Suzuki Jimny SN413 SN415D Service Manual Supplement PDF Download

Description

SUZUKI SN413 SN415D JIMNY SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD

FILE DETAILS:

SUZUKI SN413 SN415D JIMNY SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD

Language : English
Pages : 331
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

SUZUKI SN413 SN415D JIMNY SUPPLEMENTARY SERVICE MANUAL – PDF DOWNLOAD

IMPORTANT......................................................................................  1
	WARNING/CAUTION/NOTE.......................................................................  1
FOREWORD.......................................................................................  2
	RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE..................................  3
TABLE OF CONTENTS..............................................................................  4
SECTION 0A.....................................................................................  6
	CONTENTS...................................................................................  6
	Precautions................................................................................  7
		General Precautions....................................................................  7
SECTION 0B..................................................................................... 12
	CONTENTS................................................................................... 12
	Maintenance Schedule....................................................................... 14
		Maintenance Schedule Under Normal Driving Conditions................................... 14
		Maintenance Recommended Under Severe Driving Conditions................................ 17
	Maintenance Service........................................................................ 19
		Engine (K9K)........................................................................... 19
			Engine oil and filter (K9K Engine)................................................. 19
		Fuel System............................................................................ 21
			Fuel Filter........................................................................ 21
			Water Draining of Fuel Filter...................................................... 21
		Chassis and Body....................................................................... 22
			Automatic Transmission Fluid....................................................... 22
SECTION 6-2.................................................................................... 24
	CONTENTS................................................................................... 24
	General Information........................................................................ 26
		Statement of Cleanliness and Care...................................................... 26
		General Information on Engine Service.................................................. 26
			Precaution on fuel system service.................................................. 27
			Fuel pressure relief confirmation procedure........................................ 27
			Fuel leakage check procedure....................................................... 27
	Engine Diagnosis........................................................................... 28
		General Description.................................................................... 28
		On-Board Diagnostic System............................................................. 28
		Precaution in Diagnosing Trouble....................................................... 30
		Engine Diagnostic Flow Table........................................................... 32
			Diagnostic step details............................................................ 34
		Diagnostic Trouble Code (DTC) Check.................................................... 35
		Diagnostic Trouble Code (DTC) Clearance................................................ 35
		Diagnostic Trouble Code (DTC) Table.................................................... 36
		Indicator lamp operation table......................................................... 39
		Visual Inspection...................................................................... 42
		Engine Basic Check..................................................................... 43
		Fault Finding - Fault Interpretation................................................... 44
			DTC P0016 Crankshaft position - camshaft position correlation...................... 44
			DTC P0045 Turbo charger boost control solenoid circuit/open........................ 45
			DTC P0070 External air temperature sensor circuit malfunction...................... 46
			DTC P0087 Fuel rail/system pressure too low........................................ 47
			DTC P0089 Fuel pressure regulator performance problem.............................. 48
			DTC P0100 Mass air flow circuit.................................................... 49
			DTC P0115 Engine coolant temperature circuit malfunction........................... 50
			DTC P0170 Fuel trim................................................................ 51
			DTC P0180 Fuel temperature sensor circuit malfunction.............................. 53
			DTC P0190 Fuel pressure sensor circuit malfunction................................. 54
			DTC P0200 Injector circuit......................................................... 55
			DTC P0201 Injector circuit malfunction - cylinder 1................................ 57
			DTC P0202 Injector circuit malfunction - cylinder 2................................ 59
			DTC P0203 Injector circuit malfunction - cylinder 3................................ 61
			DTC P0204 Injector circuit malfunction - cylinder 4................................ 63
			DTC P0225 Pedal position sensor 1 circuit.......................................... 65
			DTC P0231 Fuel pump secondary circuit low.......................................... 67
			DTC P0235 Turbo pressure sensor circuit malfunction................................ 68
			DTC P0263 Cylinder 1 contribution/balance.......................................... 70
			DTC P0266 Cylinder 2 contribution/balance.......................................... 71
			DTC P0269 Cylinder 3 contribution/balance.......................................... 72
			DTC P0272 Cylinder 4 contribution/balance.......................................... 73
			DTC P0325 Knock sensor circuit malfunction......................................... 74
			DTC P0335 Crankshaft position sensor circuit malfunction........................... 75
			DTC P0340 Camshaft position sensor circuit malfunction............................. 76
			DTC P0380 Glow plug/heater circuit malfunction..................................... 77
			DTC P0670 Glow plug module control circuit......................................... 77
			DTC P0382 Glow plug/heater circuit B malfunction................................... 78
			DTC P0400 Exhaust gas recirculation flow........................................... 79
			DTC P2413 Exhaust gas recirculation system performance............................. 79
			DTC P0403 Exhaust gas recirculation control circuit................................ 81
			DTC P0409 Exhaust gas recirculation sensor circuit................................. 82
			DTC P0480 Radiator cooling fan low speed control system malfunction................ 83
			DTC P0481 Radiator cooling fan high speed control system malfunction............... 84
			DTC P0487 Exhaust gas recirculation throttle position control circuit.............. 85
			DTC P0500 Vehicle speed sensor circuit malfunction................................. 86
			DTC P0513 Incorrect immobilizer key................................................ 87
			DTC P0530 A/C refrigerant pressure sensor circuit.................................. 88
			DTC P0560 System voltage........................................................... 89
			DTC P0571 Brake switch circuit..................................................... 90
			DTC P0604 Control module internal fail............................................. 91
			DTC P0605 Control module program error............................................. 92
			DTC P0606 Control module program error............................................. 92
			DTC P062F Control module EEPROM failure............................................ 93
			DTC P0641 Sensor reference voltage 1 circuit/open.................................. 94
			DTC P0645 A/C compressor relay control circuit..................................... 96
			DTC P0651: Sensor reference voltage 2 circuit/open................................. 97
			DTC P0685 Main relay control circuit malfunction................................... 99
			DTC P1641 Additional heater relay circuit 1........................................100
			DTC P1642 Additional heater relay circuit 2........................................101
			DTC P2120 Pedal position sensor 2 circuit..........................................102
			DTC P2226 Barometric pressure circuit malfunction..................................104
			DTC P2263: Turbo charger boost system performance..................................104
		Fault Finding - Customer Complaints....................................................106
			Table 1 No dialogue with the ECM...................................................107
			Table 2 The engine does not start..................................................108
			Table 3 The engine starts with difficulty or starts then stalls....................109
			Table 4 Starting difficult with warm engine........................................110
			Table 5 Rough idle speed (pumping).................................................111
			Table 6 Idle speed too high/too low................................................112
			Table 7 Unexpected acceleration/deceleration and engine stalling...................113
			Table 8 Response fault.............................................................114
			Table 9 Engine stop/stalling.......................................................115
			Table 10 Engine jerking............................................................116
			Table 11 Lack of power.............................................................117
			Table 12 Too much power............................................................118
			Table 13 Excessive consumption.....................................................119
			Table 14 Overspeed when lifting off accelerator or changing gear...................120
			Table 15 Engine dies on pulling away...............................................121
			Table 16 Engine rattling, noisy....................................................122
			Table 17 Blue, white or black smoke................................................123
			Table 18 Blue, black or white smoke when accelerating..............................124
		Fault Finding - Tests..................................................................125
			Test 1: Low Pressure Circuit Check.................................................126
			Test 2: Electrical Circuit Check...................................................126
			Test 3: Injector Check.............................................................127
			Test 4: Parameter Check............................................................127
			Test 5: Air Inlet Circuit Check....................................................127
			Test 6: ECM Check..................................................................127
			Test 7 High Pressure System Check..................................................128
			Test 8 High Pressure Circuit Sealing Test..........................................128
			Test 9 Injector Sealing Check......................................................129
			Test 11: Diesel filter check.......................................................131
	Special Tool...............................................................................132
SECTION 6A2....................................................................................134
	CONTENTS...................................................................................134
	Diagnosis Information and Procedure........................................................136
		Diagnosis Table........................................................................136
		Compression Check......................................................................136
		Oil Pressure Check.....................................................................137
		Valve Lash (Clearance).................................................................139
			Measurement of valve lash (clearance)..............................................139
			Replacement of tappet..............................................................139
	Repair Instructions........................................................................141
		Air Cleaner Filter Removal and Installation............................................141
		Air Cleaner Filter Inspection and Cleaning.............................................141
		Air Cleaner Assembly Removal and Installation..........................................141
		Intercooler Components.................................................................142
		Intercooler Removal and Installation...................................................143
		Cylinder Head Cover Components.........................................................144
		Cylinder Head Cover Removal and Installation...........................................144
		Oil Pressure Switch Removal and Installation...........................................146
		Heat Exchanger Removal and Installation................................................146
		EGR Valve and Intake Pipe Components...................................................149
		EGR Valve and Intake Pipe Removal and Installation.....................................150
		EGR Valve Disassembly and Reassembly...................................................152
		EGR Valve and Intake Pipe Inspection...................................................153
		Turbocharger Components................................................................154
		Turbocharger Removal and Installation..................................................155
		Turbocharger Inspection................................................................156
		Exhaust Manifold Components............................................................156
		Exhaust Manifold Removal and Installation..............................................157
		Oil Pan and Oil Pump Strainer Components...............................................158
		Oil Pan and Oil Pump Strainer Removal and Installation.................................159
		Engine Assembly Removal and Installation...............................................163
		Timing Belt and Belt Tensioner Components..............................................167
		Timing Belt and Belt Tensioner Removal and Installation................................168
		Timing Belt and Belt Tensioner Inspection..............................................176
		Oil Pump and Oil Pump Chain Components.................................................177
		Oil Pump and Oil Pump Chain Removal and Installation...................................177
		Oil Pump and Oil Pump Chain Inspection.................................................180
		Camshaft and Tappet Components.........................................................181
		Camshaft and Tappet Removal and Installation...........................................182
		Camshaft and Tappet Inspection.........................................................186
		Valves and Cylinder Head Components....................................................190
		Valves and Cylinder Head Assembly Removal and Installation.............................190
		Valves and Cylinder Head Assembly Inspection...........................................193
		Valves and Cylinder Head Assembly Disassembly and Reassembly...........................193
		Valves and Cylinder Head Components Inspection.........................................196
		Pistons, Piston Rings, Connecting Rods and Cylinders Components........................199
		Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation..........200
		Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Reassembly........202
		Pistons, Piston Rings, Connecting Rods and Cylinders Inspection........................204
		Main Bearings, Crankshaft and Cylinder Block Components................................210
		Main Bearings, Crankshaft and Cylinder Block Removal and Installation..................211
		Main Bearings, Crankshaft and Cylinder Block Inspection................................217
	Required Service Material..................................................................222
	Tightening Torque Specifications...........................................................222
	Special Tool...............................................................................224
SECTION 6B2....................................................................................226
	CONTENTS...................................................................................226
	General Description........................................................................227
		Cooling System Circulation.............................................................227
	Maintenance................................................................................228
		Coolant................................................................................228
	On-Vehicle Service.........................................................................229
		Cooling System Component...............................................................229
		Radiator Cooling Fan Removal and Installation..........................................230
	Tightening Torque Specification............................................................231
SECTION 6C2....................................................................................232
	CONTENTS...................................................................................232
	On-Vehicle Service.........................................................................233
		Fuel System Components.................................................................233
		Water Draining of Fuel Filter..........................................................234
		Air Bleeding of Fuel System............................................................234
		Fuel Filter Removal and Installation...................................................234
SECTION 6E2....................................................................................236
	CONTENTS...................................................................................236
	General Description........................................................................238
		System Diagram.........................................................................238
		Electronic Control System..............................................................240
			System wiring diagram..............................................................240
			System location diagram............................................................243
		Air Intake System......................................................................244
		Fuel Delivery System...................................................................245
	On-Vehicle Service.........................................................................246
		Idle Speed Inspection..................................................................246
		Fuel Delivery System...................................................................247
			Precautions in fuel delivery system................................................247
			Fuel delivery system components....................................................250
			High pressure pipes removal and installation.......................................251
			Fuel injector removal and installation.............................................256
			Injection pump removal and installation............................................258
			Venturi removal and installation...................................................260
		Electronic Control System..............................................................261
			Engine control module (ECM) removal and installation...............................261
			ECM registration (Programming).....................................................263
			APP sensor removal and installation................................................265
			APP sensor inspection..............................................................266
			Fuel temperature sensor removal and installation...................................267
			Fuel flow actuator removal and installation........................................268
			Engine coolant temperature sensor (ECT sensor) removal and installation............269
			Crankshaft position (CKP) sensor (engine speed sensor) removal and installation....270
			Crankshaft position (CKP) sensor (engine speed sensor) inspection..................271
			MAF and IAT sensor removal and installation........................................272
			MAF and IAT sensor inspection......................................................272
			Boost pressure sensor removal and installation.....................................273
			Boost pressure sensor inspection...................................................273
			Boost pressure control solenoid valve removal and installation.....................274
			Boost pressure control solenoid valve inspection...................................274
			Radiator fan control system inspection.............................................275
			EGR valve removal and installation.................................................275
			EGR valve inspection...............................................................275
	Tightening Torque Specification............................................................277
	Special Tool...............................................................................277
SECTION 6G2....................................................................................278
	CONTENTS...................................................................................278
	Diagnosis..................................................................................279
		Cranking System Test...................................................................279
			Pull-in test.......................................................................279
			Hold-in test.......................................................................279
			Plunger and pinion return test.....................................................279
			No-load performance test...........................................................280
	ON-Vehicle Service.........................................................................281
		Starting Motor Dismounting and Remounting..............................................281
			Dismounting........................................................................281
SECTION 6K2....................................................................................282
	CONTENTS...................................................................................282
	On-Vehicle Service.........................................................................283
		Exhaust System Components..............................................................283
		Exhaust Pipe Removal and Installation..................................................284
	Tightening Torque Specification............................................................286
SECTION 7A2....................................................................................288
	CONTENTS...................................................................................288
	On-Vehicle Service.........................................................................289
		Gear Shift Control Lever Assembly Components...........................................289
		Gear Shift Control Lever Assembly Removal and Installation.............................290
	Unit Repair Overhaul.......................................................................292
		Manual Transmission Unit Components....................................................292
		Manual Transmission Assembly Components................................................293
		Manual Transmission Assembly Disassembly and Reassembly................................294
	Tightening Torque Specification............................................................300
SECTION 7C2....................................................................................302
	CONTENTS...................................................................................302
	General Description........................................................................303
	On-Vehicle Service.........................................................................304
		Clutch Fluid Pipe and Hose Components..................................................304
		Clutch Fluid Pipe and Hose Removal and Installation....................................305
		Clutch Fluid Pipe and Hose Inspection..................................................306
		Clutch Operating Cylinder Removal and Installation.....................................307
	Unit Repair Overhaul.......................................................................308
		Clutch Cover, Clutch Disc, Flywheel and Release Bearing Components.....................308
		Clutch Cover, Clutch Disc, Flywheel and Release Bearing Removal and Installation.......309
	Tightening Torque Specification............................................................311
SECTION 8......................................................................................312
	CONTENTS...................................................................................312
	Diagnosis..................................................................................314
		Power Door Lock System (If Equipped)...................................................314
		Power Door Lock System with Keyless Entry System (If Equipped).........................314
		Power Door Mirror Control System.......................................................315
		Door Mirror Heater (If Equipped).......................................................315
	On-Vehicle Service.........................................................................316
		Combination Meter......................................................................316
		Power Door Lock System (If Equipped)...................................................319
			Power door lock system circuit inspection..........................................319
		Power Door Lock System with Keyless Entry System (If Equipped).........................321
			Power door lock system with keyless entry system component location................321
			System description.................................................................322
			Change of signal mode..............................................................322
			Keyless entry system operation inspection..........................................322
			Keyless entry system circuit inspection............................................323
			Transmitter........................................................................326
		Power Door Mirror Control System (If Equipped).........................................328
			Door mirror actuator...............................................................328
		Door Mirror Heater (If Equipped).......................................................329
			Mirror heater (if equipped)........................................................329
Copyright......................................................................................330
Bookcover......................................................................................331

S.S