2005 SUZUKI JIMNY electric

Downloaded from www.Manualslib.com manuals search engine TABLE OF CONTENTS
GENERAL INFORMATIONGeneral Information0A0A
Maintenance and Lubrication0B
0B
HEATING AND AIR CONDITIONINGHeater and Ventilation1A
1A
Air Conditioning (Optional)1B
1B
STEERING, SUSPENSION, WHEELS AND
TIRESSteering, Suspension, Wheels and Tires3
3
Front Wheel Alignment3A
3A
Steering Gear Box (Manual Type) and Linkage3B
3B
Power Steering (P/S) System (if equipped)3B1
3B1
Steering Wheel and Column3C
3C
Front Suspension3D
3D
Rear Suspension3E
3E
Wheels and Tires3F
3F
DRIVE SHAFT AND PROPELLER SHAFT
Propeller Shafts4B
4B
BRAKE SYSTEMBrakes5
5
Antilock Brake System (ABS)5E
5E
ENGINEEngine General Information and Diagnosis6
6
Engine Mechanical (M13 Engine)6A1
6A1
Engine Cooling6B
6B
Engine Fuel6C
6C
Engine and Emission Control System6E
6E
Ignition System (Electronic Ignition System)6F
6F
Cranking System6G
6G
Charging System6H
6H
Exhaust System6K
6K
TRANSMISSION, CLUTCH AND
DIFFERENTIALManual Transmission7A
7A
Automatic Transmission (4 A/T)7B
7B
Clutch7C
7C
Transfer7D
7D
Front Differential7E
7E
Rear Differential7F
7F
ELECTRICAL SYSTEMBody Electrical System8
8
Immobilizer Control System (if equipped)8G
8G
BODY SERVICE9
9
RESTRAINT SYSTEMRestraint System10
10
Air Bag System10B
10B

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 0A-4 GENERAL INFORMATION
Servicing and handling
WARNING:
Many of service procedures require disconnection of “Air
Bag” fuse and all air bag (inflator) module(s) from initia-
tor circuit to avoid an accidental deployment.
Driver and Passenger Air Bag (Inflator) Modules
 For handling and storage of a live air bag (inflator)
module, select a place where the ambient temperature
below 65°C (150°F), without high humidity and away
from electric noise.
 When carrying a live air bag (inflator) module, make
sure the bag opening is pointed away from you. In case
of an accidental deployment, the bag will then deploy
with minimal chance of injury. Never carry the air bag
(inflator) module by the wires or connector on the
underside of the module. When placing a live air bag
(inflator) module on a bench or other surface, always
face the bag up, away from the surface. As the live pas-
senger air bag (inflator) module must be placed with its
bag (trim cover) facing up, place it on the workbench
with a slit (1) or use the workbench vise (2) to hold it
securely at its lower mounting bracket (3). This is nec-
essary so that a free space is provided to allow the air
bag to expand in the unlikely event of accidental
deployment. Otherwise, personal injury may result.
 Never dispose of live (undeployed) air bag (inflator)
modules (driver and passenger). If disposal is neces-
sary, be sure to deploy them according to deployment
procedures described in Section 10B before disposal.
 The air bag (inflator) module immediately after deploy-
ment is very hot. Wait for at least half an hour to cool it
off before proceeding the work.
 After an air bag (inflator) module has been deployed,
the surface of the air bag may contain a powdery resi-
due. This powder consists primarily of cornstarch
(used to lubricate the bag as it inflates) and by-prod-
ucts of the chemical reaction. As with many service
procedures, gloves and safety glasses should be worn.
[A]: Always Carry Air Bag (Inflator) Module With Trim Cover (Air Bag Opening) Away from
Body.
[B]: Always Place Air Bag (Inflator) Module On Workbench With Trim Cover
(Air Bag Opening) Up, Away From Loose Objects.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION 0A-5
WARNING:
SDM
 During service procedures, be very careful when handling a Sensing and Diagnostic Module (SDM).
Never strike or jar the SDM.
Never power up the air bag system when the SDM is not rigidly attached to the vehicle. All SDM and
mounting bracket fasteners must be carefully torqued and the arrow must be pointing toward the
front of the vehicle to ensure proper operation of the air bag system.
The SDM could be activated when powered while not rigidly attached to the vehicle which could
cause deployment and result in personal injury.
WARNING:
Driver and Passenger Seat Belt Pretensioners (If
equipped)
 For handling and storage of a live seat belt preten-
sioner, select a place where the ambient temperature
below 65°C (150°F), without high humidity and away
from electric noise.
 Never carry seat belt pretensioner by wire or connector
of pretensioner. When placing a live seat belt preten-
sioner on the workbench or some place like that, be
sure not to lay it with its exhaust hole (1) provided side
facing down. It is also prohibited to put something on
its face with an exhaust hole (1) or to put a seat belt
pretensioner on top of another. Otherwise, personal
injury may result.
 Never dispose of live (inactivated) seat belt pretension-
ers (driver and passenger). If disposal is necessary, be
sure to activate them according to activation proce-
dures described in Section 10B before disposal.
 The seat belt pretensioner immediately after activation
is very hot. Wait for at least half an hour to cool it off
before proceeding the work.
 With many service procedures, gloves and safety
glasses should be worn to prevent any possible irrita-
tion of the skin or eyes.

Downloaded from www.Manualslib.com manuals search engine 0A-6 GENERAL INFORMATION
CAUTION:
 Even when the accident was light enough not to cause air bags to activate, be sure to inspect sys-
tem parts and other related parts according to instructions under “Repair and Inspection Required
after an Accident” in Section 10B.
 When servicing parts other than air bag system, if shocks may be applied to air bag system compo-
nent parts, remove those parts beforehand.
 When handling the air bag (inflator) modules (driver and passenger), seat belt pretensioners (driver
and passenger) or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was
applied (e.g., dropped from a height of 90 cm (3 feet) or more), never attempt disassembly or repair
but replace it with a new one.
 When grease, cleaning agent, oil, water, etc. has got onto air bag (inflator) modules (driver and pas-
senger) or seat belt pretensioners (drive and passenger), wipe off immediately with a dry cloth.
 Air bag wire harness can be identified easily as it is covered with a yellow protection tube. Be very
careful when handling it.
 When an open in air bag wire harness, damaged wire harness, connector or terminal is found,
replace wire harness, connectors and terminals as an assembly.
 Do not apply power to the air bag system unless all components are connected or a diagnostic
chart requests it, as this will set a diagnostic trouble code.
 Never use air bag system component parts from another vehicle.
 When using electric welding, be sure to disconnect air bag (inflator) module connectors (driver and
passenger) and seat belt pretensioner connectors (driver and passenger) respectively.
 Never expose air bag system component parts directly to hot air (drying or baking the vehicle after
painting) or flames.
 WARNING / CAUTION labels are attached on each part of air bag system components. Be sure to
follow the instructions.
 After vehicle is completely repaired, perform “Air Bag Diagnostic System Check” in Section 10B.

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-9
 When disconnecting vacuum hoses, attach a tag
describing the correct installation positions so that the
hoses can be reinstalled correctly.
 After servicing fuel, oil, coolant, vacuum, exhaust or
brake systems, check all lines related to the system for
leaks.
 For vehicles equipped with fuel injection systems, never
disconnect the fuel line between the fuel pump and
injector without first releasing the fuel pressure, or fuel
can be sprayed out under pressure.
 When performing a work that produces a heat exceeding
80°C (176°F) in the vicinity of the electrical parts, remove
the heat sensitive electrical part(s) beforehand.
 Use care not to expose connectors and electrical parts
to water which will be a cause of a trouble.
 Always be careful not to handle electrical parts (com-
puter, relay, etc.) in a rough manner or drop them.