2005 SUZUKI JIMNY contact

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-1
0A
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 0A
GENERAL INFORMATION
CONTENTS
How to Use This Manual .................................0A-2
Precautions......................................................0A-3
Precaution for Vehicles Equipped with a
Supplemental Restraint (Air Bag) System ..... 0A-3
Diagnosis................................................... 0A-3
Servicing and handling .............................. 0A-4
General Precautions ..................................... 0A-7
Precautions For Catalytic Converter ........... 0A-10
Precautions For Electrical Circuit Service ... 0A-10
Electrical Circuit Inspection Procedure........ 0A-13
Open circuit check ................................... 0A-13
Short circuit check (wire harness to
ground) .................................................... 0A-15
Intermittent and Poor Connection ............... 0A-15
Precaution For Installing Mobile
Communication Equipment ......................... 0A-16Identification Information ............................. 0A-17
Body Number .............................................. 0A-17
Engine Identification Number ...................... 0A-17
Transmission Identification Number............ 0A-17
Warning, Caution and Information
Labels............................................................. 0A-18
Vehicle Lifting Points ................................... 0A-19
When Using Frame Contact Hoist .............. 0A-19
When Using Floor Jack ............................... 0A-20
Abbreviations May Be Used In This
Manual............................................................ 0A-21
Abbreviations .............................................. 0A-21
Fasteners Information .................................. 0A-24
Metric Fasteners ......................................... 0A-24
Fastener Strength Identification .................. 0A-24
Standard Tightening Torque ....................... 0A-24

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-3
Precautions
Precaution for Vehicles Equipped with a Sup-
plemental Restraint (Air Bag) System
Diagnosis
 When troubleshooting air bag system, be sure to follow “Air
Bag Diagnostic System Check” in Section 10B. Bypassing
these procedures may result in extended diagnostic time,
incorrect diagnosis, and incorrect parts replacement.
 Never use electrical test equipment other than that specified
in this manual. WARNING:
 The configuration of air bag system parts are as shown
in the figure. When it is necessary to service (remove,
reinstall and inspect) these parts, be sure to follow
procedures described in Section 10B. Failure to follow
proper procedures could result in possible air bag sys-
tem activation, personal injury, damage to parts or air
bag system being unable to activate when necessary.
 If the air bag system and another vehicle system both
need repair, SUZUKI recommends that the air bag sys-
tem be repaired first, to help avoid unintended air bag
system activation.
 Do not modify the steering wheel, dashboard, or any
other air bag system components. Modifications can
adversely affect air bag system performance and lead
to injury.
 If the vehicle will be exposed to temperatures over
93°C (200°F) (for example, during a paint baking pro-
cess), remove the air bag system components before-
hand to avoid component damage or unintended air
bag system activation.
1. Air bag wire harness (in instrument panel
wire harness and floor wire harness)5. Contact coil
2. Passenger air bag (inflator) module 6. Driver air bag (inflator) module
3. SDM 7. Seat belt pretensioner (if equipped)
4. DLC
WARNING:
Never attempt to measure the resistance of the air bag
(inflator) modules (driver and passenger) and seat belt
pretensioners (driver and passenger). It is very danger-
ous as the electric current from the tester may deploy the
air bag or activate the pretensioner.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-7
General Precautions
The WARNING and CAUTION below describe some general precautions that you should observe when servic-
ing a vehicle. These general precautions apply to many of the service procedures described in this manual, and
they will not necessarily be repeated with each procedure to which they apply.
 Before starting any service work, cover fenders, seats
and any other parts that are likely to get scratched or
stained during servicing. Also, be aware that what you
wear (e.g, buttons) may cause damage to the vehicle’s
finish.
 When performing service to electrical parts that does
not require use of battery power, disconnect the nega-
tive cable of the battery. WARNING:
 Whenever raising a vehicle for service, be sure to follow the instructions under “Vehicle Lifting
Points” in this section.
 When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for auto-
matic transmission vehicles), Keep hands, hair, clothing, tools, etc. away from the fan and belts
when the engine is running.
 When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.
 Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials (such as gasoline and refriger-
ant), make sure that the area you work in is well-ventilated.
 To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.
 New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets.
Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory ani-
mals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil,
wear a long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing
engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any
clothing or rags if wet with oil, recycle or properly dispose of used oil and filters.
 Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly
during driving, obstructing your view and resulting in an accident.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-11
 When connecting connectors, also hold connectors and
push them together until they lock securely (a click is
heard).
 When installing the wiring harness, fix it with clamps so
that no slack is left.
 When installing vehicle parts, be careful so that the wir-
ing harness is not interfered with or caught by any other
part.
 To avoid damage to the harness, protect its part which
may contact against a part forming a sharp angle by
winding tape or the like around it.
 Be careful not to touch the electrical terminals of parts
which use microcomputers (e.g. electronic control unit
like as ECM, PCM, P/S controller, etc.). The static elec-
tricity from your body can damage these parts.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-13
Electrical Circuit Inspection Procedure
While there are various electrical circuit inspection methods,
described here is a general method to check its open and short
circuit by using an ohmmeter and a voltmeter.
Open circuit check
Possible causes for the open circuit are as follows. As the cause
is in the connector or terminal in many cases, they need to be
checked particularly carefully.
 Loose connection of connector
 Poor contact of terminal (due to dirt, corrosion or rust on it,
poor contact tension, entry of foreign object etc.)
 Wire harness being open
When checking system circuits including an electronic control unit
such as ECM, TCM, ABS control module, etc., it is important to
perform careful check, starting with items which are easier to
check.
1) Disconnect negative cable from battery
2) Check each connector at both ends of the circuit being
checked for loose connection. Also check lock condition of
connector if equipped with connector lock.
3) Using a test male terminal, check both terminals of the circuit
being checked for contact tension of its female terminal.
Check each terminal visually for poor contact (possibly
caused by dirt, corrosion, rust entry of foreign object, etc.).
At the same time, check to make sure that each terminal is
locked in the connector fully.
4) Using the following continuity check or voltage check proce-
dure, check the wire harness for open circuit and poor con-
nection with its terminals. Locate abnormality, if any.
1. Check contact tension by inserting and removing just for once
1. Looseness of crimping
2. Open
3. Thin wire (single strand of wire)

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-15
Short circuit check (wire harness to ground)
1) Disconnect negative cable from battery.
2) Disconnect connectors at both ends of the circuit to be
checked.
3) Measure resistance between terminal at one end of circuit
(A-1 terminal in figure) and body ground. If continuity is indi-
cated, it means that there is a short to ground between ter-
minals A-1 and C-1 of the circuit.
4) Disconnect the connector included in circuit (connector B)
and measure resistance between A-1 and body ground.
If continuity is indicated, it means that the circuit is shorted to
the ground between terminals A-1 and B-1.
Intermittent and Poor Connection
Most intermittent are caused by faulty electrical connections or
wiring, although a sticking relay or solenoid can occasionally be at
fault. When checking it for proper connection, perform careful
check of suspect circuits for:
 Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
 Dirt or corrosion on the terminals. The terminals must be
clean and free of any foreign material which could impede
proper terminal contact. However, cleaning the terminal with
a sand paper or the like is prohibited.
 Damaged connector body, exposing the terminals to mois-
ture and dirt, as well as not maintaining proper terminal ori-
entation with the component or mating connector. NOTE:
If the circuit to be checked is connected to other parts
(1), disconnect all connectors of those parts.
Otherwise, diagnosis will be misled.
1. To other parts

Downloaded from www.Manualslib.com manuals search engine 0A-16 GENERAL INFORMATION
 Improperly formed or damaged terminals.
Check each connector terminal in problem circuits carefully
to ensure good contact tension by using the corresponding
mating terminal.
If contact tension is not enough, reform it to increase contact
tension or replace.
 Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor con-
nection by shaking it by hand lightly. If any abnormal condi-
tion is found, repair or replace.
 Wire insulation which is rubbed through, causing an intermit-
tent short as the bare area touches other wiring or parts of
the vehicle.
 Wiring broken inside the insulation. This condition could
cause continuity check to show a good circuit, but if only 1 or
2 strands of a multi-strand-type wire are intact, resistance
could be far too high.
If any abnormality is found, repair or replace.
Precaution For Installing Mobile Communica-
tion Equipment
When installing mobile communication equipment such as CB
(Citizens-Band)-radio or cellular-telephone, be sure to observe
the following precautions.
Failure to follow cautions may adversely affect electronic control
system.
 Keep the antenna as far away as possible from the vehicle’s
electronic control unit.
 Keep the antenna feeder more than 20 cm (7.9 in) away from
electronic control unit and its wire harnesses.
 Do not run the antenna feeder parallel with other wire har-
nesses.
 Confirm that the antenna and feeder are correctly adjusted.
1. Check contact tension by inserting and removing just once
2. Check each terminal for bend and proper alignment

Downloaded from www.Manualslib.com manuals search engine 0A-18 GENERAL INFORMATION
Warning, Caution and Information Labels
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handling parts, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damaged, clean or replace it as necessary.
NOTE:
Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only.
1. Emission control label (Australia only) 3. Air bag label on sun visor 5. Engine cooling fan label
2. Air bag label on engine hood 4. Radiator cap label
1. Air bag warning label on driver air bag (inflator) module 4. Air bag label on SDM
2. Air bag warning label on contact coil and combination switch assembly 5. Air bag label on passenger air bag (inflator) module
3. Air bag warning label on steering column 6. Seat belt pretensioner label on retractor