2005 SUZUKI JIMNY Pressure switch

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Oil Pressure Check
Oil level in oil pan.
If oil level is low, add oil up to Full level mark (hole) (1) on oil
level gauge.
Oil quality.
If oil is discolored, or deteriorated, change it.
For particular oil to be used, refer to the table in Section 0B.
Oil leaks.
If leak is found, repair it.
1) Disconnect oil pressure switch coupler (1) and remove oil
pressure switch (2) from cylinder block.
2) Install special tools (Oil pressure gauge) to vacated threaded
hole.
Special tool
(A) : 09915-77310
(B) : 09915-78211
3) Start engine and warm it up to normal operating tempera-
ture.
4) After warming up, raise engine speed to 4,000 rpm and mea-
sure oil pressure.
Oil pressure specification
280 – 430 kPa (2.8 – 4.3 kg/cm
2, 39.8 – 61.1 psi) at 4,000
rpm
5) Stop engine and remove oil pressure gauge and attachment.NOTE:
Prior to checking oil pressure, check the following items.
2. Low level mark (hole)
NOTE:
Be sure to place transmission gear shift lever in “Neu-
tral” (shift selector lever to “P” range for A/T model), and
set parking brake and block drive wheels.

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6) Before reinstalling oil pressure switch (2), be sure to wrap its
screw threads with sealing tape (1) and tighten switch to
specified torque.
Tightening torque
Oil pressure switch (a) : 14 N.m (1.4 kg-m, 10.5 lb-ft)
7) Start engine and check oil pressure switch for oil leakage.
If oil leakage is found, repair it.
8) Connect oil pressure switch coupler (1).NOTE:
If sealing tape edge is bulged out from screw threads of
switch, cut it off.

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a) For right hand steering vehicle:
With hose connected, detach A/C compressor from its
bracket.
b) For left hand steering vehicle:
i) Recover refrigerant from refrigeration system using recov-
ery and recycling equipment.
ii) Disconnect magnet clutch lead wire.
iii) Remove suction pipe and disconnect discharge pipe from
A/C compressor.
iv) Remove A/C compressor from its bracket.
When servicing above steps, refer to “Compressor” in Section 1B.
14) Remove air cleaner outlet No.1 and No.2 hoses.
15) Disconnect the following electric lead wires:
TP sensor (1)
MAP sensor (2)
CKP sensor (if equipped) (3)
CMP sensor
ECT sensor
Heated oxygen sensor
EGR valve (if equipped)
IAC valve (4)
EVAP canister purge valve (5)
Injectors (6)
Ignition coils
Generator
Starting motor
Oil pressure switch
Ground terminal from intake manifold and cylinder block
Each wire harness clamps
16) Remove intake manifold bracket (7) with main harness from
intake manifold.
17) Remove starting motor referring to “Dismounting” in Section
6G. NOTE:
Suspend removed A/C compressor at a place where no
damage will be caused during removal and installation of
engine assembly.

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Required Service Material
Tightening Torque Specification
MaterialRecommended SUZUKI product
(Part Number)Use
Sealant SUZUKI BOND NO. 1207C
(99000-31150)To apply to mating surface of cylinder block and oil
pan.
To apply to mating surface of cylinder block and
timing chain cover.
To apply to sealing surface of cylinder head cover.
To apply to mating surface to rear oil seal housing.
SUZUKI BOND NO. 1207B
(99000-31140)To apply to mating surface of cylinder block, cylin-
der head and timing chain cover.
SUZUKI BOND NO. 1215
(99000-31110)To flywheel (M/T) or drive plate (A/T) bolts.
Fastening partTightening torque
Nm kg-m lb-ft
Oil pressure switch 14.0 1.4 10.5
Camshaft housing bolts
(for replacement of shim)8.0 0.8 6.0
Camshaft housing bolts 11.0 1.1 8.0
Cylinder head cover bolts 8.0 0.8 6.0
Intake manifold bolts and nuts 25.0 2.5 18.0
Exhaust manifold bolts and nuts 55.0 5.5 40.0
Exhaust pipe bolts 50.0 5.0 36.5
Exhaust manifold stiffener bolts 50.0 5.0 36.5
Oil pump strainer bolt 11.0 1.1 8.0
Oil pump strainer bracket bolt 11.0 1.1 8.0
Oil pan bolts and nuts 11.0 1.1 8.0
Oil pan drain plug 50.0 5.0 36.5
Timing chain cover bolts and nut 23.0 2.3 17.0
Crankshaft pulley bolt 150.0 15.0 108.5
Oil pump rotor plate bolts 11.0 1.1 8.0
Timing chain No.1 guide bolts 9.0 0.9 6.5
Timing chain tensioner adjuster bolts 11.0 1.1 8.0
Venturi plug 5.0 0.5 3.5
Cylinder head bolt for M8 22.0 2.2 16.0
Cylinder head bolts for M10 a) Tighten 40 N·m
b) Turn 60°
c) Turn 60°a) Tighten 4.0 kg-m
b) Turn 60°
c) Turn 60°a) Tighten 29.0 lb-ft
b) Turn 60°
c) Turn 60°
Connecting rod bearing cap nuts a) Tighten 15 N·m
b) Turn 45°
c) Turn 45°a) Tighten 1.5 kg-m
b) Turn 45°
c) Turn 45°a) Tighten 11.0 lb-ft
b) Turn 45°
c) Turn 45°
Engine mounting bolts 50.0 5.0 36.5

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6F1
6F2
6G
7C1
7D
7E
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
6H
6E
10
10A
10B
SECTION 6E
ENGINE AND EMISSION CONTROL SYSTEM
CONTENTS
General Description ....................................... 6E-3
Air Intake System ......................................... 6E-5
Fuel Delivery System ................................... 6E-6
Fuel pump ................................................ 6E-6
Electronic Control System ............................ 6E-7
Engine & emission control input / output
table.......................................................... 6E-8
On-Vehicle Service....................................... 6E-15
Accelerator cable adjustment ................. 6E-15
Idle speed / idle air control (IAC) duty
inspection ............................................... 6E-15
Idle mixture inspection / adjustment
(vehicle without heated oxygen
sensor) ................................................... 6E-17
Air Intake System ....................................... 6E-18
Throttle body .......................................... 6E-18
Idle air control valve (IAC valve)............. 6E-21
Fuel Delivery System ................................. 6E-22
Fuel pressure inspection ........................ 6E-22
Fuel pump .............................................. 6E-23
Fuel pressure regulator .......................... 6E-24
Fuel injector ............................................ 6E-25
Electronic Control System .......................... 6E-29Engine control module (ECM) ................ 6E-29
Manifold absolute pressure sensor (MAP
sensor) ................................................... 6E-29
Throttle position sensor (TP sensor) ...... 6E-30
Intake air temperature sensor
(IAT sensor) ........................................... 6E-31
Engine coolant temperature sensor
(ECT sensor) .......................................... 6E-32
Heated oxygen sensor
(Sensor-1 and sensor-2) ........................ 6E-33
Camshaft position sensor....................... 6E-34
Crankshaft position sensor..................... 6E-35
Vehicle speed sensor (VSS) .................. 6E-36
Fuel level sensor (GAUGE).................... 6E-36
Knock sensor ......................................... 6E-36
Main relay, fuel pump relay and A/C
condenser fan control relay .................... 6E-36
Fuel cut operation .................................. 6E-37
A/C condenser fan control system ......... 6E-37
A/C condenser fan ................................. 6E-37
Output signals of throttle valve opening
and engine coolant temp.
(Vehicle with A/T only) ........................... 6E-38
Emission Control System ........................... 6E-38 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).
NOTE:
Whether following systems (parts) are used in the particular vehicle or not depends on specifications.
Be sure to bear this in mind when performing service work.
EGR valve
Heated oxygen sensor (s) or CO adjusting resistor
Three way catalytic converter (TWC) and warm up three-way catalytic converter (WU-TWC)

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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)

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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

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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)