2005 SUZUKI JIMNY engine warning light

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WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION
and NOTE
have special meanings. Pay special attention to the messages highlighted by
these signal words.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized Suzuki dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual.
Improper repair may result in injury to the mechanic and may render the vehicle unsafe for the driver
and passengers.
WARNING:
For vehicles equipped with a Supplemental Restraint or 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.
 If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
 Do not modify the steering wheel, instrument panel or any other air bag system component on or
around air bag system components or wiring. 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
process, remove the air bag system components, that is air bag or inflator modules, SDM and/or
seat belt with pretensioner, beforehand to avoid component damage or unintended activation.

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.

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GEARSHIFT OR SELECTOR LEVER (TRANSMISSION)
Check gear shift or selector lever for smooth shifting to all positions and for good performance of transmission in
any position.
With automatic transmission equipped vehicle, also check that shift indicator indicates properly according to
which position selector lever is shifted to.
With automatic transmission equipped vehicle, make sure that vehicle is at complete stop when shifting selector
lever to “P” range position and release all brakes.
BRAKE
Foot Brake
Check the following:
that brake pedal has proper travel,
that brake works properly,
that it is free from noise,
that braking force is applied equally on all wheels,
and that brake do not drag.
Parking Brake
Check that lever has proper travel.
Check to ensure that parking brake is fully effective when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
STEERING
Check to ensure that steering wheel is free from instability, or abnormally heavy feeling.
Check that the vehicle does not wander or pull to one side.
ENGINE
Check that engine responds readily at all speeds.
Check that engine is free from abnormal noise and abnormal vibration.
BODY, WHEELS AND POWER TRANSMITTING SYSTEM
Check that body, wheels and power transmitting system are free from abnormal noise and abnormal vibration or
any other abnormal condition.
METERS AND GAUGE
Check that speedometer, odometer, fuel meter, temperature gauge, etc. are operating accurately.
LIGHTS
Check that all lights operate properly.
WINDSHIELD DEFROSTER
Periodically check that air comes out from defroster outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan switch lever to “HI” position for this check. WARNING:
With vehicle parked on a fairly steep slope, make sure nothing is in the way downhill to avoid any per-
sonal injury or property damage. Be prepared to apply regular brake quickly even if vehicle should
start to move.

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Refrigerant Recovery, Evacuating and Charging
Operation Procedure for Refrigerant Charging
WARNING:
 Your eyes should not be exposed to refrigerant (liquid).
Any liquid HFC-134a (R-134a) escaping by accident shows a temperature as low as approximately
–6 °C (21 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause
a serious injury. To protect your eyes against such accident, it is necessary to always wear gog-
gles. Should it occur that HFC-134a (R-134a) strikes your eyes(s), consult a doctor immediately.
– Do not use your hand to rub the affected eye(s). Instead, use quantities of fresh cold water to
splash it over the affected area to gradually raise temperature of such area above freezing point.
– Obtain proper treatment as soon as possible from a doctor or eye specialist.
 Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.
 Refrigerant must not be handled near where welding or steam cleaning is performed.
 Refrigerant should be kept at a cold and dark place. It should never be stored where a high temper-
ature is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).
 Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazardous
to health.
Replenish compressor oil
Start evacuating
Inspect and repair connections
Charge 550 50 g of
refrigerant in gas form Stop evacuating 15 minutes (–760 mmHg)
Wait 10 mintues
If gauge shows
abnormal conditions Check system for
pressure tightness
Check A/C system
With refrigerant
Check system for refrigerant
leaks and refrigerant
charging quantity
Performance test

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2) Connect Low charging hose (1) and High charging hose (2)
of the manifold gauge set (3) in position. Thus open refriger-
ant container valve (4) to purge the charging line.
3) Open the high pressure side valve (5) and charge refrigerant
to system.
4) After a while, open the low pressure side valve (6) and close
the high pressure side valve (5).
5) Start engine and keep engine speed at 1500 r/min. Then,
operate air conditioning.
6) Charge A/C system with refrigerant in vapor state. At this
time, refrigerant container should be held upright.
7) When refrigerant container (3) is emptied, use the following
procedure to replace refrigerant container with a new refrig-
erant container (3).
a) Close low pressure valve.
b) Replace empty container (3) with a refrigerant container
which has been charged with refrigerant. When using
refrigerant container tap valve (4), use the following proce-
dure for replacement.
i) Retract needle (1) and remove refrigerant container tap
valve (4) by loosening its plate nut (2).
ii) Install previously-removed refrigerant container tap valve
(4) to a new refrigerant container (3).
c) Purge any air existing in center charging hose
When using refrigerant container tap valve, use the follow-
ing procedure to purge air.
i) Once fully tighten refrigerant container tap valve (1), and
then loosen (open) plate nut (2) slightly.
ii) Open low pressure side valve (3) of manifold gauge set
(4) a little.
iii) As soon as refrigerant comes out with a “hiss” through a
clearance between refrigerant container and tap valve,
tighten plate nut (2) as well as low pressure side valve (3).
iv) Turn handle of tap valve (1) clockwise so that its needle is
screwed into the new container to make a hole for refriger-
ant flow. WARNING:
Make sure that high pressure side valve is closed
securely.

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Tire
Mounting and demounting
Use tire changing machine to mount or demount tires. Follow equipment manufacturer’s instructions. Do not use
hand tools or tire irons alone to change tires as they may damage tire beads or wheel rim.
Rim bead seats should be cleaned with wire brush or coarse steel wool to remove lubricants, old rubber and
light rust. Before mounting or demounting tire, bead area should be well lubricated with approved tire lubricant.
After mounting, inflate to 240 kPa (35 psi) so that beads are completely seated. Then adjust pressure to speci-
fied shown on tire placard.
Install valve core and inflate to proper pressure.
Repair
There are many different materials and techniques on the market to repair tires. As not all of these work on all
types of tires, tire manufacturers have published detailed instructions on how and when to repair tires. These
instructions can be obtained from the tire manufacturer.WARNING:
Do not stand over tire when inflating. Bead may break when bead snaps over rim’s safety hump and
cause serious personal injury.
Do not exceed 240 kPa (35 psi) pressure when inflating. If 240 kPa (35 psi) pressure will not seat
beads, deflate, re-lubricate and reinflate. Over inflation may cause bead to break and cause serious
personal injury.

Downloaded from www.Manualslib.com manuals search engine BRAKES 5-1
6F1
6F2
6G
6H
6K
7A
7A1
7B1
7C1
7D
7E
5
9
10
10A
10B
9
10
10A
10B
SECTION 5
BRAKES
CONTENTS
General Description ......................................... 5-3
Diagnosis .......................................................... 5-4
Road Testing Brakes ...................................... 5-4
Brake Fluid Leaks .......................................... 5-4
Substandard or Contaminated Brake Fluid .... 5-4
Diagnosis Table ............................................. 5-5
Brake Pedal Free Height Adjustment ............. 5-8
Brake Pedal Play Check ................................ 5-8
Stop Light Switch Adjustment ........................ 5-8
Excessive Pedal Travel Check ....................... 5-9
Front Brake Disc Check ................................. 5-9
Front Brake Pad Check .................................. 5-9
Rear Brake Shoe Check .............................. 5-10
Master Cylinder and Brake Fluid Level
Check ........................................................... 5-10
Rear Drum Brake Shoe Adjustment ............. 5-11
Parking Brake Inspection and Adjustment ... 5-11
Booster Operation Check ............................. 5-12Fluid Pressure Test
(If Equipped with LSPV) ............................... 5-15
On-Vehicle Service ........................................ 5-17
Air Bleeding of Brake System ...................... 5-17
Brake Hose and Pipe Inspection.................. 5-18
Front Disc Brake .......................................... 5-19
Brake pad ................................................. 5-20
Caliper assembly...................................... 5-22
Brake Disc.................................................... 5-26
Rear Brake ................................................... 5-29
Brake drum............................................... 5-29
Brake shoe ............................................... 5-32
Wheel Cylinder............................................. 5-33
Brake back plate ...................................... 5-34
Master Cylinder .............................................. 5-36
Master Cylinder Reservoir ........................... 5-36
Master Cylinder Assembly ........................... 5-37 WARNING:
For lifting point of vehicle, refer to Section 0A.
WARNING:
For vehicles equipped with Supplement 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:
When inspecting and servicing vehicle equipped with ABS, be sure to refer to section 5E first.
All brake fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of
same part number or with an equivalent part if replacement becomes necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to assure proper retention of all parts. There is to be no welding as it may result
in extensive damage and weakening of the metal.

Downloaded from www.Manualslib.com manuals search engine 5-6 BRAKES
Excessive pedal travel
(Pedal stroke too
large)Partial brake system failure Check brake systems and repair as
necessary.
Insufficient fluid in master cylinder reservoirs Fill reservoirs with approved brake
fluid.
Check for leaks and air in brake
systems.
Check warning light. Bleed system
if required.
Air in system (pedal soft/spongy) Bleed system.
Rear brake system not adjusted (malfunctioning
auto adjusting mechanism)Repair auto adjusting mechanism.
Adjust rear brakes.
Bent brake shoes Replace brake shoes.
Worn rear brake shoes Replace brake shoes.
Dragging brakes (A
very light drag is
present in all disc
brakes immediately
after pedal is released)Master cylinder pistons not returning correctly Repair master cylinder.
Restricted brake tubes or hoses Check for soft hoses or damaged
tubes and replace with new hoses
and/or new brake tubes.
Incorrect parking brake adjustment on rear
brakesCheck and adjust to correct specifi-
cations.
Weakened or broken return springs in the brake Replace.
Sluggish parking-brake cables or linkage Repair or replace.
Wheel cylinder or caliper piston sticking Repair as necessary.
Malfunctioning ABS, if equipped with ABS Check system and replace as nec-
essary.
Pedal pulsation (Pedal
pulsates when
depressed for brak-
ing.) Damaged or loose wheel bearings Replace wheel bearings.
Distorted steering knuckle or rear axle shafts Replace knuckle or rear axle shaft.
Excessive disc lateral runout Check per instructions. If not within
specifications, replace or machine
the disc.
Parallelism not within specifications Check per instructions. If not with
specifications, replace or machine
the disc.
Rear drums out of round. Check runout.
Repair or replace drum as neces-
sary.
Braking noise
Glazed shoe linings, or foreign matters stuck to
liningsRepair or replace brake shoe.
Worn or distorted shoe linings Replace brake shoe (or pad).
Loose front wheel bearings Replace wheel bearing.
Distorted backing plates or loose mounting
boltsReplace or retighten securing bolts.
Brake warning light
turns on after engine
startParking brake applied Release parking brake and check
that brake warning light turns off.
Insufficient amount of brake fluid Add brake fluid.
Brake fluid leaking from brake line Investigate leaky point, correct it
and add brake fluid.
Brake warning light circuit faulty Repair circuit. Condition Possible Cause Correction