Suzuki Jimny SN413 and SN415D - Service Manual - Taller - Manuel de Reparation - Reparaturanleitung

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SUZUKI JIMNY (SN413-SN415D) - SERVICE MANUAL

- Multilanguage (English, Español, Deutsch and Français) Service Manual, to Suzuki Jimny SN413 and SN415D.


CONTENTS:

SERVICE MANUAL

IMPORTANT
- WARNING/CAUTION/NOTE

FOREWORD

TABLE OF CONTENTS

SECTION 0A
- How to Use This Manual
- Precautions
- Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
- Diagnosis
- Servicing and handling
- General Precautions
- Precautions For Catalytic Converter
- Precautions For Electrical Circuit Service
- Electrical Circuit Inspection Procedure
- Open circuit check
- Short circuit check (wire harness to ground)
- Intermittent and Poor Connection
- Precaution For Installing Mobile Communication Equipment
- Identification Information
- Body Number
- Engine Identification Number
- Transmission Identification Number
- Warning, Caution and Information Labels
- Vehicle Lifting Points
- When Using Frame Contact Hoist
- When Using Floor Jack
- Abbreviations May Be Used In This Manual
- Abbreviations
- Fasteners Information
- Metric Fasteners
- Fastener Strength Identification
- Standard Tightening Torque

SECTION 0B
- Maintenance Schedule
- Maintenance Schedule Under Normal Driving Conditions
- Maintenance Recommended Under Severe Driving Conditions
- Maintenance Service
- Engine
- Drive Belt
- Valve Lash
- Engine Oil and Filter
- Engine Coolant
- Exhaust System
- Ignition System
- Spark Plugs
- Fuel System
- Air Cleaner Filter
- Fuel Lines and Connections
- Fuel Filter
- Fuel Tank
- Emission Control System
- Crankcase Ventilation Hoses and Connections
- PCV (Positive Crankcase Ventilation) Valve
- Fuel Evaporative Emission Control System
- Chassis and Body
- Clutch
- Brake Discs and Pads
- Brake Drums and Shoes
- Brake Hoses and Pipes
- Brake Fluid
- Parking Brake Lever and Cable
- Tires/Wheels
- Suspension System
- Propeller Shafts
- Manual Transmission Oil
- Automatic Transmission Fluid
- Transfer and Differential Oil
- Steering System
- Steering Knuckle Seal
- Power Steering (P/S) System (if equipped)
- All Hinges, Latches and Locks
- Final Inspection
- Recommended Fluids and Lubricants

SECTION 1A
- General Description
- Diagnosis
- Diagnosis Table
- Wiring Circuit
- On Vehicle Service
- Heater Blower Motor
- Heater Blower Resistor
- Heater Control Lever Assembly
- Heater Blower Fan Switch
- Heater Unit/Boost Ventilation

SECTION 1B
- General Description
- Major Components and Location
- Refrigerant Circulation
- Refrigerant Type
- Diagnosis
- General Diagnosis Table
- Abnormal Noise Diagnosis
- Abnormal noise from compressor
- Abnormal noise from magnetic clutch
- Abnormal noise from tubing
- Abnormal noise from condenser
- Abnormal noise from crankshaft pulley
- Abnormal noise from tension pulley
- Abnormal noise from A/C evaporator
- Abnormal noise from blower fan motor
- Quick Checking of Refrigerant Charge
- Performance Diagnosis
- Performance diagnosis table
- Detail diagnosis table (Ambient temperature at 30°C (86°F))
- Compressor Drive Belt
- Electronical Diagnosis
- Wiring Diagram
- A/C System Inspection of ECM and ITS Circuits
- Refrigerant Recovery, Evacuating and Charging
- Operation Procedure for Refrigerant Charging
- Recovery
- Replenishing Compressor Oil
- Evacuating
- Evacuating procedure
- Charging
- Charging procedure
- Removing Manifold Gauge Set
- Leak Test
- On-Vehicle Service
- Service Precaution
- Refrigerant line
- Handling refrigerant HFC-134a (R-134a)
- Condenser Assembly
- Receiver / Dryer
- Condenser Cooling Fan Assembly
- Cooling Unit (Evaporator)
- A/C Evaporator Thermistor (A/C Evaporator Temperature Sensor)
- Expansion Valve
- Dual Pressure Switch
- A/C Switch
- Condenser Cooling Fan Motor Relay
- Compressor
- Magnet Clutch
- Lip Type Seal
- Tightening Torque Specification
- Required Service Materials
- Special Tools

SECTION 3
- General Diagnosis
- Diagnosis Table
- Tire Diagnosis
- Irregular and/or Premature Wear
- Wear Indicators
- Radial Tire Waddle
- Radial Tire Lead
- Vibration Diagnosis

SECTION 3A
- General Description
- Toe Setting
- Camber
- Alignment Service Data (Reference)
- Diagnosis
- Diagnosis Table
- Preliminary Checks Prior To Adjusting Front Wheel Alignment
- Toe Adjustment
- Camber And Caster Check And Adjustment
- Steering Angle Check And Adjustment
- Side Slip(Reference)

SECTION 3B
- General Description
- Diagnosis
- Diagnosis Table
- Steering Wheel Play Check
- Tie Rod And Drag Rod Check
- Steering Gear Box Oil Level Check
- Adjustment of Worm Shaft Starting Torque
- On-Vehicle Service
- Steering Gear Box
- Tie Rod And Drag Rod
- Tightening Torque Specifications
- Required Service Material
- Special Tools

SECTION 3B1
- General Description
- Diagnosis
- Diagnosis Table
- Steering Wheel Play Check
- Steering Force Check
- Power Steering Belt Check
- Power Steering Belt Tension Adjustment
- Power Steering Fluid Level Check
- Idle-Up System Check
- Power Steering Fluid Leakage Check
- Air Bleeding Procedure
- Hydraulic Pressure In P/S Circuit Check
- On-Vehicle Service
- Power Steering Belt
- Power Steering (P/S) Pump
- Power Steering (P/S) Gear Box
- Tightening Torque Specifications
- Required Service Materials
- Special Tools

SECTION 3C
- General Description
- Diagnosis
- Inspection and Repair Required After Accident
- On-Vehicle Service
- Service Precautions (For Vehicle with Air Bag System)
- Diagnosis and servicing
- Disabling air bag system
- Enabling air bag system
- Handling and storage
- Disposal
- Drive Air Bag (Inflator) Module (For Vehicle with Air Bag System)
- Steering Wheel
- Centering contact coil (for vehicle with air bag system)
- Combination Switch (For Vehicle without Air Bag System)/Contact Coil and Combination Switch Assem...
- Steering Column Assembly
- Steering Lock Assembly (Ignition Switch)
- Steering Lower Shaft
- Checking Steering Column for Accident Damage
- Tightening Torque Specifications
- Required Service Material
- Special Tool

SECTION 3D
- General Description
- 4WD Control System
- Diagnosis
- Diagnosis Table
- 4WD Controller and ITS Circuit Check
- 4WD Control System Check
- Stabilizer bar / bushing check
- Shock Absorber and/or Coil Spring Check
- Leading Arm / Lateral Rod / Steering Knuckle Check
- Leading Arm Bushing / Lateral Rod Bushing Check
- Kingpin / Kingpin Bearing Check
- Barfield Joint Check
- Steering Knuckle Seal Check
- Wheel Disc, Nut and Bearing Check
- On-Vehicle Service
- Stabilizer Bar / Bushings
- Front Shock Absorber
- Coil Spring
- Bump Stopper and Spring Upper Seat
- Wheel Hub / Bearing / Oil Seal
- Steering Knuckle / Wheel Spindle
- Front Axle Shaft / Oil Seal / Kingpin Bearing Outer Race
- Steering Knuckle Seal
- Lateral Rod
- Leading Arm / Bushing
- Front Axle Housing
- Tightening Torque Specifications
- Required Service Material
- Special Tool

SECTION 3E
- General Description
- Diagnosis
- Diagnosis Table
- Rear Shock Absorber Check
- Trailing Arm, Lateral Rod, Axle Housing and Coil Spring Check
- Trailing Arm and Lateral Rod Bush Check
- Rear Suspension Fasteners
- Bearing Retainer and Axle Shaft Oil Seal Check
- Bump Stopper and Spring Rubber Seat Check
- Wheel Disc, Nut and Bearing Check
- On-Vehicle Service
- Rear Shock Absorber
- Coil Spring
- Bump Stopper
- Lateral Rod
- Trailing Arm / Bushing
- Rear Axle Shaft and Wheel Bearing
- Rear Axle Shaft Inner Oil Seal
- Rear Axle Housing
- Tightening Torque Specifications
- Required Service Materials
- Special Tools

SECTION 3F
- General Description
- Tires
- Wheels
- Replacement Tires
- Replacement Wheels
- How To Measure Wheel Runout
- Metric Lug Nuts and Wheel Studs
- Diagnosis
- Diagnosis Table
- Balancing Wheels
- General Balance Procedure
- Off-vehicle balancing
- On-vehicle balancing
- Maintenance and Minor Adjustments
- Wheel and Tire
- Studs
- Matched tires and wheels (For vehicle equipped with steel wheels)
- Inflation of Tires
- Tire placard
- Tire rotation
- On-Vehicle Service
- Wheel
- Tire
- Mounting and demounting
- Repair

SECTION 4B
- General Description
- Components
- Diagnosis
- Diagnosis Table
- Propeller Shaft Joint Check
- On-Vehicle Service
- Propeller Shafts
- Universal Joint
- Tightening Torque Specification
- Required Service Material
- Special Tool

SECTION 5
- General Description
- Diagnosis
- Road Testing Brakes
- Brake Fluid Leaks
- Substandard or Contaminated Brake Fluid
- Diagnosis Table
- Brake Pedal Free Height Adjustment
- Brake Pedal Play Check
- Stop Light Switch Adjustment
- Excessive Pedal Travel Check
- Front Brake Disc Check
- Front Brake Pad Check
- Rear Brake Shoe Check
- Master Cylinder and Brake Fluid Level Check
- Rear Drum Brake Shoe Adjustment
- Parking Brake Inspection and Adjustment
- Booster Operation Check
- Fluid Pressure Test (If Equipped with LSPV)
- On-Vehicle Service
- Air Bleeding of Brake System
- Brake Hose and Pipe Inspection
- Front Disc Brake
- Brake pad
- Caliper assembly
- Brake Disc
- Rear Brake
- Brake drum
- Brake shoe
- Wheel Cylinder
- Brake back plate
- Master Cylinder
- Master Cylinder Reservoir
- Master Cylinder Assembly
- Master Cylinder
- Fill Reservoir
- LSPV (Load Sensing Proportioning Valve) Assembly (If Equipped)
- LSPV Assembly
- P (Proportioning) Valve
- Brake Booster
- Inspection and adjustment
- Brake Hose/Pipe
- Front brake hose/pipe
- Rear Brake Hose/Pipe
- Parking Brake Lever/Cable
- Parking brake lever
- Parking Brake Cable
- Tightening Torque Specifications
- Required Service Material
- Special Tool

SECTION 5E
- General Description
- System Schematic
- ABS Component Parts Location
- ABS Control Module
- Self-diagnosis function
- Fail-safe function
- Diagnosis
- Precaution in Diagnosing Troubles
- ABS Diagnostic Flow Table
- “ABS” Warning Lamp Check
- Diagnostic Trouble Code (DTC) Check
- DTC Check (Using SUZUKI Scan Tool)
- Diagnostic Trouble Code (DTC) Clearance
- Diagnostic Trouble Code (DTC) Table
- System Circuit
- Table – A “ABS” Warning Lamp Circuit Check – Lamp Does Not Come “ON” at Ignition Switch ON
- Table – B “ABS” Warning Lamp Circuit Check – Lamp Comes “ON” Steady
- Table – C “ABS” Warning Lamp Circuit Check – Lamp Flashes Continuously While Ignition Switch is ON
- Table – D Code (DTC) is Not Outputted Even With Diag. Switch Terminal Connected to Ground.
- DTC C1015 (DTC 15) – G Sensor Circuit
- DTC C1016 (DTC 16) – Stop Lamp Circuit
- DTC C1021 (DTC 21), DTC C1022 (DTC 22) – Right Front Wheel Speed Sensor Circuit
- DTC C1025 (DTC 25), DTC C1026 (DTC 26) – Left Front Wheel Speed Sensor Circuit
- DTC C1031 (DTC 31), DTC C1032 (DTC 32) – Right Rear Wheel Speed Sensor Circuit
- DTC C1035 (DTC 35), DTC C1036 (DTC 36) – Left Rear Wheel Speed Sensor Circuit
- DTC C1041 (DTC 41), DTC C1042 (DTC 42) – Right Front Solenoid Circuit
- DTC C1045 (DTC 45), DTC C1046 (DTC 46) – Left Front Solenoid Circuit
- DTC C1055 (DTC 55), DTC C1056 (DTC 56) – Rear Solenoid Circuit
- DTC C1057 (DTC 57) – Power Source Circuit
- DTC C1061 (DTC 61) – ABS Pump Motor Circuit
- DTC C1063 (DTC 63) – ABS Fail Safe Circuit
- DTC C1071 (DTC 71) – ABS Control Module
- On-Vehicle Service
- Precaution
- ABS Hydraulic Unit Operation Check
- ABS Hydraulic Unit / Control Module Assembly
- Front Wheel Speed Sensor
- Front Wheel Sensor Ring
- Rear Wheel Speed Sensor
- Rear Wheel Sensor Ring
- G Sensor
- Tightening Torque Specification
- Special Tool

SECTION 6
- General Information
- Statement on Cleanliness and Care
- General Information on Engine Service
- Precaution on fuel system service
- Fuel pressure relief procedure
- Fuel leakage check procedure
- Engine Diagnosis
- General Description
- On-Board Diagnostic System (Vehicle with Immobilizer Indicator Lamp)
- On-Board Diagnostic System (Vehicle without Immobilizer Indicator Lamp)
- Precaution in Diagnosing Trouble
- Engine Diagnostic Flow Table
- Customer problem inspection form (example)
- Malfunction indicator lamp (MIL) check
- Diagnostic trouble code (DTC) check
- Diagnostic trouble code (DTC) clearance
- Diagnostic trouble code (DTC) table
- Fail-safe table
- Visual inspection
- Engine basic inspection
- Engine diagnosis table
- Scan Tool Data
- Scan tool data definitions
- Inspection of ECM and Its Circuits
- Component Location
- Table A-1 Malfunction Indicator Lamp Circuit Check - Lamp Does Not Come “ON” at Ignition Switch O...
- Table A-2 Malfunction Indicator Lamp Circuit Check - Lamp Remains “ON” after Engine Starts
- Table A-3 Malfunction Indicator Lamp Circuit Check - Mil Flashes at Ignition Switch ON
- Table A-4 Malfunction Indicator Lamp Circuit Check - MIL Does Not Flash, Just Remains ON or Just ...
- Table A-5 ECM Power and Ground Circuit Check - MIL Doesn’t Light at Ignition Switch ON and Engine...
- DTC P0105 (DTC No.11) Manifold Absolute Pressure (MAP) Circuit Malfunction

- DTC P0110 (DTC No.18) Intake Air Temp. (IAT) Circuit Malfunction
- DTC P0115 (DTC No.19) Engine Coolant Temperature (ECT) Circuit Malfunction
- DTC P0120 (DTC No.13) Throttle Position Circuit Malfunction
- DTC P0121 Throttle Position Circuit Range / Performance Problem
- DTC P0130 (DTC No.14) Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-1)
- DTC P0133 Heated Oxygen Sensor (HO2S) Circuit Slow Response (Sensor-1)
- DTC P0135 (DTC No.14) Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-1)
- DTC P0136 Heated Oxygen Sensor (HO2S) Circuit Malfunction (Sensor-2)
- DTC P0141 Heated Oxygen Sensor (HO2S) Heater Circuit Malfunction (Sensor-2)
- DTC P0171 Fuel System Too Lean
- DTC P0172 Fuel System Too Rich
- DTC P0300 Random Misfire Detected (Misfire Detected at 2 or More Cylinders)
- DTC P0301 Cylinder 1 Misfire Detected
- DTC P0302 Cylinder 2 Misfire Detected
- DTC P0303 Cylinder 3 Misfire Detected
- DTC P0304 Cylinder 4 Misfire Detected
- DTC P0325 (DTC No.17) Knock Sensor Circuit Malfunction
- DTC P0335 (DTC No.23) Crankshaft Position (CKP) Sensor Circuit Malfunction
- DTC P0340 (DTC No.15) Camshaft Position (CMP) Sensor Circuit Malfunction
- DTC P0400 Exhaust Gas Recirculation Flow Malfunction
- DTC P0420 Catalyst System Efficiency below Threshold
- DTC P0443 Purge Control Valve Circuit Malfunction
- DTC P0481 A/C Condenser Fan Control Circuit Malfunction
- DTC P0500 (DTC No.16) Vehicle Speed Sensor (VSS) Malfunction
- DTC P0505 Idle Control System Malfunction
- DTC P0601 Internal Control Module Memory Check Sum Error (DTC No.71)
- DTC P1450 Barometric Pressure Sensor Low / High Input
- DTC P1451 Barometric Pressure Sensor Performance Problem
- DTC P1500 Engine Starter Signal Circuit Malfunction
- DTC P1510 ECM Back-up Power Supply Malfunction
- DTC P1570 (DTC No.21) ABS Signal Circuit Malfunction
- DTC P1600 Serial Communication Problem Between ECM and TCM
- DTC P1717 A/T Drive Range (Park / Neutral Position) Signal Circuit Malfunction
- Table B-1 Fuel Injector Circuit Check
- Table B-2 Fuel Pump and Its Circuit Check
- Table B-3 Fuel Pressure Check
- Table B-4 Idle Air Control System Check
- Table B-5 A/C Signal Circuits Check (Vehicle with A/C)
- Table B-6 Electric Load Signal Circuit Check
- TAble B-7 A/C Condenser Fan Control System Check
- Special Tool

SECTION 6A1
- General Description
- Engine
- Engine Lubrication
- Diagnosis
- Diagnosis Table
- Compression Check
- Engine Vacuum Check
- Oil Pressure Check
- Valve Lash (Clearance)
- On-Vehicle Service
- Air Cleaner Element
- Air Cleaner Assembly
- Knock Sensor
- Cylinder Head Cover
- Throttle Body and Intake Manifold
- Exhaust Manifold
- Oil Pan and Oil Pump Strainer
- Timing Chain Cover
- Oil Pump
- Timing Chain and Chain Tensioner
- Camshaft, Tappet and Shim
- Valves and Cylinder Head
- Pistons, Piston Rings, Connecting Rods and Cylinders
- Engine Mountings
- Unit Repair Overhaul
- Engine Assembly
- Main Bearings, Crankshaft and Cylinder Block
- Required Service Material
- Tightening Torque Specification
- Special Tool

SECTION 6B
- General Description
- Cooling System Circulation
- Radiator Cap
- Coolant Reservoir
- Water Pump
- Thermostat
- Cooling Fan Clutch
- Coolant (Water) Temperature Gauge
- Diagnosis
- Maintenance
- Coolant
- Coolant Level
- Cooling System Service
- Cooling System Flush and Refill
- Water Pump Belt Tension
- On-Vehicle Service
- Cooling System Component
- Coolant Draining
- Cooling Water Pipes or Hoses
- Thermostat
- Water Pump Belt and Cooling Fan
- Radiator
- Water Pump
- Required Service Material
- Tightening Torque Specification

SECTION 6C
- General Description
- Fuel System
- Fuel Tank
- Fuel Pump Assembly
- Fuel Filler Cap
- On-Vehicle Service
- Fuel Lines
- Fuel Filler Cap
- Fuel Tank
- Fuel Pump Assembly
- Tightening Torque Specification
- Special Tool

SECTION 6E
- General Description
- Air Intake System
- Fuel Delivery System
- Fuel pump
- Electronic Control System
- Engine & emission control input / output table
- On-Vehicle Service
- Accelerator cable adjustment
- Idle speed / idle air control (IAC) duty inspection
- Idle mixture inspection / adjustment (vehicle without heated oxygen sensor)
- Air Intake System
- Throttle body
- Idle air control valve (IAC valve)
- Fuel Delivery System
- Fuel pressure inspection
- Fuel pump
- Fuel pressure regulator
- Fuel injector
- Electronic Control System
- Engine control module (ECM)
- Manifold absolute pressure sensor (MAP sensor)
- Throttle position sensor (TP sensor)
- Intake air temperature sensor (IAT sensor)
- Engine coolant temperature sensor (ECT sensor)
- Heated oxygen sensor (Sensor-1 and sensor-2)
- Camshaft position sensor
- Crankshaft position sensor
- Vehicle speed sensor (VSS)
- Fuel level sensor (GAUGE)
- Knock sensor
- Main relay, fuel pump relay and A/C condenser fan control relay
- Fuel cut operation
- A/C condenser fan control system
- A/C condenser fan
- Output signals of throttle valve opening and engine coolant temp. (Vehicle with A/T only)
- Emission Control System
- EGR system (If equipped)
- Evaporative emission (EVAP) control system
- PCV system
- Special Tools
- Tightening Torque Specifications

SECTION 6F
- General Description
- Diagnosis
- On-Vehicle Service
- Ignition Spark Test
- High-tension Cords
- Spark Plugs
- Ignition Coil Assembly (Including Ignitor)
- Crankshaft Position Sensor (CKP Sensor)
- Ignition Timing
- Special Tools
- Tightening Torque Specification

SECTION 6G
- General Description
- Cranking Circuit
- Diagnosis
- Diagnosis Table
- Performance Test
- On-Vehicle Service
- Starting Motor
- Specifications

SECTION 6H
- General Description
- Battery
- Generator
- Diagnosis
- Battery
- Generator
- On-Vehicle Service
- Battery
- Jump starting in case of emergency
- Dismounting
- Handling
- Remounting
- Generator
- Generator belt
- Unit Repair Overhaul
- Generator
- Dismounting
- Remounting
- Disassembly and reassembly
- Inspection
- Specifications
- Battery
- Generator
- Tightening Torque Specification

SECTION 6K
- General Description
- Maintenance
- On-Vehicle Service
- Exhaust Manifold
- Exhaust Pipe