2005 SUZUKI JIMNY fuel pump relay

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.

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Precaution on fuel system service
Work must be done with no smoking, in a well-ventilated
area and away from any open flames.
As fuel feed line (between fuel pump and fuel delivery pipe)
is still under high fuel pressure even after engine was
stopped, loosening or disconnecting fuel feed line directly
may cause dangerous spout of fuel to occur where loosened
or disconnected.
Before loosening or disconnecting fuel feed line, make sure
to release fuel pressure according to “FUEL PRESSURE
RELIEF PROCEDURE”. A small amount of fuel may be
released after the fuel line is disconnected. In order to
reduce the chance of personal injury, cover the fitting to be
disconnected with a shop cloth. Put that cloth in an approved
container when disconnection is completed.
Never run engine with fuel pump relay disconnected when
engine and exhaust system are hot.
Fuel or fuel vapor hose connection varies with each type of
pipe. When reconnecting fuel or fuel vapor hose, be sure to
connect and clamp each hose correctly referring to the figure
Hose Connection.
After connecting, make sure that it has no twist or kink.
When installing injector or fuel delivery pipe, lubricate its O-
ring with spindle oil or gasoline.
When connecting fuel pipe flare nut, first tighten flare nut by
hand and then tighten it to specified torque.
[A] : With short pipe, fit hose as far as it reaches pipe joint as shown.
[B] : With following type pipe, fit hose as far as its peripheral projection as shown.
[C] : With bent pipe, fit hose as its bent part as shown or till pipe is about 20 to 30 mm
(0.79 – 1.18 in.) into the hose.
[D] : With straight pipe, fit hose till pipe is, about 20 to 30 mm (0.79 – 1.18 in.) into the
hose.
1. Hose
2. Pipe
3. Clamp
4. Clamp securely at a position 3 to 7 mm (0.1 2 – 0.27 in.) from hose end.
5. 20 to 30 mm (0.79 – 1.18 in.)

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Fuel pressure relief procedure
After making sure that engine is cold, release fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (Shift selector
lever to “P” range for A/T model), set parking brake, and
block drive wheels.
2) Remove relay box cover.
3) Disconnect fuel pump relay (1) from its connector.
4) Remove fuel filler cap to release fuel vapor pressure in fuel
tank and then reinstall it.
5) Start engine and run it till it stops for lack of fuel. Repeat
cranking engine 2-3 times for about 3 seconds each time to
dissipate fuel pressure in lines. Fuel connections are now
safe for servicing.
6) Upon completion of servicing, connect fuel pump relay (1) to
its connector.
Fuel leakage check procedure
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump)
and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pres-
sure to fuel line. (till fuel pressure is felt by hand placed on
fuel feed hose.)
2) In this state, check to see that there are no fuel leakages
from any part of fuel system. CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.

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For TYPE B (See NOTE)
E1814Diag. Switch terminal (without
immobilizer indicator lamp)4 – 5 V Ignition switch ON
15Test switch terminal (without immo-
bilizer indicator lamp)4 – 5 V Ignition switch ON
16 A/C (input) signal10 – 14 VIgnition switch ON
A/C switch OFF
0 – 2 VIgnition switch ON
A/C switch ON
17 Lighting switch10 – 14 V Lighting switch ON
0 – 1.3 V Lighting switch OFF
18A/C condenser fan motor relay
(if equipped)0 – 1.0 V A/C is operating
10 – 14 V A/C is not operating
19 Fuel pump relay0 – 1 V For 2 seconds after ignition switch ON
10 – 14 V After the above time
20 Sensor ground––
21Throttle opening signal for
TCM (A/T)Indication
deflection
repeated
0 V and
10 – 14 VIgnition switch ON
22Fuel level sensor (gauge)
(with immobilizer indicator lamp)0 – 2 VIgnition switch ON
Fuel tank fully filled
4.5 – 7.5 VIgnition switch ON
Fuel tank emptied
23–– –
24 Heater blower switch0 – 2.0 VIgnition switch ON and heater blower
switch ON
10 – 14 VIgnition switch ON and heater blower
switch OFF TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
NOTE:
See NOTE in “ECM TERMINAL VOLTAGE VALUES TABLE” for applicable model.
TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
E181 A/C compressor clutch 0 V Ignition switch ON
2–– –
3–– –
4–– –
5 Power source 10 – 14 V Ignition switch ON
6 Power source 10 – 14 V Ignition switch ON
7 Power source for buck-up 10 – 14 V Ignition switch ON and OFF
8Immobilizer indicator lamp
(with immobilizer indicator lamp)10 – 14 V Engine running
0 – 1.0 V Ignition switch ON leaving engine OFF
Duty output terminal (without
immobilizer indicator lamp)0 – 1.0 V Ignition switch ON

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For TYPE A (See NOTE)
E189 Ignition switch 10 – 14 V Ignition switch ON
10 Main relay10 – 14 V Ignition switch OFF
0.4 – 1.5 V Ignition switch ON
11 Ignition switch 10 – 14 V Ignition switch ON
12 Rear defogger switch (if equipped)10 – 14 VIgnition switch ON and rear defogger
switch ON
0 – 1.3 VIgnition switch ON and rear defogger
switch OFF
13–– –
14Diag. Switch terminal (without
immobilizer indicator lamp)4 – 5 V Ignition switch ON
15Test switch terminal (without immo-
bilizer indicator lamp)4 – 5 V Ignition switch ON
16 A/C (input) signal10 – 14 VIgnition switch ON
A/C switch OFF
0 – 2 VIgnition switch ON
A/C switch ON
17 Lighting switch10 – 14 V Lighting switch ON
0 – 1.3 V Lighting switch OFF
18A/C condenser fan motor relay
(if equipped)0 – 1.0 V A/C is operating
10 – 14 V A/C is not operating
19 Fuel pump relay0 – 1 V For 2 seconds after ignition switch ON
10 – 14 V After the above time
20 Engine start signal 6 – 14 V While engine cranking
21 Stop lamp switch0 VIgnition switch ON
Stop lamp switch OFF
10 – 14 VIgnition switch ON
Stop lamp switch ON
22 Vehicle speed sensordeflect
between
0 – 1.6 and
4 – 14 VIgnition switch ON and rear right wheel
turned slowly with rear left wheel locked
23–– –
24–– – TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
NOTE:
See NOTE in “ECM TERMINAL VOLTAGE VALUES TABLE” for applicable model.
TERMINAL
NO.CIRCUIT NORMAL
VOLTAGECONDITION
E171–– –
2 R-range signal (A/T)10 – 14 VIgnition switch ON and shift select switch
in R range
0 – 1.3 VIgnition switch ON and shift select switch
in other than R range
3 Blank––

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Resistance Check
1) Disconnect ECM couplers (1) from ECM with ignition switch
OFF.
2) Check resistance between each terminal of couplers discon-
nected. CAUTION:
Never touch terminals of ECM itself or connect voltmeter
or ohmmeter (2).
CAUTION:
Be sure to connect ohmmeter probe from wire harness
side of coupler.
Be sure to turn OFF ignition switch for this check.
Resistance in table below represents that when parts
temperature is 20 °C (68 °F).
1. ECM coupler disconnected
2. Ohmmeter
TERMINALS CIRCUIT STANDARD RESISTANCE
E19-7 to E17-9
(For TYPE A) (See NOTE)HO2S-1 heater 5 – 6.4 Ω
E19-7 to E18-11
(For TYPE B) (See NOTE)
E18-4 to E17-9
(For TYPE A) (See NOTE)HO2S-2 heater 11.7 – 14.3 Ω
E19-9 to E19-2 No.1 injector 12.0 – 13.0 Ω
E19-21 to E19-2 No.2 injector 12.0 – 13.0 Ω
E19-31 to E19-2 No.3 injector 12.0 – 13.0 Ω
E19-8 to E19-2 No.4 injector 12.0 – 13.0 Ω
E19-28 to E19-2 EGR valve (stepper motor coil 4) 20 – 24 Ω
E19-17 to E19-2 EGR valve (stepper motor coil 3) 20 – 24 Ω
E19-29 to E19-2 EGR valve (stepper motor coil 2) 20 – 24 Ω
E19-18 to E19-2 EGR valve (stepper motor coil 1) 20 – 24 Ω
E19-4 to E19-2 EVAP canister purge valve 30 – 34 Ω
E18-19 to E17-9 (For
TYPE A) (See NOTE)Fuel pump relay 70 – 110 Ω
E18-19 to E18-11 (For
TYPE B) (See NOTE)
E18-1 to Body ground A/C compressor clutch 3 – 4.5 Ω
E18-18 to E19-2 A/C condenser fan control relay 70 – 110 Ω
E18-10 to E18-7 Main relay 70 – 110 Ω
E19-1 to Body ground Ground Continuity
E19-2 to Body ground Ground Continuity
E19-3 to Body ground Ground Continuity
NOTE:
For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable
model.

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Component Location
NOTE:
The figure shows left-hand steering vehicle.
For right-hand steering vehicle, parts with (*) are installed at the other side.
1. IAT sensor a : Immobilizer indicator lamp (if equipped) A : ECM
2. TP sensor b : A/C condenser fan motor relay (if equipped) B : A/T control module
3. Monitor connector c : Main relay C : EVAP canister
4. CO adjusting resistor (if equipped) d : Fuel pump relay D : DLC
5. CKP sensor e : IAC valve E : ABS control module (if equipped)
6. MAP sensor f : EVAP canister purge valve
7. CMP sensor g : EGR valve (if equipped)
8. Transmission range switch h : Fuel injector
9. VSS i : Ignition coil assemblies
10. HO2S-1 (if equipped) j : MIL
11. HO2S-2 (if equipped)
12. ECT sensor
13. Knock sensor

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Table B-2 Fuel Pump and Its Circuit Check
INSPECTION
1. Ignition switch 3. Main relay 5. Fuel pump relay [A] : Case of TYPE A is shown (See NOTE)
2. Main relay 4. Main fuse 6. Fuel pump [B] : Case of TYPE B is shown (See NOTE)
NOTE:
For TYPE A and TYPE B, refer to the NOTE in “ECM Terminal Voltage Values Table” for applicable
model.
Step Action Yes No
1Was “Engine Diag. Flow Table” performed? Go to Step 2. Go to “Engine Diag. Flow
Table”.
2 Check Fuel Pump Control System for Opera-
tion. See Fig. 1.
Is fuel pump heard to operate for 2 sec. after
ignition switch ON?Fuel pump circuit is in
good condition.Go to Step 3.
3 Check Fuel Pump for Operation.
1) Remove fuel pump relay from relay box with
ignition switch OFF.
2) Check for proper connection to relay at each
terminals.
3) If OK, using service wire, connect terminals
“A” and “B” of relay connector. See Fig. 2
and CAUTION.
Is fuel pump heard to operate at ignition switch
ON?Go to Step 4.“P”, “B” or “Bl/B” circuit
open or fuel pump mal-
function.