2005 SUZUKI JIMNY Gear

Downloaded from www.Manualslib.com manuals search engine ENGINE MECHANICAL (M13 ENGINE) 6A1-7
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.

Downloaded from www.Manualslib.com manuals search engine 6A1-88 ENGINE MECHANICAL (M13 ENGINE)
Flywheel
If ring gear is damaged, cracked or worn, replace flywheel.
If the surface contacting clutch disc is damaged, or exces-
sively worn, replace flywheel.
Check flywheel for face runout with a dial gauge.
If runout exceeds its limit, replace flywheel.
Flywheel runout
Limit : 0.2 mm (0.0079 in.)
Sensor Plate
Check sensor plate for crack or damage. If malcondition is
found, replace it.
Cylinder Block
Distortion of gasketed surface
Using straightedge and thickness gauge, check gasketed
surface for distortion and, if flatness exceeds its limit, correct
it.
Cylinder block flatness
Limit : 0.05 mm (0.0020 in.)
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must
also be rebored at the same time.
2) Select oversized piston according to amount of cylinder
wear.
Oversize piston diameter
Size Piston diameter
Oversize 0.5078.453 – 78.468 mm
(3.0887 – 3.0893 in.)

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.

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Fuel cut operation
INSPECTION
1) Warm up engine to normal operating temperature.
2) While listening to sound of injector (1) by using sound scope
(2) or such, increase engine speed to higher than 3,000 r/
min.
3) Check to make sure that sound to indicate operation of injec-
tor stops when throttle valve is closed instantly and it is
heard again when engine speed is reduced to less than
about 2,000 r/min.
A/C condenser fan control system
SYSTEM INSPECTION
Check system for operation referring to “Flow Table B-7” in Sec-
tion 6.
If A/C condenser fan fails to operate properly, check relay, A/C
condenser fan and electrical circuit.
A/C condenser fan
INSPECTION
1) Check continuity between each two terminals.
If there is no continuity, replace A/C condenser fan motor. NOTE:
Before inspection, check to make sure that gear shift
lever is in neutral position (with A/T model, selector lever
in “P” range), A/C is OFF and that parking brake lever is
pulled all the way up.
WARNING:
Keep hands, tools, and clothing away from A/C con-
denser fan to help prevent personal injury. This fan is
electric and can come on whether or not the engine is
running. The fan can start automatically in response to
the ECT sensor with the ignition switch in the “ON” posi-
tion.

Downloaded from www.Manualslib.com manuals search engine ENGINE AND EMISSION CONTROL SYSTEM 6E-39
REMOVAL
1) Disconnect negative cable at battery.
2) Disconnect EGR valve connector.
3) Remove EGR pipe.
4) Remove EGR valve and gasket from cylinder head.
INSPECTION
1) Check resistance between following terminals of EGR valve
(1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance
2) Remove carbon from EGR valve (1) gas passage.
3) Inspect valve (2), valve seat (3) and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve assembly.
INSTALLATION
Reverse removal procedure noting following.
Clean mating surface of valve and cylinder head.
Use new gaskets.
Evaporative emission (EVAP) control system
EVAP CANISTER PURGE INSPECTION
Terminal Standard resistance
A – B
C – B
F – E
D – E 20 – 24
Ω
ΩΩ Ω
NOTE:
Do not use any sharp-edged tool to remove carbon.
Be careful not to damage or bend EGR valve, valve seat
and rod.
NOTE:
Before inspection, check to make sure that gear shift
lever is in neutral position (with A/T model, selector lever
in “P” range) and that parking brake lever is pulled all the
way up.

Downloaded from www.Manualslib.com manuals search engine 6F-8 IGNITION SYSTEM (ELECTRONIC IGNITION SYSTEM)
6) Measure resistance between terminals as follows by using
analog type ohmmeter.
If check result is not satisfactory, replace ignition coil assem-
bly.
Secondary coil resistance
“a” – “b” : 7.5 – 14 k
Ω (at 20°C, 68°F)
7) Install ignition coil assembly.
8) Tighten ignition coil bolts, and then connect ignition coil cou-
pler.
9) Install high-tension cord to ignition coil assembly while grip-
ping its cap.
10) Install cylinder head upper cover.
Crankshaft Position Sensor (CKP Sensor)
Refer to “Crankshaft Position Sensor” in Section 6E for removal,
inspection and installation.
Ignition Timing
INSPECTION
1) When using SUZUKI scan tool (1), connect SUZUKI scan
tool to DLC (2) with ignition switch OFF.
Special tool
(A) : SUZUKI scan tool
2) Start engine and warm it up to normal operating tempera-
ture.
3) Make sure that all of electrical loads except ignition are
switched off.
4) Check to be sure that idle speed is within specification.
(Refer to “Idle Speed/Idle Air Control Duty Inspection” in
Section 6E.)
NOTE:
Ignition timing is not adjustable. If ignition timing is
out of specification, check system related parts.
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for
A/T model), and set parking brake.

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 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.