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Jimny
Suzuki Jimny Service Manual
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AIR CONDITIONI
NG (OPTIONAL) 1B-41
Magn
et C
lutc
h
1.
Therm
al swi
tch
6.
Magnet
clutc
h coi
l
a.
Front head
bolt
: Tigh
ten
bolt
“
a
”
first,
and next
“
b
”
.
2.
Compre
ssor
body a
ssem
bly
7.
Compr
esso
r pulle
y
b.
Fron
t head
bolt
: Tigh
ten
bolt
“
a
”
first,
and next
“
b
”
.
3.
O-ring
8.
Circli
p
c.
Clu
tch plate bolt
4.
Lip se
al
9.
Shim
Tight
enin
g tor
que
5.
Front h
ead
10.
Clutch pla
te
Do no
t reuse.
101
103
Table of Contents
General Information
6
Default Chapter
6
Table of Contents
6
How to Use this Manual
7
Precautions
8
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
8
Diagnosis
8
Servicing and Handling
9
General Precautions
12
Precautions for Catalytic Converter
15
Precautions for Electrical Circuit Service
15
Electrical Circuit Inspection Procedure
18
Open Circuit Check
18
Short Circuit Check (Wire Harness to Ground)
20
Intermittent and Poor Connection
20
Precaution for Installing Mobile Communication Equipment
21
Identification Information
22
Body Number
22
Engine Identification Number
22
Transmission Identification Number
22
Warning, Caution and Information Labels
23
Vehicle Lifting Points
24
When Using Frame Contact Hoist
24
When Using Floor Jack
25
Abbreviations May be Used in this Manual
26
Abbreviations
26
Fasteners Information
29
Metric Fasteners
29
Fastener Strength Identification
29
Standard Tightening Torque
29
Maintenance and Lubrication
32
Maintenance Schedule
33
Maintenance Schedule under Normal Driving Conditions
33
Maintenance Recommended under Severe Driving Conditions
35
Maintenance Service
36
Engine
36
Drive Belt
36
Engine Oil and Filter
37
Valve Lash
37
Engine Coolant
39
Exhaust System
39
Ignition System
40
Spark Plugs
40
Fuel System
40
Air Cleaner Filter
40
Fuel Filter
41
Fuel Lines and Connections
41
Fuel Tank
41
Emission Control System
41
Crankcase Ventilation Hoses and Connections
41
Fuel Evaporative Emission Control System
42
PCV (Positive Crankcase Ventilation) Valve
42
Chassis and Body
42
Brake Discs and Pads
42
Clutch
42
Brake Drums and Shoes
43
Brake Fluid
43
Brake Hoses and Pipes
43
Parking Brake Lever and Cable
44
Tires/Wheels
44
Suspension System
45
Propeller Shafts
46
Automatic Transmission Fluid
47
Manual Transmission Oil
47
Transfer and Differential Oil
48
Steering Knuckle Seal
49
Steering System
49
All Hinges, Latches and Locks
50
Power Steering (P/S) System (if Equipped)
50
Final Inspection
51
Recommended Fluids and Lubricants
53
Heater and Ventilation
54
General Description
55
Diagnosis
56
Diagnosis Table
56
Wiring Circuit
56
On Vehicle Service
57
Heater Blower Motor
57
Heater Blower Resistor
58
Heater Control Lever Assembly
58
Heater Blower Fan Switch
60
Heater Unit/Boost Ventilation
60
Air Conditioning (Optional)
62
General Description
64
Major Components and Location
64
Refrigerant Circulation
65
Refrigerant Type
65
Diagnosis
66
General Diagnosis Table
66
Abnormal Noise Diagnosis
68
Abnormal Noise from Compressor
68
Abnormal Noise from Condenser
68
Abnormal Noise from Magnetic Clutch
68
Abnormal Noise from Tubing
68
Abnormal Noise from A/C Evaporator
69
Abnormal Noise from Blower Fan Motor
69
Abnormal Noise from Crankshaft Pulley
69
Abnormal Noise from Tension Pulley
69
Quick Checking of Refrigerant Charge
70
Performance Diagnosis
71
Performance Diagnosis Table
73
Detail Diagnosis Table
74
Compressor Drive Belt
76
Electronical Diagnosis
77
Wiring Diagram
77
A/C System Inspection of ECM and ITS Circuits
78
Refrigerant Recovery, Evacuating and Charging
82
Operation Procedure for Refrigerant Charging
82
Recovery
83
Replenishing Compressor Oil
83
Evacuating
84
Evacuating Procedure
84
Charging
86
Charging Procedure
86
Removing Manifold Gauge Set
89
Leak Test
89
On-Vehicle Service
90
Service Precaution
90
Refrigerant Line
90
Handling Refrigerant HFC-134A
91
Condenser Assembly
92
Receiver / Dryer
93
Condenser Cooling Fan Assembly
94
Cooling Unit (Evaporator)
95
A/C Evaporator Thermistor (A/C Evaporator Temperature Sensor)
98
Expansion Valve
98
Dual Pressure Switch
99
A/C Switch
100
Compressor
100
Condenser Cooling Fan Motor Relay
100
Magnet Clutch
102
Lip Type Seal
106
Tightening Torque Specification
107
Special Tools
108
Required Service Materials
108
Steering, Suspension, Wheels and Tires
110
Diagnosis
111
General Diagnosis
111
Wear Indicators
114
Radial Tire Waddle
114
Tire Diagnosis
114
Radial Tire Lead
116
Vibration Diagnosis
116
And Linkage
122
General Description
123
Diagnosis
124
Diagnosis Table
124
Steering Wheel Play Check
124
Tie Rod and Drag Rod Check
124
Steering Gear Box Oil Level Check
125
Adjustment of Worm Shaft Starting Torque . 3B-4
125
On-Vehicle Service
127
Steering Gear Box
127
Tie Rod and Drag Rod
129
Required Service Material
131
Special Tools
131
Tightening Torque Specifications
131
(If Equipped)
132
General Description
133
Diagnosis
134
Diagnosis Table
134
Steering Wheel Play Check
136
Steering Force Check
136
Power Steering Belt Check
137
Power Steering Belt Tension Adjustment
137
Power Steering Fluid Level Check
137
Idle-Up System Check
138
Power Steering Fluid Leakage Check
138
Air Bleeding Procedure
139
Hydraulic Pressure in P/S Circuit Check
141
On-Vehicle Service
143
Power Steering Belt
143
Power Steering (P/S) Pump
143
Power Steering (P/S) Gear Box
149
Tightening Torque Specifications
152
Special Tools
152
Required Service Materials
152
Steering Wheel and Column
154
General Description
155
On-Vehicle Service
156
Service Precautions (for Vehicle with Air Bag System)
156
Diagnosis and Servicing
156
Disabling Air Bag System
156
Disposal
156
Enabling Air Bag System
156
Handling and Storage
156
Drive Air Bag (Inflator) Module (for Vehicle with Air Bag System)
157
Steering Wheel
158
Centering Contact Coil (for Vehicle with Air Bag System)
161
Combination Switch (for Vehicle Without Air Bag System)/Contact Coil and Combination Switch Assembly (for Vehicle with Air Bag System)
162
Steering Column Assembly
164
Steering Lock Assembly (Ignition Switch)
168
Steering Lower Shaft
169
Diagnosis
156
Inspection and Repair Required after Accident
156
Checking Steering Column for Accident Damage
171
Special Tool
172
Required Service Material
172
Tightening Torque Specifications
172
Front Suspension
174
General Description
175
4WD Control System
175
Diagnosis
181
Diagnosis Table
181
4WD Controller and ITS Circuit Check
183
4WD Control System Check
184
Stabilizer Bar / Bushing Check
186
Shock Absorber And/Or Coil Spring Check
187
Leading Arm / Lateral Rod / Steering Knuckle Check
187
Leading Arm Bushing / Lateral Rod Bushing Check
188
Kingpin / Kingpin Bearing Check
188
Barfield Joint Check
188
Steering Knuckle Seal Check
188
Wheel Disc, Nut and Bearing Check
189
On-Vehicle Service
190
Stabilizer Bar / Bushings
190
Front Shock Absorber
192
Coil Spring
192
Bump Stopper and Spring Upper Seat
194
Wheel Hub / Bearing / Oil Seal
194
Steering Knuckle / Wheel Spindle
201
Front Axle Shaft / Oil Seal / Kingpin Bearing Outer Race
205
Steering Knuckle Seal
207
Lateral Rod
208
Leading Arm / Bushing
209
Front Axle Housing
211
Tightening Torque Specifications
217
Required Service Material
217
Special Tool
218
Rear Suspension
220
General Description
221
Diagnosis
222
Diagnosis Table
222
Rear Shock Absorber Check
222
Trailing Arm, Lateral Rod, Axle Housing and Coil Spring Check
222
Trailing Arm and Lateral Rod Bush Check
222
Rear Suspension Fasteners
223
Bearing Retainer and Axle Shaft Oil Seal Check
223
Bump Stopper and Spring Rubber Seat Check
223
Wheel Disc, Nut and Bearing Check
223
On-Vehicle Service
224
Rear Shock Absorber
224
Coil Spring
225
Bump Stopper
228
Lateral Rod
228
Trailing Arm / Bushing
229
Rear Axle Shaft and Wheel Bearing
231
Rear Axle Shaft Inner Oil Seal
236
Rear Axle Housing
237
Tightening Torque Specifications
241
Required Service Materials
241
Special Tools
242
Wheels and Tires
244
General Description
245
Tires
245
Wheels
245
Replacement Tires
245
How to Measure Wheel Runout
246
Metric Lug Nuts and Wheel Studs
246
Replacement Wheels
246
Diagnosis
247
Diagnosis Table
247
Balancing Wheels
247
General Balance Procedure
247
Off-Vehicle Balancing
247
On-Vehicle Balancing
247
Maintenance and Minor Adjustments
249
Wheel and Tire
249
Matched Tires and Wheels
249
Studs
249
Inflation of Tires
249
Tire Placard
250
Tire Rotation
250
On-Vehicle Service
251
Wheel
251
Tire
252
Mounting and Demounting
252
Repair
252
Propeller Shafts
254
Diagnosis
255
Diagnosis Table
255
Propeller Shaft Joint Check
255
General Description
255
Components
255
On-Vehicle Service
256
Propeller Shafts
256
Universal Joint
258
Required Service Material
260
Tightening Torque Specification
260
Special Tool
261
Brakes
262
Default Chapter
262
Table of Contents
262
General Description
264
Diagnosis
265
Road Testing Brakes
265
Brake Fluid Leaks
265
Substandard or Contaminated Brake Fluid
265
Diagnosis Table
266
Brake Pedal Free Height Adjustment
269
Brake Pedal Play Check
269
Stop Light Switch Adjustment
269
Excessive Pedal Travel Check
270
Front Brake Disc Check
270
Front Brake Pad Check
270
Rear Brake Shoe Check
271
Master Cylinder and Brake Fluid Level Check
271
Rear Drum Brake Shoe Adjustment
272
Parking Brake Inspection and Adjustment
272
Booster Operation Check
273
Fluid Pressure Test (if Equipped with LSPV)
276
On-Vehicle Service
278
Air Bleeding of Brake System
278
Brake Hose and Pipe Inspection
279
Front Disc Brake
280
Brake Pad
281
Caliper Assembly
283
Brake Disc
287
Rear Brake
290
Brake Drum
290
Brake Shoe
292
Wheel Cylinder
294
Brake Back Plate
295
Master Cylinder
297
Master Cylinder Reservoir
297
Master Cylinder Assembly
298
Master Cylinder
299
Fill Reservoir
301
LSPV (Load Sensing Proportioning Valve) Assembly (if Equipped)
303
LSPV Assembly
304
P (Proportioning) Valve
305
Brake Booster
306
Inspection and Adjustment
307
Brake Hose/Pipe
309
Front Brake Hose/Pipe
309
Rear Brake Hose/Pipe
312
Parking Brake Lever/Cable
313
Parking Brake Lever
313
Parking Brake Cable
314
Required Service Material
315
Tightening Torque Specifications
315
Special Tool
316
Antilock Brake System (Abs)
318
General Description
319
System Schematic
320
ABS Component Parts Location
321
ABS Control Module
322
Fail-Safe Function
322
Self-Diagnosis Function
322
Diagnosis
323
Precaution in Diagnosing Troubles
323
ABS Diagnostic Flow Table
323
ABS" Warning Lamp Check
326
Diagnostic Trouble Code (DTC) Check
326
DTC Check (Using SUZUKI Scan Tool)
327
Diagnostic Trouble Code (DTC) Clearance
327
Diagnostic Trouble Code (DTC) Table
328
System Circuit
329
At Ignition Switch
331
While Ignition Switch Is
333
Connected to Ground
334
DTC C1015 (DTC 15) - G Sensor Circuit
335
DTC C1016 (DTC 16) - Stop Lamp Circuit
337
DTC C1021 (DTC 21), DTC C1022 (DTC 22) - Right Front Wheel Speed Sensor Circuit
338
DTC C1025 (DTC 25), DTC C1026 (DTC 26) - Left Front Wheel Speed Sensor Circuit
338
DTC C1031 (DTC 31), DTC C1032 (DTC 32) - Right Rear Wheel Speed Sensor Circuit
338
DTC C1035 (DTC 35), DTC C1036 (DTC 36) - Left Rear Wheel Speed Sensor Circuit
338
DTC C1041 (DTC 41), DTC C1042 (DTC 42) - Right Front Solenoid Circuit
341
DTC C1045 (DTC 45), DTC C1046 (DTC 46) - Left Front Solenoid Circuit
341
DTC C1055 (DTC 55), DTC C1056 (DTC 56) - Rear Solenoid Circuit
341
DTC C1057 (DTC 57) - Power Source Circuit
342
DTC C1061 (DTC 61) - ABS Pump Motor Circuit
343
DTC C1063 (DTC 63) - ABS Fail Safe Circuit
344
DTC C1071 (DTC 71) - ABS Control Module
345
On-Vehicle Service
346
Precaution
346
ABS Hydraulic Unit Operation Check
346
ABS Hydraulic Unit / Control Module Assembly
347
Front Wheel Speed Sensor
349
Front Wheel Sensor Ring
352
Rear Wheel Speed Sensor
353
Rear Wheel Sensor Ring
355
G Sensor
356
Tightening Torque Specification
357
Special Tool
357
Diagnosis
358
General Information
360
Statement on Cleanliness and Care
360
General Information on Engine Service
360
Precaution on Fuel System Service
361
Fuel Leakage Check Procedure
362
Fuel Pressure Relief Procedure
362
Engine Diagnosis
363
General Description
363
On-Board Diagnostic System (Vehicle with Immobilizer Indicator Lamp)
366
Malfunction Indicator Lamp (MIL) Check
371
Diagnostic Trouble Code (DTC) Check
371
Diagnostic Trouble Code (DTC) Clearance
372
Diagnostic Trouble Code (DTC) Table
373
Fail-Safe Table
376
Visual Inspection
377
Engine Basic Inspection
378
Engine Diagnosis Table
380
Scan Tool Data
385
Scan Tool Data Definitions
387
Inspection of ECM and Its Circuits
390
Component Location
399
Switch on (but Engine at Stop)
402
DTC P0105 (DTC No.11) Manifold Absolute Pressure (MAP) Circuit Malfunction
405
DTC P0115 (DTC No.19) Engine Coolant Temperature (ECT) Circuit Malfunction
410
DTC P0120 (DTC No.13) Throttle Position Circuit Malfunction
412
DTC P0121 Throttle Position Circuit Range / Performance Problem
414
DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)
416
DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1)
418
DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1)
419
DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2)
421
DTC P0141 Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2)
423
DTC P0171 Fuel System too Lean
425
DTC P0172 Fuel System too Rich
425
DTC P0300 Random Misfire Detected (Misfire Detected at 2 or more Cylinders)
429
DTC P0301 Cylinder 1 Misfire Detected
429
DTC P0302 Cylinder 2 Misfire Detected
429
DTC P0303 Cylinder 3 Misfire Detected
429
DTC P0304 Cylinder 4 Misfire Detected
429
DTC P0325 (DTC No.17) Knock Sensor Circuit Malfunction
434
DTC P0335 (DTC No.23) Crankshaft Position (CKP) Sensor Circuit Malfunction
436
DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction
439
DTC P0400 Exhaust Gas Recirculation Flow Malfunction
442
DTC P0420 Catalyst System Efficiency below Threshold
445
DTC P0443 Purge Control Valve Circuit Malfunction
448
DTC P0481 A/C Condenser Fan Control Circuit Malfunction
449
DTC P0500 (DTC No.16) Vehicle Speed Sensor (VSS) Malfunction
451
DTC P0505 Idle Control System Malfunction
453
DTC P0601 Internal Control Module Memory Check Sum Error (DTC No.71)
455
DTC P1450 Barometric Pressure Sensor Low / High Input
456
DTC P1451 Barometric Pressure Sensor Performance Problem
456
DTC P1500 Engine Starter Signal Circuit Malfunction
458
DTC P1510 ECM Back-Up Power Supply Malfunction
460
DTC P1570 (DTC No.21) ABS Signal Circuit Malfunction
461
DTC P1600 Serial Communication Problem between ECM and TCM
462
DTC P1717 A/T Drive Range
464
Check
472
Special Tool
480
Engine Mechanical (M13 Engine)
482
General Description
483
Engine
483
Engine Lubrication
484
Diagnosis
485
Diagnosis Table
485
Compression Check
485
Engine Vacuum Check
487
Oil Pressure Check
488
Valve Lash (Clearance)
490
On-Vehicle Service
494
Air Cleaner Element
494
Air Cleaner Assembly
495
Knock Sensor
495
Cylinder Head Cover
496
Throttle Body and Intake Manifold
499
Exhaust Manifold
502
Oil Pan and Oil Pump Strainer
505
Timing Chain Cover
509
Oil Pump
514
Timing Chain and Chain Tensioner
518
Camshaft, Tappet and Shim
523
Valves and Cylinder Head
529
Pistons, Piston Rings, Connecting Rods and Cylinders
543
Engine Mountings
553
Unit Repair Overhaul
554
Engine Assembly
554
Main Bearings, Crankshaft and Cylinder Block
560
Tightening Torque Specification
574
Required Service Material
574
Special Tool
575
Section 6B Engine Cooling
578
Default Chapter
578
Engine Cooling
578
General Description
579
Cooling System Circulation
579
Radiator Cap
580
Coolant Reservoir
580
Water Pump
581
Thermostat
581
Cooling Fan Clutch
581
Coolant (Water) Temperature Gauge
581
Diagnosis
582
Maintenance
583
Coolant
583
Coolant Level
584
Cooling System Service
584
Cooling System Flush and Refill
585
Water Pump Belt Tension
586
On-Vehicle Service
587
Cooling System Component
587
Coolant Draining
588
Cooling Water Pipes or Hoses
588
Thermostat
588
Water Pump Belt and Cooling Fan
590
Radiator
591
Water Pump
592
Tightening Torque Specification
594
Required Service Material
594
Engine Fuel
596
General Description
597
Fuel System
597
Fuel Tank
597
Fuel Pump Assembly
598
Fuel Filler Cap
598
On-Vehicle Service
599
Fuel Lines
599
Fuel Filler Cap
599
Fuel Tank
599
Fuel Pump Assembly
602
Special Tool
605
Tightening Torque Specification
605
Engine and Emission Control System
606
General Description
608
Air Intake System
610
Fuel Delivery System
611
Fuel Pump
611
Electronic Control System
612
Engine & Emission Control Input / Output Table
613
On-Vehicle Service
620
Accelerator Cable Adjustment
620
Idle Speed / Idle Air Control (IAC) Duty Inspection
620
Idle Mixture Inspection / Adjustment (Vehicle Without Heated Oxygen Sensor)
622
Air Intake System
623
Throttle Body
623
Idle Air Control Valve (IAC Valve)
626
Fuel Delivery System
627
Fuel Pressure Inspection
627
Fuel Pump
628
Fuel Pressure Regulator
629
Fuel Injector
630
Electronic Control System
634
Engine Control Module (ECM)
634
Manifold Absolute Pressure Sensor (MAP Sensor)
634
Throttle Position Sensor (TP Sensor)
635
Intake Air Temperature Sensor (IAT Sensor)
636
Engine Coolant Temperature Sensor (ECT Sensor)
637
Heated Oxygen Sensor (Sensor-1 and Sensor-2)
638
Camshaft Position Sensor
639
Crankshaft Position Sensor
640
Vehicle Speed Sensor (VSS)
641
Fuel Level Sensor (GAUGE)
641
Knock Sensor
641
Main Relay, Fuel Pump Relay and A/C Condenser Fan Control Relay
641
Fuel Cut Operation
642
A/C Condenser Fan Control System
642
A/C Condenser Fan
642
Output Signals of Throttle Valve Opening and Engine Coolant Temp
643
(Vehicle with A/T Only)
643
Emission Control System
643
General Description
651
Diagnosis
652
High-Tension Cords
654
Ignition Spark Test
654
On-Vehicle Service
654
Spark Plugs
655
Ignition Coil Assembly (Including Ignitor)
656
Crankshaft Position Sensor (CKP Sensor)
657
Ignition Timing
657
Special Tools
659
Tightening Torque Specification
659
Cranking Circuit
661
Diagnosis
661
Diagnosis Table
661
General Description
661
Performance Test
663
On-Vehicle Service
664
Starting Motor
664
Specifications
666
Charging System
668
General Description
669
Battery
669
Generator
671
Diagnosis
673
Battery
673
Generator
674
On-Vehicle Service
676
Battery
676
Jump Starting in Case of Emergency
676
Dismounting
678
Handling
678
Remounting
678
Generator
678
Generator Belt
678
Unit Repair Overhaul
679
Generator
679
Dismounting
679
Disassembly and Reassembly
680
Remounting
680
Inspection
681
Specifications
684
Battery
684
Generator
684
Tightening Torque Specification
684
Exhaust Pipe
687
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Suzuki Jimny Specifications
General
Brand
Suzuki
Model
Jimny
Category
Automobile
Language
English
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