/T)
23 G/R CKP sensor 3––
24––4––
25 W Knock sensor 5 B/Or Overdrive cut signal (A/T)
26 G MAP sensor 6 G/Y D-range idle-up signal (A/T)
27 W/R A/C evaporator temp. sensor 7 G/W Stop lamp switch
28 Gr/BEGR valve (stepper motor coil 4, if
equipped)8––
29 Gr/REGR valve (stepper motor coil 2, if
equipped)9 B/W Ignition switch
30––10––
31 W/G No.3 fuel injector 11 Y Vehicle speed sensor
12 G ABS signal (if equipped)
E181 P A/C compressor clutch (if equipped) 13B/Y (M/T)
B/R (A/T)Engine start signal
2 V/Y Malfunction indicator lamp 14––
3 P/G Data link connector (12 V) 15––
4 R/BI Heater of HO2S-2 (if equipped) 16 R/W Rear defogger switch (if equipped)
5 Bl/B Power source 17 G/RA/T failure signal (A/T) (vehicle with
immobilizer indicator lamp)
6 Bl/B Power source
NOTE:
See NOTE in “ECM INPUT / OUTPUT CIRCUIT DIAGRAM” for applicable model.

Downloaded from www.Manualslib.com manuals search engine 6E-14 ENGINE AND EMISSION CONTROL SYSTEM
For TYPE B (See NOTE)
CONNEC-
TORTERMINAL WIRE COLOR CIRCUITCONNEC-
TORTERMINAL WIRE COLOR CIRCUIT
E191 B Ground for ECM
E187 W Backup power source
2 B/R Ground for drive circuit
8R/GImmobilizer indicator lamp
(if equipped)
3 B/R Ground for drive circuitDuty output terminal (vehicle without
immobilizer indicator lamp)
4 Bl/G Canister purge valve 9––
5 Bl/OrPower steering pressure switch
(if equipped)10 Bl Main relay
6 G/Y IAC valve 11 B/W Ignition switch
7 P/B Heater of HO2S-1 (if equipped) 12 R/W Rear defogger switch
8 W/B No.4 fuel injector 13––
9 R/W No.1 fuel injector 14 W/BIDiagnosis switch terminal
(vehicle without immobilizer indicator
lamp)
10 B/Bl Ground for sensor circuit 15 PTest switch terminal
(vehicle without immobilizer indicator
lamp)
11 W CMP sensor 16 G/W A/C SW signal (if equipped)
12––17 R/Y Lighting switch
13R
R/BlHeated oxygen sensor-1
(if equipped)
CO adjusting resistor (w/o HO2S)18 P/B A/C condenser fan relay (if equipped)
14 G/B ECT sensor 19 W/G Fuel pump relay
15 Lg/B IAT sensor 20B/Y (M/T)
B/R (A/T)Engine start signal
16 Lg TP sensor 21 G/W Stop lamp switch
17 Gr/BIEGR valve (stepper motor coil 3, if
equipped)22 Y Vehicle speed sensor
18 GrEGR valve (stepper motor coil 1, if
equipped)23––
19 Br/BIG coil assembly for No.2 and 3 spark
plugs24––
20 Br/WIG coil assembly for No.1 and 4 spark
plugs
21 R/G No.2 fuel injector
E171 W/R A/C evaporator temp. sensor
22 Lg/R Power supply for sensor 2 R R-range signal (A/T)
23 G/R CKP sensor 3––
24––4––
25 W Knock sensor 5 B/Or Overdrive cut signal (A/T)
26 G MAP sensor 6 G/Y D-range idle-up signal (A/T)
27––7 Y/B Data link connector
28 Gr/BEGR valve (stepper motor coil 4, if
equipped)8––
29 Gr/REGR valve (stepper motor coil 2, if
equipped)9 V/Y Malfunction indicator lamp
30––10––
31 W/G No.3 fuel injector 11 P/G Data link connector (12 V)
12 G ABS signal (if equipped)
E181 P A/C compressor clutch (if equipped) 13 Bl/Y Heater blower switch
2––14 B/Bl Ground for sensor
3––15 B/R Throttle opening sensor
4 R/BI Heater of HO2S-2 (if equipped) 16 Br Tachometer
5 Bl/B Power source 17––
6 Bl/B Power source
NOTE:
See NOTE in “ECM INPUT / OUTPUT CIRCUIT DIAGRAM” for applicable model.

Downloaded from www.Manualslib.com manuals search engine 6G-2 CRANKING SYSTEM
General Description
Cranking Circuit
Diagnosis
Diagnosis Table
Possible symptoms due to starting system trouble would be as follows:
Starting motor does not run (or runs slowly)
Starting motor runs but fails to crank engine
Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies.....in battery, wiring
harness, (including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check following items and narrow down scope
of possible causes.
1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor termi-
nals
3) Discharge of battery
4) Mounting of starting motor
1. Pinion drive lever 5. Plunger 9. A/T: Transmission range switch (shift lever switch)
2. Pinion & Over-running clutch 6. Magnetic switch contacts 10. Ignition & Starter switch
3. Magnetic switch 7. Pull-in coil 11. Battery
4. Hold-in coil 8. Starting motor

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-3
Condition Possible Cause Correction
Motor not running
(No operating sound of
magnetic switch)Shift lever switch is not in P or N, or not adjusted
(A/T)Shift in P or N, or adjust switch.
Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Poor contact in battery terminal connection Retighten or replace.
Loose grounding cable connection Retighten.
Fuse set loose or blown off Tighten or replace.
Poor contacting action of ignition switch and mag-
netic switchReplace.
Lead wire coupler loose in place Retighten.
Open-circuit between ignition switch and magnetic
switchRepair.
Open-circuit in pull-in coil Replace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Poor sliding of plunger and/or pinion Repair.
Motor not running
(Operating sound of
magnetic switch
heard)Battery run down Recharge battery.
Battery voltage too low due to battery deteriora-
tionReplace battery.
Loose battery cable connections Retighten.
Burnt main contact point, or poor contacting action
of magnetic switchReplace magnetic switch.
Brushes are seating poorly or worn down Repair or replace.
Weakened brush spring Replace.
Burnt commutator Replace armature.
Layer short-circuit of armature Replace.
Crankshaft rotation obstructed Repair.
Starting motor running
but too slow (small
torque) (If battery and
wiring are satisfac-
tory, inspect starting
motor)Insufficient contact of magnetic switch main con-
tactsReplace magnetic switch.
Layer short-circuit of armature Replace.
Disconnected, burnt or worn commutator Repair commutator or replace
armature.
Worn brushes Replace brush.
Weakened brush springs Replace spring.
Burnt or abnormally worn end bush Replace bush.
Starting motor run-
ning, but not cranking
engineWorn pinion tip Replace over-running clutch.
Poor sliding of over-running clutch Repair.
Over-running clutch slipping Replace over-running clutch.
Worn teeth of ring gear Replace flywheel (M/T) or drive
plate (A/T).
Noise
Abnormally worn bush Replace bush.
Worn pinion or worn teeth of ring gear Replace pinion or flywheel
(M/T) or drive plate (A/T).
Poor sliding of pinion (failure in return movement) Repair or replace.
Worn internal or planetary gear teeth Replace.
Lack of oil in each part Lubricate.

Downloaded from www.Manualslib.com manuals search engine CRANKING SYSTEM 6G-5
NO-LOAD PERFORMANCE TEST
Connect battery and ammeter to starter as shown.
Check that starter rotates smoothly and steadily with pinion mov-
ing out. Check that ammeter indicates specified current.
Specified current (No-load performance test)
: 90 A MAX. at 11 V
On-Vehicle Service
Starting Motor
DISMOUNTING
1) Disconnect negative (–) battery lead at battery.
2) Disconnect magnetic switch lead wire (6) and battery cable (7) from starting motor terminals.
3) Remove starting motor mount bolts (4) and nut (5).
4) Remove starting motor (1).
REMOUNTING
Reverse the dismounting procedure.
1. Starting motor 3. Transmission case 5. Starting motor mounting nut 7. Battery cable
2. Clutch housing upper plate 4. Starting motor mounting bolt 6. Magnetic switch lead wire Tightening Torque

Downloaded from www.Manualslib.com manuals search engine 6G-6 CRANKING SYSTEM
DISASSEMBLY AND REASSEMBLY
NOTE:
Make sure to apply grease before assembly, where are indicated “A” in the figure below.
Spare parts have been lubricated.
1. Front housing 6. Over-running clutch 11. Magnetic switch 16. Packing 21. Rear bracket
2. Bush 7. Lever 12. Ball 17. Yoke 22. Rear bush
3. Snap ring 8. Plunger 13. Internal gear 18. Armature 23. Brush spring
4. Pinion stop ring 9. Plate 14. Planetary carrier shaft 19. Brush Apply grease (99000-25010)
5. Pinion gear 10. Seal rubber 15. Planetary gear 20. Brush holder Do not reuse.