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GRAND VITARA -
SUZUKI GRAND VITARA - Manuals
Manuals and User Guides for SUZUKI GRAND VITARA -. We have
9
SUZUKI GRAND VITARA - manuals available for free PDF download: Owner's Manual, Service Manual, Supplementary Service Manual, Manual, Brochure
Suzuki GRAND VITARA - Owner's Manual (1736 pages)
GRAND VITARA
Brand:
Suzuki
| Category:
Automobile
| Size: 68.83 MB
Table of Contents
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
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SUZUKI GRAND VITARA - Service Manual (836 pages)
Brand:
SUZUKI
| Category:
Automobile
| Size: 29.07 MB
Table of Contents
Table of Contents
3
General Information
5
Abbreviations Used in this Manual
7
General Precautions
9
Body Number
12
Engine Identification Number
12
Transmission Identification Number
12
Identification Information
12
Metric Fasteners Fastener Strength Identification
13
Metric Information
13
Standard Tightening Torque
14
Vehicle Lifting Points
15
Front Support Location
16
Rear Support Location
16
Maintenance and Lubrication
17
Maintenance Schedule under Normal Driving Conditions
18
Maintenance Recommended under Severe Driving Conditions
20
Maintenance Service
24
Water Pump Belt Inspection and Replacement
24
A/C Compressor And/Or Power Steering Pump Drive Belt
25
Camshaft Timing Belt Inspection
25
Engine Oil and Filter Change
26
Engine Bolts Tightening
26
Valve Lash Inspection
26
Cooling System Hoses and Connections Inspection
28
Engine Coolant Change
28
Engine Oil Capacity
28
Ignition System
29
Exhaust Pipes and Mountings Inspection
29
Ignition Wiring Replacement
29
Distributor Cap and Rotor Inspection
30
Spark Plugs Replacement
30
Plug Specification
30
Fuel System
31
Ignition Timing Inspection
31
Distributor Advancer Inspection
31
Air Cleaner Element Replacement and Inspection
31
Emission Control System
32
Carburetor Choke System Lubrication and Inspection
32
Engine Idle Speed and Idle Mixture Inspection
32
Oxygen Sensor Replacement
32
Electrical
33
Crankcase Ventilation Hoses and Connections Inspection
33
PCV (Positive Crankcase Ventilation) Valve Inspection
33
Fuel Vapor Storage System Inspection
33
Chassis and Body
34
Clutch Pedal Inspection
34
Brake Discs, Pads, Brake Drums and Shoes Inspection
34
Brake Hoses and Pipes Inspection
34
Brake Lever and Cable Inspection
35
Tire Inspection and Rotation
35
Wheel Discs and Free Wheeling Hubs Inspection
35
Wheel Bearing Inspection
35
Suspension Inspection
36
Propeller Shafts Inspection
37
Transmission Oil Inspection and Change
37
Fluid Level Inspection
38
Transfer and Differential Oil Inspection and Change
38
Steering System Inspection
38
Final Inspection
39
Power Steering System Inspection
39
Door Hinges Lubrication
39
Recommended Fluids and Lubricants
41
Heater and Ventilation
42
Heater General Description
43
Heater Control Operation
44
Forced Ventilation
44
Outside Air-Introduced Heating
45
Inside Air-Circulated Heating
45
Head-Cooled/Feet-Warmed Heating
45
Trouble Diagnosis
46
Servicing
46
Wiring Circuit
46
Heater Blower Motor Removal
47
Heater Blower Motor Installation
47
Heater Blower Resistor Removal
47
Heater Blower Resistor Inspection
47
Heater Blower Resistor Installation
48
Heater Blower Motor Switch Removal and Inspection
48
Heater Blower Motor Switch Installation
48
Control Cables
48
Air Control Cable Adjustment
49
Heater Control Cable Adjustment
49
Fresh Air Control Cable Adjustment
49
Heater Unit
50
Body Ventilation
51
Heater Unit Removal
51
Heater Unit Installation
51
Rear Duct Description
52
Rear Duct Removal
52
Rear Duct Installation
52
Bumpers and Sheet Metal
53
Front Bumper
53
Rear Bumper
54
Hood Adjustment
54
Hood Vertical Adjustment
55
Hood Lock Adjustment
55
Front Fender Removal
55
Front Fender Installation
55
Steering, Suspension, Wheels and Tires General Diagnosis
56
Tire Diagnosis
61
Irregular And/Or Premature Wear
61
Wear Indicator
61
Radial Tire Waddle
61
Vibration Diagnosis
63
Radial Tire Lead
63
Front End Alignment General Information
64
Toe Setting
64
Camber
65
Preliminary Checks Prior to Adjusting Front Alignment
65
Toe Adjustment
65
Camber and Caster Adjustment
65
Steering Angle
66
Steering Gear Box and Linkage
67
Steering Gear Box and Linkage General Description
68
Steering Gear Box Construction and Operation
69
Steering Gear Box Removal
70
Steering Gear Box Installation
70
Tie Rod End Removal
71
Tie Rod End Installation
71
Idler Arm Removal
72
Idler Arm Installation
72
Steering Wheel Inspection
73
Steering Gear Box Oil Level
73
Adjustment of Worm Shaft Starting Torque
74
Torque Specifications
76
Special Tools
76
Power Steering (P/S) System
77
Power Steering (P/S) System General Description
78
Power Steering System Layout
78
Hydraulic Pressure Circuit
78
Operation with Steering Wheel in Straight-Ahead Position
79
Operation with Steering Wheel Turned to Right
79
Valve Unit
80
Operation with Steering Wheel Turned to Left
80
Manual Steering
80
Spring Reaction Mechanism
80
Power Steering (P/S) Pump
81
Flow Contol Valve
81
Components of P/S Pump
81
Operation of Flow Control Valve (When Idling)
81
Relief Valve
82
Operation of Flow Control Valve (When Running at Low Speed)
82
Operation of Flow Control Valve (When Running at High Speed)
82
Power Steering System General Diagnosis
83
On Vehicle Service
85
Steering Wheel Play Inspection
85
Steering Force Inspection
85
Power Steering Belt Tension
86
Power Steering Belt Tension Adjustment
86
Power Steering Fluid Level
86
Idle up System
86
Air Bleeding Procedure
87
Hydraulic Pressure in P/S Circuit
87
Power Steering (P/S) Gear Box Removal
89
Power Steering (P/S) Gear Box Installation
90
Removing Steering Lower Shaft
91
Removing Center Link End
91
Removing Steering Gear Box
91
Installing Steering Gear Box
91
Power Steering (P/S) Pump Removal
92
Installing Steering Lower Shaft
92
Power Steering (P/S) Pump Installation
93
Power Steering (P/S) Pump Disassembly
94
Removing P/S Pump Pulley
94
Removing Terminal Assembly and Discharge Connector
95
Removing P/S Pump Cover
95
Removing Cam Ring
95
Removing Rotor
95
Power Steering Pump Assembly
96
Installing Shaft
96
Installing Rotor
96
Installing Vane
96
Installing Cover
97
Installing Flow Control Valve
97
Installing Terminal
97
Installing Suction Connector
97
P/S Pump Body and Shaft Inspection
98
Cam Ring Inspection
98
Rotor Vane Inspection
98
Flow Control Valve Inspection
98
Steering Wheel, Column and Shaft Description
100
Steering Wheel Removal
102
Steering Wheel Installation
102
Turn Signal/Dimmer Switch Removal
103
Turn Signal/Dimmer Switch Installation
103
Steering Column Removal
103
Steering Column Installation
104
Steering Lock Removal
104
Steering Lock Installation
105
Steering Lower Shaft Removal
105
Steering Lower Shaft Installation
105
Checking Steering Column for Accident Damage
106
Checking Tilt Steering Column Torque Specifications
107
Checking Tilt Steering Column Special Tool
107
Front Suspension
108
Front Suspension General Description
109
Stabilizer Bar/Bushings Removal
110
Stabilizer Bar/Bushings Installation
110
Strut Damper Removal
111
Strut Damper Installation
111
Coil Spring/Bump Stopper/Spring Rubber Seat Removal
112
Coil Spring/Bump Stopper/Spring Rubber Seat Installation
113
Bump Stopper/Spring Rubber Seat Removal
114
Bump Stopper/Spring Rubber Seat Installation
114
Wheel Hub/Bearing/Oil Seal Removal
114
Wheel Hub/Bearing/Oil Seal Installation
115
Knuckle/Wheel Spindle Removal
117
Knuckle/Wheel Spindle Installation
118
Suspension Control Arm/Ball Stud/Bushings Removal
119
Suspension Control Arm/Ball Stud/Bushings Installation
120
Front Free Wheeling Hub (Optional) General Description
121
Manual Free Wheeling Hub Operation
121
Manual Free Wheeling Hub Installation Instruction
122
Manual Free Wheeling Hub Maintenance Service
123
Automatic Free Wheeling Hub Operation
124
Automatic Free Wheeling Hub Installation Instruction
125
Automatic Free Wheeling Hub Maintenance Service
126
Post-Assembly Confirmation
126
Front Suspension Inspection
127
Bar
127
Bushing
127
Strut Damper And/Or Coil Spring
127
Required Service Materials
129
Front Suspension Special Tools
130
Rear Suspension
131
Rear Suspension General Description
132
Rear Shock Absorber Removal
133
Rear Shock Absorber Installation
133
Coil Spring Removal
134
Coil Spring Installation
134
Trailing Rod and Bush Removal
135
Trailing Rod and Bush Installation
136
Rear Upper Arm Removal
137
Rear Upper Arm Installation
139
Rear Axle Shaft and Wheel Bearing Removal
141
Rear Axle Shaft and Wheel Bearing Installation
142
Rear Axle Shaft Inner Oil Seal Removal
144
Rear Axle Shaft Inner Oil Seal Installation
144
Rear Axle Housing Removal
145
Rear Axle Housing Installation
147
Rear Suspension Inspection
151
Trailing Rod, Upper Arm, Axle Housing and Coil Spring
151
Rear Suspension Fasteners
151
Upper Arm Ball Joint
151
Bearing Retainer and Axle Shaft Inner Oil Seal
152
Trailing Rod and Upper Arm Bush
152
Wheel Disc, Nut & Bearing
152
Recommended Torque Specifications
153
Wheels and Tires General Description
155
Replacement Tires
155
Wheels for Replacement
156
Wheel Maintenance
156
Wheel Attaching Studs
156
Inflation of Tires
156
Wheels and Tires Service Operations
157
Metric Lug Nuts and Wheel Studs
157
Tire Placard
157
Tire Rotation
157
Balancing Wheels
158
Tire Mounting and Demounting
158
Tire Repair
158
Wheels and Tires Torque Specifications
159
General Balance Procedure
159
Off-Vehicle Balancing
159
On-Vehicle Balancing
159
Front Drive Axle/Axle Bearing, Oil Seal
160
Drive Axle General Description
160
Drive Axle Removal
161
Drive Axle Disassembly
161
Suzuki GRAND VITARA - Supplementary Service Manual (481 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 29.81 MB
Table of Contents
Table of Contents
3
Abbreviations
4
Front Suspension
5
Free Wheel Device
6
Manual Free Wheel Performance
6
Automatic Free Wheel Performance
6
Free Wheel Types Description
7
Installation of "A" Type Manual Free Wheel
9
Installation of "B" Type Manual Free Wheel
11
Installation of "A" Type Automatic Free Wheel
13
Free Wheel Performance Checking
14
Installation of "B" Type Automatic Free Wheel
15
Replacement of "A" Type Manual Free Wheel
17
Replacement of "B" Type Manual Free Wheel
18
Replacement of "A" Type Automatic Free Wheel
19
Replacement of "B" Type Automatic Free Wheel
20
Front Suspension - Specified Torques
21
Front Suspension - Tools Needed
21
Electronic Fuel Injection System (Sequential Multiport Fuel Injection)
23
Electronic Fuel Injection System - General Description
25
Electronic Fuel Injection System Diagram
26
Electronic Control System
28
Engine Control Module (ECM)
32
On-Board Diagnostic System (Self-Diagnosis Function)
32
Fail-Safe Function
33
Throttle Position Sensor (TP Sensor)
34
Engine Coolant Temperature Sensor (ECT Sensor)
34
Exhaust Gas Recirculation (EGR) System (for Vehicle with EGR Stepper Motor)
35
Exhaust Gas Recirculation (EGR) System (for Vehicle with EGR Valve, Pressure Transducer and Solenoid Vacuum Valve)
36
Diagnosis
37
Diagnosis Flow Chart
38
Diagnostic Trouble Code Table (1 of 2 T/T/ and A/T)
39
A-1 ECM Power and Ground Circuit Check (Vehicle with Immobilizer)
41
A-1 ECM Power and Ground Circuit Check (Vehicle Without Immobilizer)
43
A-2 Malfunction Indicator Lamp ("Check Engine" Light) Circuit Check
44
A-3 Malfunction Indicator Lamp ("Check Engine" Light) Circuit Check
45
Code No. 13 Heated Oxygen Sensor Circuit (Signal Voltage Doesn't Change)
46
Code no 14 ECT Sensor (Engine Coolant Temp. Sensor) Circuit (Low Temperature Indicated, Signal Voltage High)
47
Code no 15 ECT Sensor (Engine Coolant Temp. Sensor) Circuit (High Temperature Indicated, Signal Voltage Low)
48
Code no 21 TP Sensor (Throttle Position Sensor) Circuit (Signal Voltage High)
49
Code no 22 TP Sensor (Throttle Position Sensor) Circuit (Signal Voltage Low)
50
Code No. 24 VSS (Vehicle Speed Sensor) Circuit
51
Code No. 33 MAF Sensor (Mass Air Flow Sensor) Circuit
52
Code No. 34 MAF Sensor (Mass Air Flow Sensor) Circuit
53
Code No. 42 CMP Sensor (Camshaft Position Sensor) Circuit
54
Code No. 44 CTP Switch Circuit
55
Code No. 45 CTP Switch Circuit
56
Code no 51 EGR Valve (Stepper Motor or Its Circuit Open or Short)
57
B-1 Fuel Pump Circuit Check
58
B-1 Fuel Injector Circuit Check
59
B-3 Fuel Pressure Check
61
B-4 Idle Air Control System Check
63
B-5 EGR System Check (Vehicle with EGR Stepper Motor)
65
B-5 EGR System Check (Vehicle with EGR Solenoid Vacuum Valve)
66
B-6 Evaporative Emission Control System Check
67
Inspection of ECM and Its Circuits
68
M/T Vehicle
69
A/T Vehicle
71
Terminal Arrangement of ECM Coupler (Viewed from Harness Side)
74
On Vehicle Service
77
Electronic Control System Service
77
Mass Air Flow Sensor (MAF Sensor) Inspection
77
Automatic Transmission
79
Electronic Shift Control System Chart
80
Powertrain (Engine) Control Module (PCM/ECM)
80
Throttle Positon Sensor
81
Vehicle Speed Sensor
81
Transmission Range Switch
81
Brake Switch
82
Engine Coolant Temperature Sensor (ECT Sensor) Usage
82
O/D Cut Switch
82
Transfer 4L Switch
82
Mode Selector Switch
83
Fail Safe Function
83
Change Mechanism
83
Automatic Gear Shift Diagram
84
Power Mode
84
Gear Shift Diagram
84
TCC Lock-Up Diagram
84
Normal Mode
85
Transmission Unit Diagnosis
86
Manual Road Test
86
Electronic Shift Control System
87
Precaution in Identifying Diag. Trouble Code
87
Electronic Shift Control System - Diagnostic Flow Chart
88
Diagnostic Trouble Code Table (A/T Related Code)
89
Fail-Safe Table
89
Diagnostic Flow Chart a
90
Diagnostic Flow Chart B
91
Diagnostic Flow Chart C
92
Diagnostic Flow Chart D
94
Group 2 - Supplementary Service Manual
95
Heater and Ventilation
99
Heater and Ventilation - Diagram and General Description
100
Heater Control Operation
101
Mode Control Switch
101
Control Lever a
101
Control Lever B, C
101
A. Forced Ventilation
102
B. Outside Air-Introduced Heating
102
C. Inside Air-Circulated Heating
102
D. Head-Cooled/Feet-Warmed Heating
103
Trouble Diagnosis (Heater and Ventilation)
103
Heater and Ventilation - Wiring Circuit
104
Heater and Ventilation - On-Vehicle Service
105
Mode Control Switch Removal
105
Mode Control Switch Inspection
105
Mode Control Switch Installation
105
Mode Actuator Removal
106
Mode Actuator Inspection
106
Mode Actuator Installation
107
Heater Control Lever Assembly Removal
107
Inspection of Heater Blower Motor Switch
108
Heater Control Lever Assembly Installation
108
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Suzuki GRAND VITARA - Service Manual (518 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 14.65 MB
Table of Contents
Table of Contents
1
Precautions
7
Precautions for Engine
7
Engine General Information and Diagnosis
8
Precautions
8
Precautions on Engine Service
8
Precautions in Diagnosing Trouble
8
Precautions for DTC Troubleshooting
9
Precautions of ECM Circuit Inspection
9
Precautions of Electric Throttle Body System Calibration
9
General Description
9
Statement on Cleanliness and Care
9
Engine Diagnosis General Description
10
On-Board Diagnostic System Description
10
Engine and Emission Control System Description
13
CAN Communication System Description
13
Air Intake System Description
16
Description of Electric Throttle Body System
17
Description of Electric Throttle Body System Calibration
18
Generator Control System Description
18
A/F Sensor Description
19
Electronic Control System Description
20
Engine and Emission Control Input / Output Table
28
Schematic and Routing Diagram
29
Engine and Emission Control System Diagram
29
Component Location
30
Electronic Control System Components Location
30
Diagnostic Information and Procedures
32
Engine and Emission Control System Check
32
Malfunction Indicator Lamp (MIL) Check
35
DTC Check
35
DTC Clearance
36
DTC Table
37
P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder
37
Fail-Safe Table
43
Scan Tool Data
44
Visual Inspection
50
Engine Basic Inspection
51
Engine Symptom Diagnosis
55
Malfunction Indicator Lamp Does Not Come on with Ignition Switch on and Engine Stop (but Engine Can be Started)
64
Malfunction Indicator Lamp Remains on after Engine Starts
66
DTC P0010: Camshaft Position Actuator Circuit (for M16 Engine)
67
DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (for M16 Engine)
69
DTC P0030: HO2S Heater Control Circuit (Sensor-1)
71
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)
72
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)
76
DTC P0101: Mass Air Flow Circuit Range / Performance
79
DTC P0102: Mass Air Flow Circuit Low Input
82
DTC P0103: Mass Air Flow Circuit High Input
84
DTC P0106: Manifold Absolute Pressure Range / Performance
86
DTC P0107: Manifold Absolute Pressure Circuit Low Input
87
DTC P0108: Manifold Absolute Pressure Circuit High Input
89
DTC P0111: Intake Air Temperature Circuit Range / Performance
91
DTC P0112: Intake Air Temperature Sensor Circuit Low
94
DTC P0113: Intake Air Temperature Sensor Circuit High
96
DTC P0116: Engine Coolant Temperature Circuit Range / Performance
98
DTC P0117: Engine Coolant Temperature Circuit Low
101
DTC P0118: Engine Coolant Temperature Circuit High
102
DTC P0122: Throttle Position Sensor (Main) Circuit Low
105
DTC P0123: Throttle Position Sensor (Main) Circuit High
108
DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / no Activity Detected (Sensor-1)
111
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)
112
Suzuki GRAND VITARA - Service Manual (835 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 29.08 MB
Suzuki GRAND VITARA - Manual (184 pages)
Transmission / Transaxle
Brand:
Suzuki
| Category:
Automobile
| Size: 5.65 MB
Table of Contents
Table of Contents
1
Precautions
4
Precautions for Transmission / Transaxle
4
Automatic Transmission/Transaxle
5
Precautions
5
Precautions in Diagnosing Trouble
5
General Service Procedure Information
5
Precautions for Disassembly and Reassembly
5
General Description
7
Automatic Transmission Description
7
Clutch / Brake Functions of Automatic Transmission
9
Table of A/T System Component Operation
10
CAN Communication System Description
11
Electronic Shift Control Input / Output Table
12
Brake Interlock System Description
15
A/T Diagnosis General Description
15
On-Board Diagnostic System Description
15
Schematic and Routing Diagram
17
Automatic Gear Shift Table
17
Bearing and Race Installation Diagram
20
Component Location
21
Electronic Shift Control System Components Location
21
Diagnostic Information and Procedures
22
A/T System Check
22
Malfunction Indicator Lamp (MIL) Check
24
Transmission Warning Light Operation Check (Vehicle Is Equipped with Engine Diagnosis Connector)
24
POWER" Lamp Operation Check
24
DTC Table
25
DTC Check
26
DTC Clearance
27
Fail Safe Table
28
Scan Tool Data
30
Visual Inspection
33
A/T Basic Check
33
Road Test
34
Manual Road Test
35
Stall Test
36
Time Lag Test
37
Line Pressure Test
37
Engine Brake Test
39
P" Range Test
39
A/T Symptom Diagnosis
40
No Gear Shift to 4Th Gear
47
No Lock-Up Occurs
48
Transmission Warning Light Circuit Check - Light Does Not Come "ON" at Ignition Switch on (Vehicle Is Equipped with Engine Diagnosis Connector)
49
Transmission Warning Light Circuit Check - Light Remains "ON" at Ignition Switch on (Vehicle Is Equipped with Engine Diagnosis Connector)
49
POWER" Light Circuit Check - Light Does Not Come "ON" at Ignition Switch on
50
DTC P0705 Transmission Range Sensor Circuit Malfunction
50
DTC P0707 Transmission Range Sensor Circuit Low
52
DTC P0712 Transmission Fluid Temperature Sensor "A" Circuit Low
54
DTC P0713 Transmission Fluid Temperature Sensor "A" Circuit High
55
DTC P0717 Input / Turbine Speed Sensor Circuit no Signal
56
DTC P0722 Output Speed Sensor Circuit no Signal
57
DTC P0741 / P0742 TCC Circuit Performance or Stuck off / TCC Circuit Stuck
58
Performance or Stuck off / TCC Circuit Stuck on
58
DTC P0751 / P0752 Shift Solenoid-A Performance or Stuck off / Shift Solenoid-A Stuck
59
Performance or Stuck off / Shift Solenoid-A Stuck on
59
DTC P0756 / P0757 Shift Solenoid-B Performance or Stuck off / Shift Solenoid-B Stuck
60
Performance or Stuck off / Shift Solenoid-B Stuck on
60
DTC P0962 Pressure Control Solenoid "A" Control Circuit Low
61
DTC P0963 Pressure Control Solenoid "A" Control Circuit High
62
DTC P0973 / P0976 Shift Solenoid "A" Control Circuit Low / Shift Solenoid "B" Control Circuit Low
63
DTC P0974 / P0977 Shift Solenoid "A" Control Circuit High / Shift Solenoid "B" Control Circuit High
65
DTC P1702 Internal Control Module Memory Check Sum Error
66
DTC P1703 CAN Invalid Data - TCM
66
DTC P1723 Range Select Switch Malfunction
67
Www.cargarage.ir DTC P1774: CAN Communication Bus off
67
DTC P1777: TCM Lost Communication with ECM (Reception Error)
70
DTC P1778: TCM Lost Communication with BCM (Reception Error)
71
DTC P1874 4L Switch Circuit Malfunction (Short)
72
DTC P1875 4L Switch Circuit Malfunction (Open)
73
DTC P1878 Torque Converter Clutch Shudder
75
DTC P2763 Torque Converter Clutch (TCC) Circuit High
75
DTC P2764 Torque Converter Clutch (TCC) Circuit Low
77
Inspection of TCM and Its Circuits
78
TCM Power and Ground Circuit Check
82
Suzuki GRAND VITARA - Service Manual (146 pages)
Driveline / Axle
Brand:
Suzuki
| Category:
Automobile
| Size: 4.52 MB
Table of Contents
Table of Contents
1
Precautions
4
Precautions for Driveline / Axle
4
Drive Shaft / Axle
5
Front
5
General Description
5
Front Drive Shaft Construction
5
Diagnostic Information and Procedures
5
Front Drive Shaft Symptom Diagnosis
5
Repair Instructions
6
Front Drive Shaft Boot and Joint Check
6
Front Drive Shaft Components
6
Front Drive Shaft Assembly Removal and Installation
7
Front Drive Shaft Disassembly and Assembly
7
Specifications
10
Tightening Torque Specifications
10
Special Tools and Equipment
10
Recommended Service Material
10
Special Tool
10
Rear
11
General Description
11
Rear Drive Shaft Construction
11
Repair Instructions
11
Rear Drive Shaft Components
11
Rear Drive Shaft Assembly Removal and Installation
12
Rear Drive Shaft Disassembly and Assembly
12
Specifications
13
Tightening Torque Specifications
13
Special Tools and Equipment
13
Recommended Service Material
13
Special Tool
13
Differential
14
Front
14
General Description
14
Front Differential Construction
14
Diagnostic Information and Procedures
14
Front Differential Symptom Diagnosis
14
Repair Instructions
15
Front Differential Oil Change
15
Front Differential Unit Components
16
Front Differential Dismounting and Remounting
16
Front Differential Components
17
Front Differential Assembly Disassembly and Reassembly
18
Front Differential Inspection
30
Specifications
31
Tightening Torque Specifications
31
Special Tools and Equipment
31
Recommended Service Material
31
Special Tool
31
Suzuki GRAND VITARA - Owner's Manual (13 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 8.45 MB
Table of Contents
Product View
2
Foreword
3
Modification Warning
4
Introduction
5
Recommendation of Genuine Suzuki Parts and Accessories Use
6
Non-Genuine Suzuki Parts and Accessories
6
Re-Use of Genuine Suzuki Parts and Accessories
6
Service Station Guide
7
Table of Contents
9
Illustrated Table of Contents
10
Instrument Panel
10
SUZUKI GRAND VITARA - Brochure (5 pages)
Brand:
SUZUKI
| Category:
Automobile
| Size: 0.7 MB
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