Table Of Contents - Suzuki GRAND VITARA JB416 Service Manual

Table of Contents

Warning/Caution/Note1
Recommendaton Of Genuine Suzuki Parts And Accessories Use4
Non-Genuine Suzuki Parts And Accessories4
Re-Use Of Genuine Suzuki Parts And Accessories4
Table Of Contents5
Precautions7
Brakes Caution And Note8
Esp Control Module8
General Information9
General Description10
Abbreviations10
Engine13
Engine General Information And Diagnosis19
Precautions In Diagnosing Trouble19
On-Board Diagnostic System Description20
Vehicle Equipped With Diagnosis Connector20
Warm-Up Cycle21
Driving Cycle21
2 Driving Cycle Detection Logic21
Pending Dtc21
Freeze Frame Data22
Priority Of Freeze Frame Data22
Data Link Connector (Dlc)23
Engine And Emission Control System Description23
Can Communication System Description23
Ecm Transmission Data24
Ecm Reception Data25
Electronic Control System Description25
Engine And Emission Control System Flow Diagram26
Ecm Input / Output Circuit Diagram27
For J20 Engine27
For M16 Engine29
Terminal Arrangement Of Ecm Coupler (Viewed From Harness Side)30
Connector: C3730
Connector: E2331
Engine And Emission Control Input / Output Table33
Schematic And Routing Diagram34
Engine And Emission Control System Diagram34
Component Location35
Electronic Control System Components Location35
Diagnostic Information And Procedures37
Dtc Table37
Malfunction Indicator Lamp Does Not Come On43
Wiring Diagram43
Circuit Description43
Troubleshooting44
Malfunction Indicator Lamp Remains On After Engine Starts45
Dtc Check45
Can Communication Line Circuit Check45
Dtc P0500: Vehicle Speed Sensor (Vss) Malfunction46
Dtc Confirmation Procedure46
Dtc Detecting Condition And Trouble Area46
Dtc Troubleshooting47
Dtc P1603: Tcm Trouble Code Detected (For J20 Engine)47
Dtc Detecting Condition48
Dtc P1674: Can Communication (Bus Off Error)49
Can Communication Circuit Check53
Dtc P1676: Can Communication (Reception Error For Tcm (For A/T Model))53
Check Can Communication Error For Ecm54
Dtc Check In Tcm (For A/T Model)54
Ecm Power And Ground Circuit Check54
Dtc Check In Ecm55
Dtc P1678: Can Communication (Reception Error For Bcm)56
Dtc P1685: Can Communication60
Inspection Of Ecm And Its Circuits64
Voltage Check64
Viewed From Harness Side64
Reference Waveform No.175
Reference Waveform No.375
Reference Waveform No.275
Egr Valve Signal75
Generator Field Coil Monitor Signal (1) At Engine Idling76
Heated Oxygen Sensor-2 Signal (1) With Engine Idling76
Evap Canister Purge Valve Signal77
No.4 Fuel Injector Signal With Engine Idling77
No.3 Fuel Injector Signal With Engine Idling77
Ignition Coil Signal With Engine Idling78
Mass Air Flow Sensor Signal With Engine Racing80
A/F Sensor Signal With Engine Idling80
Cmp Sensor Signal With Engine Idling81
Throttle Actuator Output Signal With Ignition Switch Turned On82
Manifold Absolute Pressure Sensor Signal With Engine Racing83
Knock Sensor Signal At Engine Speed 4000 R/Min.83
Oil Control Valve Signal With Engine Idling83
Oil Control Valve Signal With Engine Racing84
Ignition Coil Signal And Fuel Injector Signal With Engine Cranking84
Can Communication Line Signal With Ignition Switch Turned On84
Resistance Check85
A/C System Circuits Check86
Reception Data Check From Bcm87
Dtc Check Of Hvac Control Module87
A/C Switch Signal Circuit Check87
Dtc Check Of Ect Sensor Circuit87
A/C Compressor Control System Check88
A/C Compressor Relay Circuit Check88
A/C Compressor Relay Check88
Electric Load Signal Circuit Check89
Special Tools And Equipment90
Suspension91
Front Suspension93
Front Suspension Construction93
Front Wheel Alignment Construction94
Preliminary Checks Prior To Adjustment Front Wheel Alignment94
Repair Instructions94
Front Wheel Alignment Inspection And Adjustment94
Steering Angle Check And Adjustment95
Reference Information95
Side Slip95
Front Strut Assembly Components96
Front Strut Assembly Removal And Installation97
Front Strut Assembly Disassembly And Assembly99
Front Strut Assembly Check100
Front Wheel Hub Assembly And Steering Knuckle Components101
Front Wheel Hub Assembly Removal And Installation101
Steering Knuckle Removal And Installation103
Front Wheel Hub, Disc, Nut And Bearing Check105
Suspension Control Arm Removal And Installation105
Suspension Control Arm / Bushing Disassembly And Assembly106
Suspension Control Arm Joint Check107
Front Suspension Frame, Stabilizer Bar And/Or Bushings Components107
Front Suspension Frame Check112
Front Stabilizer Bar, Bushing And/Or Joint Check112
Stabilizer Bushing112
Specifications113
Front Suspension Fasteners Check113
Tightening Torque Specifications113
Recommended Service Material114
Driveline / Axle115
Transfer118
Motor-Shift Type (Transfer With Shift Actuator)118
Transfer Warning118
Transfer Description119
Transfer Shift Control System Components120
4Wd Control System Description121
Transfer Shift Control121
Relationship Of Transfer Shift Position And Switches121
Retry Control121
Function Of 4Wd Control System Component123
4Wd Control System Operation123
4H (4Wd High) Position124
4H-Lock (4Wd High Center Differential Lock) Position125
N (Neutral) Position126
4L-Lock (4Wd Low Center Differential Lock) Position127
4Wd Control System Wiring Circuit Diagram128
Terminal Arrangement Of 4Wd Control Module129
Input / Output Signal Table Of 4Wd Control Module129
4Wd Control Module Transmission Data131
4Wd Control Module Reception Data131
4Wd Control System Check131
Visual Inspection132
Trouble Symptom Confirmation132
Rechecking And Record Of Dtc / Freeze Frame Data132
4Wd Control Symptom Diagnosis132
Detail Of 4Wd Control System Check133
Customer Questionnaire (Example)133
4Wd Control System Operation Inspection134
Transfer Position Indicator Operation Check134
Using Suzuki Scan Tool136
Using Diagnosis Connector136
Dtc Clearance137
Fail-Safe Table138
Scan Tool Data139
Scan Tool Data Definitions139
Vehicle Speed (Km/H, Mph)139
Center Diff Lock Sw (On / Off)139
Mode Switch 3 (Transfer Switch) (On / Off)140
Transfer Position Indicator Does Not Come On At Ignition Switch On But Engine Stops142
Transfer Position Indicator Remains On Steady At Ignition Switch On144
Dtc C1213: Transfer Switch Circuit Open145
Dtc C1214: Transfer Switch Circuit Short146
Dtc C1223 / C1235: Transfer Shift Actuator Motor Position Switch 1 Circuit Open / Transfer Shift Actuator Motor Position Switch 2 Circuit Open148
Dtc C1224 / C1236: Transfer Shift Actuator Motor Position Switch 1 Circuit Short / Transfer Shift Actuator Motor Position Switch 2 Circuit Short150
Dtc C1227: 4L/N Switch Circuit Open152
Dtc C1228: 4L/N Switch Circuit Short153
Dtc C1230: Transfer Actuator Circuit Malfunction155
Dtc C1237: Center Differential Lock Switch Circuit Open157
Dtc C1238: Center Differential Lock Switch Circuit Short159
Dtc C1240: 4Wd Control Module Power Supply Circuit Malfunction161
Dtc C1243: Internal Circuit Malfunction Of 4Wd Control Module162
Dtc C1246: Clutch Pedal Position (Cpp) Switch Circuit Short162
Dtc U1073: Control Module Communication Bus Off164
Dtc U1100: Lost Communication With Ecm167
Dtc U1101: Lost Communication With Tcm168
Dtc U1121: Lost Communication With Abs / Electronic Stability Program Hydraulic Unit / Control Module169
Inspection Of 4Wd Control Module And Its Circuits170
Terminal Arrangement Of 4Wd Control Module Connector170
Transfer Oil Level Check172
Transfer Oil Change172
Transfer Oil Seal Removal And Installation173
Transfer Switch Inspection174
Transfer Switch Removal And Installation174
4Wd Control Module Removal And Installation174
Transfer Assembly Dismounting And Remounting175
Installation175
Transfer Assembly Components176
Transfer Assembly Disassembly And Reassembly177
Transfer Assembly Inspection185
Input Gear Assembly Disassembly And Reassembly187
Input Gear Assembly, Counter Gear Assembly, Front Output Shaft Assembly And Rear Output Shaft Assembly Components187
Counter Gear Assembly Disassembly And Reassembly188
Front Output Shaft Assembly Disassembly And Reassembly189
Rear Output Shaft Assembly Disassembly And Reassembly190
Special Tool191
Non-Shift Type (Transfer Without Shift Actuator)193
Transfer Construction193
Transfer Symptom Diagnosis194
Brakes205
Precautions For Brakes209
Wheels And Tires Caution209
Brake Caution209
General Precautions209
Brake Control System And Diagnosis210
Brakes Construction210
Front Brake Hose / Pipe Construction211
Front Brake Hose / Pipe Removal And Installation214
Master Cylinder Reservoir Removal And Installation214
Rear Brake Hose / Pipe Removal And Installation214
Master Cylinder Assembly Removal And Installation215
Brake Booster Components218
Brake Booster Removal And Installation219
Front Brakes221
Front Disc Brake Pad Removal And Installation221
Front Disc Brake Caliper Removal And Installation222
Front Brake Disc Removal And Installation222
Abs224
Precautions In Diagnosing Troubles224
Precautions In On-Vehicle Service224
Precautions In Hydraulic Unit Operation Check224
Abs Description225
Self-Diagnosis Description225
Abs Transmission Data226
Abs Reception Data226
Abs Schematic227
Abs Wiring Circuit Diagram228
Abs Components Location230
Abs Check231
Problem Symptom Confirmation232
Dtc Check, Record And Clearance232
Abs Warning Lamp Check233
Ebd Warning Lamp (Brake Warning Lamp) Check233
Abs Warning Lamp Does Not Come On At Ignition Switch On236
Abs Warning Lamp Comes On Steady237
Ebd Warning Lamp (Brake Warning Lamp) Comes On Steady239
Serial Data Link Circuit Check240
Dtc C1015: G Sensor Circuit Failure (For 4Wd Vehicle)242
Dtc C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit Or Encoder243
Dtc C1057: Abs (Esp®) Control Module Power Supply Circuit Failure247
Dtc C1061: Pump Motor And/Or Motor Driver Circuit249
Dtc C1063: Solenoid Valve Power Supply Driver Circuit Failure250
Dtc C1071: Abs (Esp®) Control Module Internal Defect251
Dtc U1100: Lost Communication With Ecm (Reception Error)255
Hydraulic Unit Operation Check256
Depressurization Check256
Pressurization Check256
Abs (Esp®) Hydraulic Unit / Control Module Assembly On-Vehicle Inspection256
Abs (Esp®) Hydraulic Unit / Control Module Assembly Removal And Installation257
Front Wheel Speed Sensor On-Vehicle Inspection259
Front Wheel Speed Sensor Removal And Installation260
Front Wheel Speed Sensor Inspection261
Rear Wheel Speed Sensor Removal And Installation261
Rear Wheel Speed Sensor Inspection262
Front Wheel Encoder Removal And Installation262
Rear Wheel Encoder On-Vehicle Inspection262
Rear Wheel Encoder Removal And Installation263
Electronic Stability Program264
Precautions In Sensor Calibration265
Precautions In Speedometer Test Or Other Tests265
Electronic Stability Program Description265
Esp® Hydraulic Unit / Control Module Assembly Description265
Warning Lamp, Indicator Lamp Description266
Fail-Safe Mode266
Can Communication System For Electronic Stability Program Description268
Electronic Stability Program Schematic269
Electronic Stability Program Wiring Circuit Diagram270
Terminal Arrangement Of Esp Control Module Connector271
Electronic Stability Program Component Location272
Electronic Stability Program Check273
Esp Warning Lamp Check275
Ignition Switch284
Esp® Warning Lamp Comes On Steady285
Dtc C1015 / C1017 / C1023: Longitudinal G Sensor / Lateral G Sensor / Yaw Rate Sensor In Yaw Rate / G Sensor Assembly Failure288
Dtc C1016: Stop Lamp Switch Circuit Failure288
Dtc C1018: Brake Fluid Level Switch Failure290
Dtc 1020: Master Cylinder Pressure Sensor Power Supply Failure291
Dtc C1024: Steering Angle Sensor Circuit Failure291
Dtc C1021, C1022 / C1025, C1026 / C1031, C1032 / C1035, C1036: Right-Front / Left-Front / Right-Rear / Left-Rear Wheel Speed Sensor Circuit Or Encoder Failure291
Dtc C1027: Esp Off Switch Circuit Failure292
Dtc C1028: Master Cylinder Pressure Sensor Circuit Failure293
Dtc C1034: Yaw Rate / G Sensor Assembly Power Supply Failure294
Dtc C1037: Steering Angle Sensor Power Supply Failure295
Dtc C1038: Steering Angle Sensor Detect Rolling Counter Failure From Esp® Control Module296
Dtc C1039: Yaw Rate / G Sensor Assembly Internal Failure297
Dtc C1040: Stability Control System Function Failure297
Dtc C1050: Back Switch Failure298
Dtc C1057: Esp (Abs) Control Module Power Supply Circuit Failure299
Dtc C1061: Pump Motor And/Or Motor Driver Circuit Failure299
Dtc C1071: Esp (Abs) Control Module Internal Defect299
Dtc C1073: Lost Communication With Yaw Rate / G Sensor Assembly299
Dtc C1090: Ecm Detect Rolling Counter Failure From Esp Control Module301
Dtc C1091 / 1092 / 1093: Ecm / Tcm / 4Wd Control Module Data In Can Line Failure302
Dtc U1101: Lost Communication With Tcm (Reception Error)303
Dtc U1126: Lost Communication With Steering Angle Sensor (Reception Error)305
Dtc U1139: Lost Communication With 4Wd Control Module (Reception Error)306
Dtc U1140: Lost Communication With Bcm (Reception Error)307
Sensor Calibration308
Esp Hydraulic Unit / Control Module Assembly On-Vehicle Inspection309
Esp Hydraulic Unit / Control Module Assembly Removal And Installation309
Master Cylinder Pressure Sensor On-Vehicle Inspection310
Yaw Rate / G Sensor Assembly On-Vehicle Inspection311
Yaw Rate Inspection312
Lateral G Specification312
Yaw Rate Specification312
Yaw Rate / G Sensor Assembly Removal And Installation313
Yaw Rate / G Sensor Inspection314
Steering Angle Sensor Removal And Installation314
Esp Off Switch Removal And Installation315
Esp Off Switch Inspection315
Transmission / Transaxle317
Automatic Transmission/Transaxle320
Automatic Transmission Description321
Tcm Reception Data323
Electronic Shift Control Input / Output Table324
Electronic Shift Control System Wiring Diagram326
Automatic Gear Shift Table327
Shift Point In D Position And Normal Mode327
Lock-Up Point In D Position And Normal Mode327
Slip Lock-Up Point In D And/Or 3 Position327
Power Mode328
Shift Point In D Position And Power Mode328
Lock-Up Point In D Position And Power Mode328
Slope Shift Control329
Cruise Shift Control329
Electronic Shift Control System Components Location330
Fail Safe Table333
No Gear Shift To 4Th Gear339
No Lock-Up Occurs340
Dtc P1774: Can Communication Bus Off341
Dtc P1874 4L Switch Circuit Malfunction (Short)345
Inspection Of Tcm And Its Circuits348
Connector "E92"349
Connector "E93"350
Reference Waveform No. 1351
Reference Waveform No. 2351
Reference Waveform No. 3351
Reference Waveform No. 4351
Automatic Transmission Unit Components353
Automatic Transmission Unit Assembly354
Accumulator Spring Specification360
Steering365
Steering Wheel And Column367
Steering Wheel And Column Construction367
Service Precautions Of Steering Angle Sensor367
Contact Coil Cable Assembly Removal And Installation369
Hvac373
Air Conditioning System377
Auto A/C Electronic Control Input / Output Table377
A/C System Wiring Circuit Diagram378
Dtc B1553: Can Communication Circuit Malfunction379
Camshaft Position (Cmp) Sensor And/Or Its Circuit Malfunction380
Dtc B1557: Wheel Speed Sensor And/Or Its Circuit Malfunction380
A/C System Inspection At Ecm380
Operation Procedure For Charging A/C With Refrigerant381
Body, Cab And Accessories387
Precautions On Body, Cab And Accessories393
Lighting Systems394
Headlight Auto Leveling System Wiring Circuit Diagram394
Drl System Symptom Diagnosis394
Turn Signal And Hazard Warning Light Symptom Diagnosis395
Front Fog Light Symptom Diagnosis396
Headlight Switch (In Lighting Switch) Inspection397
Headlight Relay Inspection398
Turn Signal Light Switch (In Lighting Switch)399
Headlight Manual Leveling Switch Inspection399
Illumination Cancel Switch Inspection399
Instrumentation / Driver Info. / Horn400
Combination Meter Reception Data401
Combination Meter Circuit Diagram402
Terminal Arrangement Of Coupler Viewed From Combination Meter Side403
Low Fuel Warning Light Symptom Diagnosis404
Low Fuel Warning Light Operation404
Seat Belt Reminder Light Symptom Diagnosis404
Warning Buzzer Circuit Symptom Diagnosis405
Information Display Symptom Diagnosis406
Ignition Switch Inspection407
Fuel Level Sensor Removal And Installation407
Main Fuel Level Sensor407
Sub Fuel Level Sensor407
Remote Audio Control Switch Inspection408
Remote Audio Control Switch Resistance408
Wipers / Washers409
Windshield Wiper And Washer Switch409
Intermittent Wiper Relay Circuit409
Washer Linked Circuit410
Rear Wiper And Washer Switch Inspection411
Control Systems413
Cruise Control System Construction415
Cancel Conditions Of Cruise Control System417
Input / Output Diagram417
Cruise Control System Wiring Diagram418
Cruise Control System Symptom Diagnosis419
Body Electrical Control System421
Bcm General Description421
Bcm Transmission Data422
Bcm Reception Data422
Body Electrical Control System Wiring Circuit Diagram423
Body Electrical Control System Check424
Customer Complaint Analysis425
Body Electrical Control System Symptom Diagnosis425
Check For Intermittent Problem425
Final Confirmation Test426
Dtc U1073 (No. 1073): Control Module Communication Bus Off431
Immobilizer Control System439
Immobilizer Control System Wiring Circuit Diagram440
Diagnostic Trouble Code (Dtc) Table441
Dtc P1614: Transponder Response Error442
Dtc P1615: Steering Lock Unit Communication Error443
Dtc P1616: Unregistered Keyless Start Control Module446
Detecting Condition And Trouble Area446
Dtc P1618: Keyless Start Control Module Can Communication Error447
Dtc P1621: Immobilizer Communication Line Error449
Dtc P1622: Eeprom Error452
Dtc P1623: Unregistered Transponder452
Dtc P1625: Immobilizer Antenna Error453
Dtc P1636: Immobilizer Information Registration Failure454
Dtc P1638: Immobilizer Information Mismatched455
Keyless Start System457
Operation Area Of Remote Controller457
Keyless Start Control Module Transmission Data458
Keyless Start Control Module Reception Data458
Keyless Start System Electric Wiring Circuit Diagram459
Replacement Of The Keyless Start Control Module460
Keyless Start Control Module Substitution460
Inspection Of Keyless Start Control Module And Its Circuits462
Dtc No. 31: Lost Communication With Bcm468
Dtc No. 33: Control Module Communication Bus Off471