SUZUKI GRAND VITARA JB420 - SUPLEMENTARY SERVICE Manuals

Manuals and User Guides for SUZUKI GRAND VITARA JB420 - SUPLEMENTARY SERVICE. We have 3 SUZUKI GRAND VITARA JB420 - SUPLEMENTARY SERVICE manuals available for free PDF download: Owner's Manual, Service Manual, Manual

Suzuki GRAND VITARA JB420 - SUPLEMENTARY SERVICE Owner's Manual (1736 pages)

GRAND VITARA

Brand: Suzuki | Category: Automobile | Size: 68.83 MB

Table of Contents
5
Precautions
7
Air Bag Locations
8
Precautions
8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
8
Diagnosis, Servicing and Handling
9
General Precautions
11
Precaution in Servicing Full-Time 4WD Vehicle
14
Precautions for Catalytic Converter
15
Precaution for CAN Communication System
16
Precautions for Electrical Circuit Service
16
Precautions for Installing Mobile Communication Equipment
18
Air Bag Warning
18
Discharge Headlight Warning
18
A/C System Caution
18
Fastener Caution
18
Suspension Caution
19
Wheels and Tires Caution
19
Brakes Caution and Note
19
Differential Gear Oil Note
19
Repair Instructions
19
Electrical Circuit Inspection Procedure
19
Intermittent and Poor Connection Inspection
22
General Information
23
General Information
24
General Description
24
Abbreviations
24
Symbols
25
Wire Color Symbols
26
Fastener Information
26
General Information
27
Vehicle Lifting Points
28
Engine Supporting Points
30
Vehicle Identification Number
30
Engine Identification Number
30
Transmission Identification Number
30
Component Location
31
Warning, Caution and Information Label Location
31
Maintenance and Lubrication
33
Precautions
33
Precautions for Maintenance and Lubrication
33
Scheduled Maintenance
33
Maintenance Schedule under Normal Driving Conditions
33
Maintenance Recommended under Severe Driving Conditions
34
Repair Instructions
36
Engine Accessory Drive Belt Inspection
36
Engine Accessory Drive Belt Replacement
36
Valve Lash (Clearance) Inspection
36
Engine Oil and Filter Change
37
Engine Coolant Change
38
Exhaust System Inspection
39
Spark Plugs Replacement
39
Air Cleaner Filter Inspection
39
Air Cleaner Filter Replacement
39
Fuel Lines and Connections Inspection
39
Fuel Filter Replacement
39
Fuel Tank Inspection
39
Crankcase Ventilation Hoses and Connections Inspection (Vehicle Without A/F Sensor)
39
PCV Valve Inspection
39
Fuel Evaporative Emission Control System Inspection
40
Brake Discs and Pads Inspection
40
Brake Drums and Shoes Inspection
40
Brake Hoses and Pipes Inspection
40
Brake Fluid Change
40
Parking Brake Lever and Cable Inspection
41
Clutch Fluid Inspection
41
Tire / Wheel Inspection and Rotation
41
Wheel Discs Inspection
42
Wheel Bearing Inspection
42
Suspension System Inspection
42
Steering System Inspection
42
Propeller Shafts and Drive Shafts Inspection
43
Manual Transmission Oil Inspection
43
Manual Transmission Oil Change
43
Automatic Transmission Fluid Inspection
43
Automatic Transmission Fluid Change
44
Automatic Transmission Fluid Cooler Hose Inspection
44
Transfer Oil Inspection (if Equipped)
44
Differential Oil Inspection
44
Transfer (if Equipped) and Differential Oil Change
44
Power Steering (P/S) System Inspection
45
All Hinges, Latches and Locks Inspection
45
HVAC Air Filter Inspection (if Equipped)
45
HVAC Air Filter Replacement (if Equipped)
45
Final Inspection for Maintenance Service
45
Specifications
47
Tightening Torque Specifications
47
Special Tools and Equipment
47
Recommended Fluids and Lubricants
47
Special Tool
47
Engine
49
Precautions
55
Precautions for Engine
55
Engine General Information and Diagnosis
56
Precautions
56
Precautions on Engine Service
56
Precautions in Diagnosing Trouble
56
Precautions for DTC Troubleshooting
57
Precautions of ECM Circuit Inspection
57
Precautions of Electric Throttle Body System Calibration
57
General Description
57
Statement on Cleanliness and Care
57
Engine Diagnosis General Description
58
On-Board Diagnostic System Description
58
Engine and Emission Control System Description
61
CAN Communication System Description
61
Air Intake System Description
64
Description of Electric Throttle Body System
65
Description of Electric Throttle Body System Calibration
66
Generator Control System Description
66
A/F Sensor Description
67
Electronic Control System Description
68
Engine and Emission Control Input / Output Table
76
Schematic and Routing Diagram
77
Engine and Emission Control System Diagram
77
Component Location
78
Electronic Control System Components Location
78
Diagnostic Information and Procedures
80
Engine and Emission Control System Check
80
Malfunction Indicator Lamp (MIL) Check
83
DTC Check
83
DTC Clearance
84
DTC Table
85
Fail-Safe Table
91
Scan Tool Data
92
Visual Inspection
98
Engine Basic Inspection
99
Engine Symptom Diagnosis
103
Malfunction Indicator Lamp Does Not Come on with Ignition Switch on and Engine Stop (but Engine Can be Started)
112
Wiring Diagram
112
Malfunction Indicator Lamp Remains on after Engine Starts
114
DTC P0010: Camshaft Position Actuator Circuit (for M16 Engine)
115
DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (for M16 Engine)
117
DTC P0030: HO2S Heater Control Circuit (Sensor-1)
119
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)
120
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)
124
DTC P0101: Mass Air Flow Circuit Range / Performance
127
DTC P0102: Mass Air Flow Circuit Low Input
130
DTC P0103: Mass Air Flow Circuit High Input
132
DTC P0106: Manifold Absolute Pressure Range / Performance
134
DTC P0107: Manifold Absolute Pressure Circuit Low Input
135
DTC P0108: Manifold Absolute Pressure Circuit High Input
137
DTC P0111: Intake Air Temperature Circuit Range / Performance
139
DTC P0112: Intake Air Temperature Sensor Circuit Low
142
DTC P0113: Intake Air Temperature Sensor Circuit High
144
DTC P0116: Engine Coolant Temperature Circuit Range / Performance
146
DTC P0117: Engine Coolant Temperature Circuit Low
149
DTC P0118: Engine Coolant Temperature Circuit High
150
DTC P0122: Throttle Position Sensor (Main) Circuit Low
153
DTC P0123: Throttle Position Sensor (Main) Circuit High
156
DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / no Activity Detected (Sensor-1)
159
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)
160
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)
162
DTC P0140: O2 Sensor (HO2S) Circuit no Activity Detected (Sensor-2)
165
DTC P0171 / P0172 / P2195 / P2196: Fuel System too Lean / Rich / Stuck Lean / Stuck Rich
166
DTC P0222: Throttle Position Sensor (Sub) Circuit Low
170
DTC P0223: Throttle Position Sensor (Sub) Circuit High
173
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected
176
DTC P0327 / P0328: Knock Sensor Circuit Low / High
178
DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for J20 Engine)
180
Dtc Confirmation Procedure
180
DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for M16 Engine)
182
DTC P0340: Camshaft Position (CMP) Sensor Circuit
185
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
188
DTC P0403: Exhaust Gas Recirculation Control Circuit
191
DTC P0420: Catalyst System Efficiency below Threshold
193
DTC P0443: Evaporative Emission System Purge Control Valve Circuit
195
DTC P0462: Fuel Level Sensor Circuit Low
197
DTC P0463: Fuel Level Sensor Circuit High
199
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
201
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction
205
DTC P0504: Brake Switch "A"/"B" Correlation (for J20 Engine)
207
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low
209
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High
211
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
212
DTC P0616: Starter Relay Circuit Low
213
DTC P0617: Starter Relay Circuit High
215
DTC P0620: Generator Control Circuit
216
DTC P0625 / P0626: Generator Field Terminal Circuit Low / High
218
DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (for J20 Engine)
220
DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High
222
DTC P1510: ECM Back-Up Power Supply Malfunction
224
DTC P1603: TCM Trouble Code Detected (for J20 Engine)
225
DTC P1674: CAN Communication (Bus off Error)
226
DTC P1676: CAN Communication (Reception Error for TCM (for A/T Model))
231
DTC P1678: CAN Communication (Reception Error for BCM)
235
DTC P1685: CAN Communication (Reception Error for ABS Control Module)
239
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance
242
DTC P2102: Throttle Actuator Control Motor Circuit Low
244
DTC P2103: Throttle Actuator Control Motor Circuit High
246
DTC P2111: Throttle Actuator Control System - Stuck Open
247
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance
248
DTC P2122: Pedal Position Sensor (Main) Circuit Low Input
250
DTC P2123: Pedal Position Sensor (Main) Circuit High Input
253
DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input
255
DTC P2128: Pedal Position Sensor (Sub) Circuit High Input
257
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation
260
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation
263
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
265
Inspection of ECM and Its Circuits
267
ECM Power and Ground Circuit Check
289
Fuel Injector Circuit Check
293
Fuel Pump and Its Circuit Check
295
Fuel Pressure Check
298
A/C System Circuits Check
300
Electric Load Signal Circuit Check
303
Radiator Cooling Fan Low Speed Control System Check
305
Troubleshooting
305
Radiator Cooling Fan High Speed Control System Check
308
Repair Instructions
310
Idle Speed and IAC Throttle Valve Opening Inspection
310
Special Tools and Equipment
311
Special Tool
311
Aux. Emission Control Devices
312
Diagnostic Information and Procedures
312
EGR System Inspection
312
Repair Instructions
312
EVAP Canister Purge Inspection
312
EVAP Canister Purge Valve and Its Circuit Inspection
313
Vacuum Passage Inspection
313
Vacuum Hose and Purge Valve Chamber Inspection
314
EVAP Canister Purge Valve Inspection
314
EVAP Canister Inspection
315
EGR Valve Removal and Installation
315
EGR Valve Inspection
315
PCV Hose Inspection
315
PCV Valve Removal and Installation
316
PCV Valve Inspection
316
Specifications
317
Tightening Torque Specifications
317
Special Tools and Equipment
317
Recommended Service Material
317
Special Tool
317
Engine Electrical Devices
318
Repair Instructions
318
Engine Control Module (ECM) Removal and Installation
318
Manifold Absolute Pressure (MAP) Sensor Inspection
318
Electric Throttle Body Assembly On-Vehicle Inspection
319
Electric Throttle Body System Calibration
321
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection
322
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation
322
Accelerator Pedal Position (APP) Sensor Assembly Inspection
323
Engine Coolant Temperature (ECT) Sensor Removal and Installation
323
Engine Coolant Temperature (ECT) Sensor Inspection
324
Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection
324
Heated Oxygen Sensor (HO2S-2) Heater On-Vehicle Inspection
325
Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S-2) Removal and Installation
325
Camshaft Position (CMP) Sensor Removal and Installation
325
Camshaft Position (CMP) Sensor Inspection
326
Crankshaft Position (CKP) Sensor Removal and Installation
326
Crankshaft Position (CKP) Sensor Inspection
327
Knock Sensor Removal and Installation
328
Control Relay Inspection
329
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection
330
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation
330
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection
331
Vacuum Tank Assembly Inspection (for J20 Engine)
331
Electric Load Current Sensor On-Vehicle Inspection (for J20 Engine)
333
Electric Load Current Sensor Removal and Installation (for J20 Engine)
333
Specifications
334
Engine Mechanical
335
For M16A Engine with VVT
335
General Description
335
Engine Construction Description
335
Camshaft Position Control (VVT Variable Valve Timing) System Description
336
Diagnostic Information and Procedures
338
Compression Check
338
Engine Vacuum Check
339
Valve Lash (Clearance) Inspection
340
Repair Instructions
342
Air Cleaner Filter Removal and Installation
342
Air Cleaner Filter Inspection and Cleaning
343
Cylinder Head Cover Removal and Installation
343
Throttle Body and Intake Manifold Components
345
Throttle Body On-Vehicle Inspection
345
Electric Throttle Body Assembly Removal and Installation
346
Throttle Body Cleaning
346
Intake Manifold Removal and Installation
347
Engine Mountings Components
348
Engine Assembly Removal and Installation
348
Timing Chain Cover Components
352
Timing Chain Cover Removal and Installation
353
Timing Chain Cover Inspection
355
Oil Control Valve Removal and Installation
355
Oil Control Valve Inspection
356
Timing Chain and Chain Tensioner Components
357
Timing Chain and Chain Tensioner Removal and Installation
357
Timing Chain and Chain Tensioner Inspection
360
Camshaft, Tappet and Shim Components
361
Camshaft, Tappet and Shim Removal and Installation
361
Camshaft, Tappet and Shim Inspection
364
Valves and Cylinder Head Components
367
Valves and Cylinder Head Removal and Installation
368
Valves and Cylinder Head Disassembly and Assembly
369
Valves and Valve Guides Inspection
372
Cylinder Head Inspection
374
Valve Spring Inspection
375
Pistons, Piston Rings, Connecting Rods and Cylinders Components
376
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
376
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
378
Cylinders, Pistons and Piston Rings Inspection
379
Piston Pins and Connecting Rods Inspection
381
Crank Pin and Connecting Rod Bearings Inspection
382
Main Bearings, Crankshaft and Cylinder Block Components
386
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
387
Crankshaft Inspection
390
Main Bearings Inspection
391
Sensor Plate Inspection
395
Rear Oil Seal Inspection
395
Flywheel Inspection
396
Cylinder Block Inspection
396
Specifications
397
Tightening Torque Specifications
397
Special Tools and Equipment
398
Recommended Service Material
398
Special Tool
398
For J20 Engine
400
General Description
400
Engine Construction Description
400
Air Cleaner Element Introduction
402
IMT (Intake Manifold Tuning) System
402
Diagnostic Information and Procedures
404
Compression Check
404
Engine Vacuum Check
405
Valve Lash (Clearance) Inspection
406
Repair Instructions
409
Air Cleaner Assembly Removal and Installation
409
Air Cleaner Filter Removal and Installation
409
Air Cleaner Filter Inspection and Cleaning
409
Throttle Body and Intake Manifold Components
410
Throttle Body On-Vehicle Inspection
410
Electric Throttle Body Assembly Removal and Installation
410
Throttle Body Cleaning
411
Intake Manifold Removal and Installation
411
Cylinder Head Cover Removal and Installation
412
Engine Mountings Components
414
Engine Assembly Removal and Installation
415
Timing Chain Cover Components
418
Timing Chain Cover Removal and Installation
418
Timing Chain Cover Cleaning and Inspection
421
2Nd Timing Chain and Chain Tensioner Components
421
Tightening Torque
421
2Nd Timing Chain and Chain Tensioner Removal and Installation
422
2Nd Timing Chain and Chain Tensioner Inspection
424
1St Timing Chain and Chain Tensioner Components
425
Camshaft Sprocket
425
1St Timing Chain and Chain Tensioner Removal and Installation
426
1St Timing Chain and Chain Tensioner Inspection
428
Camshafts, Tappet and Shim Components
429
Camshafts, Tappet and Shim Removal and Installation
429
Camshaft, Tappet and Shim Inspection
431
Valves and Cylinder Head Components
433
Valves and Cylinder Head Removal and Installation
433
Valves and Cylinder Head Disassembly and Assembly
435
Valves and Valve Guides Inspection
438
Cylinder Head Inspection
440
Valve Spring Inspection
441
Pistons, Piston Rings, Connecting Rods and Cylinders Components
442
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
442
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
443
Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning
446
Main Bearings, Crankshaft and Cylinder Block Components
452
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
453
Main Bearings, Crankshaft and Cylinder Block Inspection
456
Specifications
463
Tightening Torque Specifications
463
Special Tools and Equipment
464
Recommended Service Material
464
Special Tool
464
Engine Lubrication System
467
For M16A Engine with VVT
467
General Description
467
Engine Lubrication Description
467
Diagnostic Information and Procedures
469
Oil Pressure Check
469
Repair Instructions
470
Oil Pan and Oil Pump Strainer Components
470
Oil Pan and Oil Pump Strainer Removal and Installation
471
Oil Pan and Oil Pump Strainer Cleaning
472
Oil Pump Components
473
Oil Pump Removal and Installation
473
Oil Pump Disassembly and Reassembly
473
Oil Pump Inspection
474
Specifications
476
Tightening Torque Specifications
476
Special Tools and Equipment
476
Recommended Service Material
476
Special Tool
476
For J20 Engine
477
General Description
477
Engine Lubrication Description
477
Diagnostic Information and Procedures
479
Oil Pressure Check
479
Repair Instructions
480
Oil Pan and Oil Pump Strainer Components
480
Oil Pan and Oil Pump Strainer Removal and Installation
481
Oil Pan and Oil Pump Strainer Cleaning
482
Oil Pump Components
482
Oil Pump Removal and Installation
483
Oil Pump Disassembly and Assembly
483
Oil Pump Inspection
484
Special Tools and Equipment
486
Recommended Service Material
486
Special Tool
486
Engine Cooling System
487
General Description
487
Cooling System Description
487
Coolant Description
487
Schematic and Routing Diagram
488
Coolant Circulation
488
Diagnostic Information and Procedures
489
Engine Cooling Symptom Diagnosis
489
Repair Instructions
490
Cooling System Components
490
Coolant Level Check
492
Engine Cooling System Inspection and Cleaning
492
Cooling System Draining
493
Cooling System Flush and Refill
493
Cooling Water Pipes or Hoses Removal and Installation
494
Thermostat Removal and Installation
494
Thermostat Removal and Installation
495
Thermostat Inspection
495
Radiator Cooling Fan Motor On-Vehicle
496
Inspection
496
Radiator Cooling Fan Relay Inspection
496
Radiator Cooling Fan Assembly Removal and Installation
497
Radiator On-Vehicle Inspection and Cleaning
497
Radiator Removal and Installation
498
Water Pump Removal and Installation
498
Water Pump Removal and Installation
499
Water Pump Inspection
500
Specifications
500
Tightening Torque Specifications
500
Special Tools and Equipment
500
Recommended Service Material
500
Fuel System
501
Precautions
501
Precautions on Fuel System Service
501
General Description
501
Fuel System Description
501
Fuel Delivery System Description
501
Fuel Pump Description
502
Schematic and Routing Diagram
502
Fuel Delivery System Diagram
502
Diagnostic Information and Procedures
503
Fuel Pressure Inspection
503
Fuel Cut Operation Inspection
504
Repair Instructions
505
Fuel System Components
505
Fuel Hose Disconnecting and Reconnecting
508
Fuel Pressure Relief Procedure
510
Fuel Leakage Check Procedure
510
Fuel Lines On-Vehicle Inspection
511
Fuel Pipe Removal and Installation
511
Fuel Injector Removal and Installation
512
Fuel Injector Inspection
513
Fuel Pressure Regulator Removal and Installation
515
Fuel Pressure Regulator Inspection
515
Fuel Filler Cap Inspection
516
Fuel Tank Inlet Valve Removal and Installation
516
Fuel Tank Inlet Valve Inspection
517
Fuel Tank Removal and Installation
517
Fuel Tank Inspection
519
Fuel Tank Purging Procedure
519
Fuel Pump On-Vehicle Inspection
519
Fuel Pump Assembly Removal and Installation
520
Main Fuel Level Sensor Removal and Installation
521
Fuel Pump Inspection
521
Sub Fuel Level Sensor Removal and Installation
521
Sub Fuel Level Sensor Inspection
522
Specifications
522
Tightening Torque Specifications
522
Special Tools and Equipment
523
Recommended Service Material
523
Special Tool
523
Ignition System
524
General Description
524
Ignition System Construction
524
Component Location
526
Ignition System Components Location
526
Diagnostic Information and Procedures
527
Ignition System Symptom Diagnosis
527
Reference Waveform of Ignition System
527
Ignition System Check
527
Ignition Spark Test
527
Repair Instructions
530
High-Tension Cord Inspection
530
Spark Plug Removal and Installation
530
Spark Plug Inspection
531
Ignition Coil Assembly (Including Ignitor) Removal and Installation
531
Ignition Coil Assembly (Including Ignitor) Inspection
532
Ignition Timing Inspection
532
Specifications
534
Tightening Torque Specifications
534
Special Tools and Equipment
534
Starting System
535
Precautions
535
Cranking System Note
535
General Description
535
Cranking Circuit Introduction
535
Starting Motor Circuit Description
535
Diagnostic Information and Procedures
536
Cranking System Symptom Diagnosis
536
Starting Motor Performance Test
537
Repair Instructions
539
Starting Motor Dismounting and Remounting
539
Starting Motor Components
540
Starting Motor Inspection
541
Specifications
544
Starting Motor Specifications
544
Tightening Torque Specifications
544
Special Tools and Equipment
544
Recommended Service Material
544
Charging System
545
General Description
545
Battery Description
545
Generator Description
546
Diagnostic Information and Procedures
547
Battery Inspection
547
Generator Symptom Diagnosis
548
Generator Test (Undercharged Battery Check)
548
Generator Test (Overcharged Battery Check)
549
Repair Instructions
550
Jump Starting in Case of Emergency
550
Battery Dismounting and Remounting
551
Water Pump and Generator Drive Belt Removal and Installation (for M16 Engine)
551
Water Pump and Generator Drive Belt Tension Inspection and Adjustment (for M16 Engine)
552
Water Pump and Generator Drive Belt On-Vehicle Inspection (for J20 Engine)
553
Water Pump and Generator Drive Belt Removal and Installation (for J20 Engine)
554
Generator Dismounting and Remounting
555
Generator Components
556
Generator Inspection
557
Specifications
560
Charging System Specifications
560
Tightening Torque Specifications
560
Exhaust System
561
General Description
561
Exhaust System Description
561
Diagnostic Information and Procedures
561
Exhaust System Check
561
Repair Instructions
561
Exhaust System Components
561
Exhaust Manifold Removal and Installation (for M16 Engine Model)
564
Exhaust Manifold Removal and Installation (for J20 Engine Model)
564
Exhaust Pipe and Muffler Removal and Installation
565
Specifications
566
Tightening Torque Specifications
566
Suspension
567
Precautions
569
Precautions on Suspension
569
Suspension General Diagnosis
570
Diagnostic Information and Procedures
570
Suspension, Wheels and Tires Symptom Diagnosis
570
Specifications
572
Wheel Alignment Specifications
572
Front Suspension
573
General Description
573
Front Suspension Construction
573
Front Wheel Alignment Construction
574
Repair Instructions
574
Front Wheel Alignment Inspection and Adjustment
574
Front Strut Assembly Components
576
Front Strut Assembly Removal and Installation
577
Front Strut Assembly Disassembly and Assembly
579
Front Strut Assembly Check
580
Front Wheel Hub Assembly and Steering Knuckle Components
581
Front Wheel Hub Assembly Removal and Installation
581
Steering Knuckle Removal and Installation
583
Front Wheel Hub, Disc, Nut and Bearing Check
584
Suspension Control Arm Removal and Installation
585
Suspension Control Arm / Bushing Disassembly and Assembly
587
Suspension Control Arm / Steering Knuckle Check
588
Suspension Control Arm Bushing Check
588
Suspension Control Arm Joint Check
588
Front Suspension Frame, Stabilizer Bar And/Or Bushings Components
589
Front Suspension Frame, Stabilizer Bar And/Or Bushings Removal and Installation
590
Front Suspension Frame Check
594
Front Stabilizer Bar, Bushing And/Or Joint Check
594
Special Tools and Equipment
596
Recommended Service Material
596
Special Tool
596
Rear Suspension
597
General Description
597
Rear Suspension Construction
597
Rear Wheel Alignment Construction
598
Repair Instructions
598
Rear Wheel Alignment Inspection and Adjustment
598
Rear Shock Absorber and Rear Coil Spring Components
600
Rear Shock Absorber Removal and Installation
601
Shock Absorber Check
602
Rear Coil Spring and Bump Stopper Removal and Installation
602
Rear Coil Spring Check
604
Rod and Arm Components
605
Control Rod Removal and Installation
606
Control Rod / Bushing Disassembly and Assembly
608
Control Rod Check
608
Trailing Rod Removal and Installation
609
Trailing Rod / Bushing Disassembly and Assembly
610
Trailing Rod Check
611
Lower Arm Removal and Installation
611
Lower Arm / Bushing Disassembly and Assembly
612
Lower Arm Check
613
Upper Arm Removal and Installation
613
Upper Arm / Bushing Disassembly and Assembly
615
Upper Arm Check
615
Rear Suspension Frame Components
616
Rear Suspension Frame Removal and Installation
617
Rear Suspension Frame / Bushing Disassembly and Assembly
619
Rear Suspension Frame, Bushing and Pad Check
620
Rear Wheel Hub Assembly and Rear Suspension Knuckle Components
620
Rear Wheel Hub Assembly Removal and Installation
621
Rear Wheel Hub Assembly, Wheel Bearing and Wheel Stud Inspection
623
Rear Wheel Disc, Nut and Bearing Check
623
Rear Suspension Knuckle Removal and Installation
624
Rear Suspension Knuckle Check
627
Rear Suspension Fasteners Check
627
Special Tools and Equipment
629
Recommended Service Material
629
Wheels and Tires
630
General Description
630
Tires Description
630
Wheels Description
631
Irregular And/Or Premature Wear Description
631
Wear Indicators Description
632
Radial Tire Waddle Description
632
Radial Tire Lead / Pull Description
633
Balancing Wheels Description
633
Repair Instructions
634
General Balance Procedures
634
Tire Rotation
634
Wheel Removal and Installation
635
Tire Mounting and Dismounting
635
Tire Repair
635
Specifications
636
Wheels and Tires Specifications
636
Tightening Torque Specifications
636
Driveline / Axle
637
Precautions
640
Precautions for Driveline / Axle
640
Drive Shaft / Axle
641
Front
641
General Description
641
Front Drive Shaft Construction
641
Diagnostic Information and Procedures
641
Front Drive Shaft Symptom Diagnosis
641
Repair Instructions
642
Front Drive Shaft Boot and Joint Check
642
Front Drive Shaft Components
642
Front Drive Shaft Assembly Removal and Installation
643
Front Drive Shaft Disassembly and Assembly
643
Specifications
646
Tightening Torque Specifications
646
Special Tools and Equipment
646
Recommended Service Material
646
Special Tool
646
Rear
647
General Description
647
Rear Drive Shaft Construction
647
Repair Instructions
647
Rear Drive Shaft Components
647
Rear Drive Shaft Assembly Removal and Installation
648
Rear Drive Shaft Disassembly and Assembly
648
Specifications
649
Tightening Torque Specifications
649
Special Tools and Equipment
649
Recommended Service Material
649
Special Tool
649
Differential
650
Front
650
General Description
650
Front Differential Construction
650
Diagnostic Information and Procedures
650
Front Differential Symptom Diagnosis
650
Repair Instructions
651

Suzuki GRAND VITARA JB420 - SUPLEMENTARY SERVICE Service Manual (475 pages)

Brand: Suzuki | Category: Automobile | Size: 13.16 MB

Warning/Caution/Note
1
Recommendaton of Genuine Suzuki Parts and Accessories Use
4
Non-Genuine SUZUKI Parts and Accessories
4
Re-Use of Genuine SUZUKI Parts and Accessories
4
Table of Contents
5
Precautions
7
Brakes Caution and Note
8
ESP Control Module
8
General Information
9
Abbreviations
10
General Description
10
Engine
13
Precautions in Diagnosing Trouble
19
Engine General Information and Diagnosis
19
Vehicle Equipped with Diagnosis Connector
20
On-Board Diagnostic System Description
20
2 Driving Cycle Detection Logic
21
Driving Cycle
21
Pending DTC
21
Warm-Up Cycle
21
Freeze Frame Data
22
Priority of Freeze Frame Data
22
Engine and Emission Control System Description
23
CAN Communication System Description
23
Data Link Connector (DLC)
23
ECM Transmission Data
24
ECM Reception Data
25
Electronic Control System Description
25
Engine and Emission Control System Flow Diagram
26
ECM Input / Output Circuit Diagram
27
For J20 Engine
27
For M16 Engine
29
Terminal Arrangement of ECM Coupler (Viewed from Harness Side)
30
Connector: C37
30
Connector: E23
31
Engine and Emission Control Input / Output Table
33
Engine and Emission Control System Diagram
34
Schematic and Routing Diagram
34
Component Location
35
Electronic Control System Components Location
35
Diagnostic Information and Procedures
37
DTC Table
37
Wiring Diagram
43
Malfunction Indicator Lamp Does Not Come on
43
Circuit Description
43
Troubleshooting
44
CAN Communication Line Circuit Check
45
DTC Check
45
Malfunction Indicator Lamp Remains on after Engine Starts
45
DTC Confirmation Procedure
46
DTC Detecting Condition and Trouble Area
46
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction
46
DTC P1603: TCM Trouble Code Detected (for J20 Engine)
47
DTC Troubleshooting
47
DTC Detecting Condition
48
DTC P1674: CAN Communication (Bus off Error)
49
CAN Communication Circuit Check
53
DTC P1676: CAN Communication (Reception Error for TCM (for A/T Model))
53
Check CAN Communication Error for ECM
54
DTC Check in TCM (for A/T Model)
54
ECM Power and Ground Circuit Check
54
DTC Check in ECM
55
DTC P1678: CAN Communication (Reception Error for BCM)
56
DTC P1685: CAN Communication
60
Voltage Check
64
Viewed from Harness Side
64
Inspection of ECM and Its Circuits
64
EGR Valve Signal
75
Reference Waveform No.1
75
Reference Waveform No.2
75
Reference Waveform No.3
75
Generator Field Coil Monitor Signal (1) at Engine Idling
76
Heated Oxygen Sensor-2 Signal (1) with Engine Idling
76
No.4 Fuel Injector Signal with Engine Idling
77
No.3 Fuel Injector Signal with Engine Idling
77
EVAP Canister Purge Valve Signal
77
Ignition Coil Signal with Engine Idling
78
A/F Sensor Signal with Engine Idling
80
Mass Air Flow Sensor Signal with Engine Racing
80
CMP Sensor Signal with Engine Idling
81
Throttle Actuator Output Signal with Ignition Switch Turned on
82
Knock Sensor Signal at Engine Speed 4000 R/Min.
83
Manifold Absolute Pressure Sensor Signal with Engine Racing
83
Oil Control Valve Signal with Engine Idling
83
Oil Control Valve Signal with Engine Racing
84
CAN Communication Line Signal with Ignition Switch Turned on
84
Ignition Coil Signal and Fuel Injector Signal with Engine Cranking
84
Resistance Check
85
A/C System Circuits Check
86
A/C Switch Signal Circuit Check
87
DTC Check of ECT Sensor Circuit
87
DTC Check of HVAC Control Module
87
Reception Data Check from BCM
87
A/C Compressor Control System Check
88
A/C Compressor Relay Check
88
A/C Compressor Relay Circuit Check
88
Electric Load Signal Circuit Check
89
Special Tools and Equipment
90
Suspension
91
Table of Contents
92
Front Suspension
93
Front Suspension Construction
93
Front Wheel Alignment Construction
94
Front Wheel Alignment Inspection and Adjustment
94
Preliminary Checks Prior to Adjustment Front Wheel Alignment
94
Repair Instructions
94
Steering Angle Check and Adjustment
95
Reference Information
95
Side Slip
95
Front Strut Assembly Components
96
Front Strut Assembly Removal and Installation
97
Front Strut Assembly Disassembly and Assembly
99
Front Strut Assembly Check
100
Front Wheel Hub Assembly and Steering Knuckle Components
101
Front Wheel Hub Assembly Removal and Installation
101
Steering Knuckle Removal and Installation
103
Suspension Control Arm Removal and Installation
105
Front Wheel Hub, Disc, Nut and Bearing Check
105
Suspension Control Arm / Bushing Disassembly and Assembly
106
Front Suspension Frame, Stabilizer Bar And/Or Bushings Components
107
Suspension Control Arm Joint Check
107
Front Stabilizer Bar, Bushing And/Or Joint Check
112
Front Suspension Frame Check
112
Stabilizer Bushing
112
Front Suspension Fasteners Check
113
Specifications
113
Tightening Torque Specifications
113
Recommended Service Material
114
Driveline / Axle
115
Motor-Shift Type (Transfer with Shift Actuator)
118
Transfer
118
Transfer Warning
118
Transfer Description
119
Transfer Shift Control System Components
120
4WD Control System Description
121
Relationship of Transfer Shift Position and Switches
121
Retry Control
121
Function of 4WD Control System Component
123
4WD Control System Operation
123
4WD Control System Wiring Circuit Diagram
128
4WD Control System Check
131
CAN Communication System Description
131
Diagnostic Information and Procedures
131
Terminal Arrangement of 4WD Control Module
129
Input / Output Signal Table of 4WD Control Module
129
On-Board Diagnostic System Description
130
4WD Control System Operation Inspection
134
Transfer Position Indicator Operation Check
134
DTC Check
136
DTC Clearance
137
DTC Table
137
Fail-Safe Table
138
Scan Tool Data
139
4WD Control Symptom Diagnosis
140
DTC C1213: Transfer Switch Circuit Open
145
DTC U1100: Lost Communication with ECM
167
Transfer Oil Level Check
172
Transfer Oil Change
172
Repair Instructions
172
Transfer Oil Seal Removal and Installation
173
Transfer Switch Inspection
174
Transfer Switch Removal and Installation
174
4WD Control Module Removal and Installation
174
Transfer Assembly Dismounting and Remounting
175
Installation
175
Transfer Assembly Components
176
Transfer Assembly Disassembly and Reassembly
177
Transfer Assembly Inspection
185
Input Gear Assembly Disassembly and Reassembly
187
Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly and Rear Output Shaft Assembly Components
187
Counter Gear Assembly Disassembly and Reassembly
188
Front Output Shaft Assembly Disassembly and Reassembly
189
Rear Output Shaft Assembly Disassembly and Reassembly
190
DTC U1101: Lost Communication with TCM
168
DTC U1121: Lost Communication with ABS / Electronic Stability Program Hydraulic Unit / Control Module
169
Inspection of 4WD Control Module and Its Circuits
170
DTC C1214: Transfer Switch Circuit Short
146
DTC C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open
148
DTC C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short
150
DTC C1227: 4L/N Switch Circuit Open
152
DTC C1228: 4L/N Switch Circuit Short
153
DTC C1230: Transfer Actuator Circuit Malfunction
155
DTC C1237: Center Differential Lock Switch Circuit Open
157
DTC C1238: Center Differential Lock Switch Circuit Short
159
DTC C1240: 4WD Control Module Power Supply Circuit Malfunction
161
DTC C1243: Internal Circuit Malfunction of 4WD Control Module
162
DTC C1246: Clutch Pedal Position (CPP) Switch Circuit Short
162
Transfer Position Indicator Does Not Come on at Ignition Switch on but Engine Stops
142
Visual Inspection
135

Suzuki GRAND VITARA JB420 - SUPLEMENTARY SERVICE Manual (35 pages)

Brand: Suzuki | Category: Automobile | Size: 0.49 MB

Precautions

3
Section 0 General Information

21
- General Information
  
  23
- General Description
  
  23
  - Abbreviations
    23
  - Symbols
    24
  - Wire Color Symbols
    25
  - Fastener Information
    25
  - Vehicle Lifting Points
    28
  - Engine Supporting Points
    30
  - Vehicle Identification Number
    30
  - Engine Identification Number
    31
  - Transmission Identification Number
    31
- Component Location
  
  32
  - Warning, Caution and Information Label Location
    32
- Maintenance and Lubrication
  
  34
- Precautions
  
  34
  - Precautions for Maintenance and Lubrication
    34
- Scheduled Maintenance
  
  34

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Suzuki GRAND VITARA JB420 - SUPLEMENTARY SERVICE Service Manual (475 pages)

Table of Contents

Suzuki GRAND VITARA JB420 - SUPLEMENTARY SERVICE Manual (35 pages)

Table of Contents

Precautions

Precautions

Repair Instructions

Section 0 General Information

General Information

General Description

Component Location

Maintenance and Lubrication

Precautions

Scheduled Maintenance

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