Suzuki XL7 2007 Service Manual page 104

1- viii Table of Contents
DTC P0615 ....................................................... 1I–10
DTC P0616 ....................................................... 1I–12
DTC P0617 ....................................................... 1I–13
Symptoms - Engine Electrical ........................... 1I–14
Starter Solenoid Does Not Click........................ 1I–14
Starter Solenoid Clicks,
Engine Does Not Crank .................................. 1I–16
Engine Cranks Slowly ....................................... 1I–16
Starter Motor Noise Diagnosis .......................... 1I–17
Repair Instructions ............................................ 1I–18
Starter Motor Replacement ............................... 1I–18
Starter Removal ................................................ 1I–19
Starter Installation ............................................. 1I–20
Specifications..................................................... 1I–21
Fastener Tightening Specifications -
Engine Mechanical - 3.6L (LY7)...................... 1I–21
Fastener Tightening Specifications -
Engine Electrical ............................................. 1I–21
Special Tools and Equipment ........................... 1I–21
Special Tools - Engine Electrical....................... 1I–21
Charging System..................................... 1J–1
Precautions.......................................................... 1J–1
Battery Disconnect Caution................................. 1J–1
Batteries Produce Explosive Gases Caution ...... 1J–1
General Description ............................................ 1J–2
Battery Description and Operation ...................... 1J–2
Charging System Description and Operation...... 1J–3
Electrical Power Management Description and
Operation .......................................................... 1J–6
Schematic and Routing Diagram....................... 1J–6
Starting and Charging Schematics...................... 1J–6
Engine Electrical Connector End Views.............. 1J–9
Component Location ........................................ 1J–10
Engine Electrical Component Views ................. 1J–10
Diagnostic Information and Procedures ......... 1J–13
Diagnostic Starting Point - Engine Electrical..... 1J–13
Scan Tool Output Controls - Engine Electrical.. 1J–13
Scan Tool Data List - Engine Electrical............. 1J–13
Scan Tool Data Definitions - Engine Electrical.. 1J–15
DTC B1325 ....................................................... 1J–15
DTC B1405 ....................................................... 1J–17
DTC B1424 ....................................................... 1J–18
DTC B1516 ....................................................... 1J–19
DTC B1517 ....................................................... 1J–20
DTC B1527 ....................................................... 1J–22
DTC P0621 ....................................................... 1J–22
DTC P0622 ....................................................... 1J–23
DTC P0625 ....................................................... 1J–24
DTC P0626 ....................................................... 1J–26
DTC C0899 ....................................................... 1J–27
DTC C0900 ....................................................... 1J–27
Symptoms - Engine Electrical ........................... 1J–28
Charging System Test....................................... 1J–29
Battery Charging ............................................... 1J–32
Battery Common Causes of Failure .................. 1J–33
Jump Starting in Case of Emergency................ 1J–34
Charge Indicator Always On ............................. 1J–35
Charge Indicator Inoperative............................. 1J–36
Generator Noise Diagnosis ............................... 1J–36
Engine Cranks Slowly ....................................... 1J–38
Battery Inspection/Test ..................................... 1J–38
Battery Electrical Drain/Parasitic Load Test ...... 1J–41
Repair Instructions............................................ 1J–43
Battery Negative Cable Disconnection and
Connection ...................................................... 1J–43
Battery Current Sensor Replacement ............... 1J–45
Battery Negative Cable Replacement ............... 1J–46
Battery Positive Cable Replacement................. 1J–48
Battery Replacement......................................... 1J–50
Battery Tray Replacement ................................ 1J–52
Battery Box Replacement ................................. 1J–52
Generator Replacement .................................... 1J–54
Specifications .................................................... 1J–55
Fastener Tightening Specifications -
Engine Electrical ............................................. 1J–55
Battery Usage ................................................... 1J–56
Generator Usage............................................... 1J–56
Special Tools and Equipment .......................... 1J–56
Special Tools - Engine Electrical....................... 1J–56
Exhaust System...................................... 1K–1
Precautions.......................................................... 1K–1
Exhaust Service Caution .................................... 1K–1
Hot Exhaust System Caution ............................. 1K–1
Three-Way Catalytic Converter
Damage Notice ................................................ 1K–1
General Description ............................................ 1K–2
Exhaust System Description .............................. 1K–2
Diagnostic Information and Procedures ........... 1K–3
Diagnostic Starting Point - Engine Exhaust ....... 1K–3
Symptoms - Engine Exhaust .............................. 1K–3
Restricted Exhaust ............................................. 1K–4
Exhaust Leakage ............................................... 1K–6
Exhaust Noise .................................................... 1K–6
Repair Instructions.............................................. 1K–7
Exhaust Manifold Replacement - Left Side ........ 1K–7
Exhaust Manifold Replacement - Right Side...... 1K–8
Exhaust Flexible Pipe Replacement .................. 1K–9
Catalytic Converter Replacement - Left Side ... 1K–11
Catalytic Converter Replacement - Right Side. 1K–13
Muffler Replacement ........................................ 1K–15
Catalytic Converter Heat Shield Replacement . 1K–16
Exhaust Heat Shield Replacement -
Dash Panel..................................................... 1K–17
Exhaust Manifold Heat Shield Replacement .... 1K–18
Exhaust Manifold Heat Shield Replacement -
Right Side....................................................... 1K–19
Exhaust Manifold Heat Shield Replacement -
Left Side ......................................................... 1K–20
Exhaust Manifold Removal - Left Side ............. 1K–21
Exhaust Manifold Removal - Right Side........... 1K–22
Exhaust Manifold Cleaning and Inspection -
Left Side ......................................................... 1K–25
Exhaust Manifold Cleaning and Inspection -
Right Side....................................................... 1K–26
Exhaust Manifold Installation - Left Side .......... 1K–27
Exhaust Manifold Installation - Right Side........ 1K–28