2005 SUZUKI JIMNY diagram

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This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replace-
ment of components (Service) and for disassembly and assembly of major components (Unit Repair-Overhaul).
Applicable model: JIMNY (SN413) of and after the vehicle identification numbers below.
The contents are classified into sections each of which is given a section number as indicated in the Table of
Contents on following page. And on the first page of each individual section is an index of that section.
This manual should be kept in a handy place for ready reference of the service work.
Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials (lubricant, sealants, etc.) as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
Related Manual
© COPYRIGHT SUZUKI MOTOR CORPORATION 2002JSAFJA43V00140001
JSAFJB43V00140001
JSAFJB43V20140001
JSAFJB43V24140001
JSAFJB43V34140001
JS3JB43V 24140001
JS3JB43V 34140001
Manual Name Manual No.
JIMNY (SN413) WIRING DIAGRAM MANUAL 99512-81A20-015

Downloaded from www.Manualslib.com manuals search engine AIR CONDITIONING (OPTIONAL) 1B-1
6F1
6F2
1B
7A
7A1
7B1
7C1
7D
7E
7F
8A
8B
8C
8D
8E
9
10
10A
10B
SECTION 1B
AIR CONDITIONING (OPTIONAL)
CONTENTS
General Description ....................................... 1B-3
Major Components and Location ................. 1B-3
Refrigerant Circulation ................................. 1B-4
Refrigerant Type .......................................... 1B-4
Diagnosis ........................................................ 1B-5
General Diagnosis Table .............................. 1B-5
Abnormal Noise Diagnosis ........................... 1B-7
Abnormal noise from compressor ............ 1B-7
Abnormal noise from magnetic clutch ...... 1B-7
Abnormal noise from tubing ..................... 1B-7
Abnormal noise from condenser .............. 1B-7
Abnormal noise from crankshaft pulley .... 1B-8
Abnormal noise from tension pulley ......... 1B-8
Abnormal noise from A/C evaporator ....... 1B-8
Abnormal noise from blower fan motor .... 1B-8
Quick Checking of Refrigerant Charge......... 1B-9Performance Diagnosis.............................. 1B-10
Performance diagnosis table.................. 1B-12
Detail diagnosis table (Ambient
temperature at 30°C (86°F)) .................. 1B-13
Compressor Drive Belt ............................... 1B-15
Electronical Diagnosis ................................ 1B-16
Wiring Diagram .......................................... 1B-16
A/C System Inspection of ECM and ITS
Circuits ....................................................... 1B-17
Refrigerant Recovery, Evacuating and
Charging ....................................................... 1B-21
Operation Procedure for Refrigerant
Charging .................................................... 1B-21
Recovery .................................................... 1B-22
Replenishing Compressor Oil .................... 1B-22 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).
CAUTION:
The air conditioning system of this vehicle uses refrigerant HFC-134a (R-134a).
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using refrigerant HFC-134a (R-134a) and the other using refrigerant CFC-12 (R-12).
Be sure to check which refrigerant is used before any service work including inspection and mainte-
nance. For identification between these two types, refer to “Refrigerant Type” in this section.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
NOTE:
For basic servicing method of the air conditioning system that is not described in this section, refer to
AIR CONDITIONING BASIC MANUAL (Part number: 99520-02130).

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Electronical Diagnosis
Wiring Diagram
[A]: 4WD model 4. Dual pressure switch 9. Thermal switch 14. Circuit fuse box
[B]: 2WD model 5. 4WD controller 10. Ignition switch 15. Main fuse box
1. Blower fan motor 6. Condenser cooling fan motor relay 11. A/C evaporator thermistor 16. Generator
2. Blower fan motor resistor 7. Condenser cooling fan motor 12. ECT sensor 17. ECM
3. Blower fan motor switch and A/C switch 8. Compressor 13. Lighting switch

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Table – B “ABS” Warning Lamp Circuit Check – Lamp Comes “ON” Steady
Refer to TABLE – A for System Circuit Diagram and Circuit Description.
INSPECTION
3 1) Remove combination meter.
Is bulb of ABS warning lamp in good condition?“R/Bl” circuit shorted to ground.
If OK, replace ABS warning cir-
cuit (lamp driver module).Replace bulb.
4 Is IG fuse in good condition? Open in “B/W” wire to combina-
tion meter or poor connection.Repair and replace. Step Action Yes No
Step Action Yes No
1 Perform diagnostic trouble code check. Is there
any DTC (including code No.12, NO CODES on
SUZUKI scan tool) exists?Go to step 2. Go to step 3.
2 Is malfunction DTC (other than code No.12)
exists at step 1?Go to step 7 of ABS diag-
nostic flow table in this
section.Go to step 3.
3 1) Disconnect ABS hydraulic unit / control
module connector.
2) Check for proper connection to ABS hydrau-
lic unit / control module connector at termi-
nals “A14” and “A18”.
3) If OK, turn ignition switch “ON” and mea-
sure voltage at terminal “A18” of connector.
Is it 10 – 14 V?Go to step 4.“B/W” circuit open.
4 1) With ABS control module connector discon-
nected, turn ignition switch ON and light
ABS warning lamp.
2) Connect terminal “A14” of disconnected
connector to ground using service wire.
Does “ABS warning lamp” turn off?Go to step 5.“R/Bl” circuit open.
If wire and connection are
OK, replace ABS lamp
driver module.
5 1) Measure resistance from connector termi-
nal “A24” to body ground.
Is continuity indicated?Substitute a known-good
ABS hydraulic unit / con-
trol module assembly and
recheck.“B” circuit open.

Downloaded from www.Manualslib.com manuals search engine 6-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS
Table A-2 Malfunction Indicator Lamp Circuit Check - Lamp Remains “ON”
after Engine Starts
WIRING DIAGRAM / CIRCUIT DESCRIPTION
Refer to table A-1.
INSPECTION
2 ECM Power and Ground Circuit Check
Does engine start?Go to Step 3. Go to “Table A-5 ECM
Power and Ground Circuit
Check”.
If engine is not cranked,
go to “Diagnosis” in Sec-
tion 8G.
3 MIL Circuit Check
1) Turn ignition switch OFF and disconnect
connectors from ECM.
2) Check for proper connection to ECM at ter-
minal E18-2 (Case of TYPE A) (See NOTE)
or E17-9 (Case of TYPE B) (See NOTE).
3) If OK, then using service wire, ground termi-
nal E18-2 (Case of TYPE A) (See NOTE) or
E17-9 (Case of TYPE B) (See NOTE) in
connector disconnected.
Does MIL turn on at ignition switch ON?Substitute a known-good
ECM and recheck.Bulb burned out, “V/Y”
wire circuit open or “P”
wire shorted to ground. Step Action Yes No
Step Action Yes No
1 Diagnostic Trouble Code (DTC) check
1) Check DTC referring to DTC CHECK sec-
tion.
Is there any DTC(s)?Go to Step 2 of “Engine
Diag. Flow Table”.Go to Step 2.
2DTC check
1) Start engine and recheck DTC while engine
running.
Is there any DTC(s)?Go to Step 3.
3 MIL Circuit check
1) Turn OFF ignition switch.
2) Disconnect connectors from ECM.
Does MIL turn ON at ignition switch ON?“V/Y” wire circuit shorted
to ground.Substitute a known-good
ECM and recheck.

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Table A-3 Malfunction Indicator Lamp Circuit Check - Mil Flashes at Ignition
Switch ON
WIRING DIAGRAM / CIRCUIT DESCRIPTION
Refer to table A-1.
INSPECTION
Table A-4 Malfunction Indicator Lamp Circuit Check - MIL Does Not Flash, Just
Remains ON or Just Remains OFF Even with Grounding Diagnosis Switch
Terminal
WIRING DIAGRAM / CIRCUIT DESCRIPTION
Refer to table A-1.
INSPECTION
Step Action Yes No
1 MIL flashing pattern check :
1) With the ignition switch ON position, check
MIL flashing pattern.
Does MIL flashing pattern indicate DTC (diag-
nostic trouble code)?Go to Step 2. Go to “Diagnosis” in Sec-
tion 8G.
2 Diagnosis switch terminal check :
1) With the ignition switch ON position, check
voltage between E18-14 terminal of ECM
coupler and ground.
Is voltage 4 – 5 V?Substitute a known-good
ECM and recheck.“W/Bl” wire (diagnosis
switch terminal) shorted
to ground circuit.
If OK, substitute a known-
good ECM and recheck.
Step Action Yes No
1 MIL flashing pattern check :
1) With grounding diagnosis switch terminal
and turn the ignition switch ON position,
check voltage between E18-14 terminal of
ECM connector and ground.
Is voltage 0 – 1 V?Go to Step 2.“W/Bl” wire (diagnosis
switch terminal), “B” wire
of monitor connector
open.
If OK, substitute a known-
good ECM and recheck.
2 Test switch terminal circuit check :
1) With the ignition switch ON position, check
voltage between E18-15 terminal of ECM
connector and ground.
Is voltage 4 – 5 V?Substitute a known-good
ECM and recheck.“P” wire (test switch termi-
nal) shorted to ground cir-
cuit.
If OK, substitute a known-
good ECM and recheck.

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DTC P0121 Throttle Position Circuit Range / Performance Problem
WIRING DIAGRAM
Refer to DTC P0120 section.
CIRCUIT DESCRIPTION
DTC CONFIRMATION PROCEDURE
1) Turn ignition switch OFF. Clear DTC with ignition switch ON, check vehicle and environmental condition for :
–Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg, 75 kPa or more)
–Ambient temp. : –10 °C, 14 °F or higher
–Intake air temp. : 70 °C, 158 °F or lower
–Engine coolant temp. : 70 °C, 158 °F or higher
2) Warm up engine to normal operating temperature.
3) Increase vehicle speed to 30 – 40 mph, 50 – 60 km/h in 3rd gear or “D” range and hold throttle valve at that
opening position for 1 min.
4) Stop vehicle.
5) Check DTC in “DTC” mode and pending DTC in “ON BOARD TEST” or “PENDING DTC” mode.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
After engine warmed up.
Difference between actual throttle opening (detected from TP sensor)
and opening calculated by ECM (Obtained on the basis of engine
speed and intake manifold pressure) in larger than specified value.
✱2 driving cycle detection logic, continuous monitoringTP sensor malfunction
High resistance in the circuit
ECM malfunction
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Is SUZUKI scan tool available? Go to Step 3. Go to Step 4.
3 Check TP Sensor and Its Circuit.
1) Turn ignition switch OFF and connect
SUZUKI scan tool to DLC. See Fig. 1.
2) Turn ignition switch ON and check TP sen-
sor output voltage when throttle valve is at
idle position and fully opened. See Fig. 3.
Dose voltage vary within specified value linearly
as shown in figure?Substitute a known-good
ECM and recheck.Go to Step 5.

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DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1)
WIRING DIAGRAM
Refer to DTC P0130 section.
CIRCUIT DESCRIPTION
Fig. 1
DTC CONFIRMATION PROCEDURE
Refer to DTC P0130 section.
INSPECTION
DTC DETECTING CONDITION POSSIBLE CAUSE
When running at specified idle speed after engine warmed up and
running at specified vehicle speed, response time (time to change
from lean to rich or from rich to lean) of HO2S-1 output voltage is
about 1 sec. at minimum or average time of 1 cycle is 5 sec. at
minimum. See. Fig. 1
✱
✱✱ ✱2 driving cycle detection logic, Monitoring once / 1 driving.Heated oxygen sensor-1 malfunction
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Is there DTC(s) other than HO2S-1 (DTC
P0133)?Go to applicable DTC
Diag. Flow Table.Replace HO2S-1.