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GRAND VITARA 2008
Suzuki GRAND VITARA 2008 Manuals
Manuals and User Guides for Suzuki GRAND VITARA 2008. We have
3
Suzuki GRAND VITARA 2008 manuals available for free PDF download: Manual, Owner's Manual
Suzuki GRAND VITARA 2008 Manual (2253 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 88.7 MB
Table of Contents
Table of Contents
5
Precautions
7
Precautions
8
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
8
General Precautions
11
Precaution in Servicing Full-Time 4WD Vehicle
14
Precautions for Catalytic Converter and Diesel Particulate Filter (Diesel Engine Model)
16
Precautions for Electrical Circuit Service
16
Precautions for Catalytic Converter (Petrol Engine Model)
16
Precaution for Vehicle Equipped with ESP® System
16
Precaution for CAN Communication System
16
Precautions for Installing Mobile Communication Equipment
18
Air Bag Warning
18
Discharge Headlight Warning
18
A/C System Caution
19
Fastener Caution
19
Suspension Caution
19
Wheels and Tires Caution
19
Electrical Circuit Inspection Procedure
20
Brakes Caution and Note
20
Repair Instructions
20
Differential Gear Oil Note
20
Intermittent and Poor Connection Inspection
23
Section 0 General Information
25
General Information
25
Abbreviations
27
General Description
27
General Information
27
Symbols
28
Fastener Information
29
Wire Color Symbols
29
General Information
31
Vehicle Lifting Points
32
Engine Supporting Points
34
Vehicle Identification Number
34
Engine Identification Number
35
Transmission Identification Number
35
Component Location
36
Warning, Caution and Information Label Location
36
Maintenance and Lubrication
38
Maintenance Schedule under Normal Driving Conditions (Petrol Engine Model)
38
Precautions
38
Precautions for Maintenance and Lubrication
38
Scheduled Maintenance
38
Maintenance Schedule under Normal Driving Conditions (Diesel Engine Model)
40
Maintenance Recommended under Severe Driving Conditions (Petrol Engine Model)
41
Maintenance Recommended under Severe Driving Conditions (Diesel Engine Model)
42
(Petrol Engine Model)
43
Engine Accessory Drive Belt Inspection
43
Engine Accessory Drive Belt Replacement (Petrol Engine Model)
43
Engine Accessory Drive Belt, Tensioner and Idler Replacement (Diesel Engine Model)
43
Repair Instructions
43
Camshaft Timing Belt and Tensioner Replacement
44
Engine Oil and Filter Change (Petrol Engine Model)
44
Valve Lash (Clearance) Inspection
44
Engine Oil and Filter Change (Diesel Engine Model)
46
Air Cleaner Filter Inspection
47
Air Cleaner Filter Replacement
47
Engine Coolant Change
47
Exhaust System Inspection
47
Fuel Lines and Connections Inspection
47
Spark Plugs Replacement
47
Brake Discs and Pads Inspection
48
Brake Drums and Shoes Inspection
48
Crankcase Ventilation Hoses and Connections Inspection (Vehicle Without A/F Sensor)
48
Fuel Evaporative Emission Control System Inspection
48
Fuel Filter Replacement (Diesel Engine Model)
48
Fuel Filter Replacement (Petrol Engine Model)
48
Fuel Tank Inspection
48
PCV Valve Inspection
48
Brake Fluid Change
49
Brake Hoses and Pipes Inspection
49
Clutch Fluid Inspection
49
Parking Brake Lever and Cable Inspection
49
Suspension System Inspection
50
Tire / Wheel Inspection and Rotation
50
Wheel Bearing Inspection
50
Wheel Discs Inspection
50
Steering System Inspection
51
Manual Transmission Oil Inspection
52
Propeller Shafts and Drive Shafts Inspection
52
Automatic Transmission Fluid Change
53
Automatic Transmission Fluid Cooler Hose Inspection
53
Automatic Transmission Fluid Inspection
53
Differential Oil Inspection
53
Manual Transmission Oil Change
53
Transfer Oil Inspection (if Equipped)
53
Power Steering (P/S) System Inspection
54
Transfer (if Equipped) and Differential Oil Change
54
All Hinges, Latches and Locks Inspection
55
Final Inspection for Maintenance Service
55
HVAC Air Filter Inspection (if Equipped)
55
HVAC Air Filter Replacement (if Equipped)
55
Specifications
56
Tightening Torque Specifications
56
Recommended Fluids and Lubricants (Petrol Engine Model)
57
Special Tools and Equipment
57
Section 1 Engine
59
Engine
59
Precautions
69
Precautions for Engine (Diesel Engine Model)
69
Precautions for Engine (Petrol Engine Model)
69
Engine General Information and Diagnosis
70
For Petrol Engine Model
70
Precautions
70
Precautions in Diagnosing Trouble
70
Precautions on Engine Service
70
Precautions for DTC Troubleshooting
71
Precautions of ECM Circuit Inspection
71
Precautions of Electric Throttle Body System Calibration
71
Engine Diagnosis General Description
72
General Description
72
Statement on Cleanliness and Care
72
On-Board Diagnostic System Description
73
Engine and Emission Control System Description
76
Air Intake System Description
79
Electric Throttle Body System Description
80
Description of Electric Throttle Body System Calibration
81
Generator Control System Description
81
A/F Sensor Description
82
Electronic Control System Description
83
Engine and Emission Control Input / Output Table
84
Engine and Emission Control System Diagram
85
Schematic and Routing Diagram
85
Engine and Emission Control System Flow Diagram
87
ECM Input / Output Circuit Diagram
88
Component Location
94
Electronic Control System Components Location
94
Diagnostic Information and Procedures
96
Engine and Emission Control System Check
96
Malfunction Indicator Lamp (MIL) Check
99
DTC Check
100
DTC Clearance
101
DTC Table
102
Fail-Safe Table
108
Scan Tool Data
110
Visual Inspection
116
Engine Basic Inspection
117
Engine Symptom Diagnosis
121
Malfunction Indicator Lamp Does Not Come on with Ignition Switch on and Engine Stop (but Engine Can be Started)
132
Malfunction Indicator Lamp Remains on after Engine Starts
134
DTC P0010: Camshaft Position Actuator Circuit (for M16 Engine)
135
DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (for M16 Engine)
137
DTC P0030: HO2S Heater Control Circuit (Sensor-1)
139
DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)
141
DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)
144
DTC P0101: Mass Air Flow Circuit Range / Performance
148
DTC P0102: Mass Air Flow Circuit Low Input
152
DTC P0103: Mass Air Flow Circuit High Input
153
DTC P0106: Manifold Absolute Pressure Range / Performance
155
DTC P0107: Manifold Absolute Pressure Circuit Low Input
156
DTC P0108: Manifold Absolute Pressure Circuit High Input
158
DTC P0111: Intake Air Temperature Circuit Range / Performance
160
DTC P0112: Intake Air Temperature Sensor Circuit Low
162
DTC P0113: Intake Air Temperature Sensor Circuit High
164
DTC P0116: Engine Coolant Temperature Circuit Range / Performance
166
DTC P0117: Engine Coolant Temperature Circuit Low
169
DTC P0118: Engine Coolant Temperature Circuit High
171
DTC P0122: Throttle Position Sensor (Main) Circuit Low
173
DTC P0123: Throttle Position Sensor (Main) Circuit High
176
DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / no Activity Detected (Sensor-1)
179
DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)
181
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)
182
DTC P0140: O2 Sensor (HO2S) Circuit no Activity Detected (Sensor-2)
185
DTC P0171 / P0172 / P2195 / P2196: Fuel System too Lean / Rich / Stuck Lean / Stuck Rich
187
DTC P0223: Throttle Position Sensor (Sub) Circuit High
193
Dtc P0301, P0302, P0303, P0304
196
Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected
196
DTC P0327 / P0328: Knock Sensor Circuit Low / High
198
DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for J20 Engine)
200
DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for M16 Engine)
202
DTC P0340: Camshaft Position (CMP) Sensor Circuit
206
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
209
DTC P0403: Exhaust Gas Recirculation Control Circuit
212
DTC P0420: Catalyst System Efficiency below Threshold
213
DTC P0443: Evaporative Emission System Purge Control Valve Circuit
215
DTC P0462: Fuel Level Sensor Circuit Low
217
DTC P0463: Fuel Level Sensor Circuit High
219
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
221
DTC P0500: Vehicle Speed Sensor (VSS) Malfunction
225
DTC P0504: Brake Switch "A"/"B" Correlation (for J20 Engine)
227
DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low
229
DTC P0533: A/C Refrigerant Pressure Sensor Circuit High
231
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance
232
DTC P0616: Starter Relay Circuit Low
233
DTC P0617: Starter Relay Circuit High
234
DTC P0620: Generator Control Circuit
236
DTC P0625 / P0626: Generator Field Terminal Circuit Low / High
238
DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (for J20 Engine)
240
DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High
242
DTC P1510: ECM Back-Up Power Supply Malfunction
244
DTC P1603: TCM Trouble Code Detected (for J20 Engine)
245
DTC P1674: CAN Communication (Bus off Error)
247
DTC P1676: CAN Communication (Reception Error for TCM (for A/T Model))
251
DTC P1678: CAN Communication (Reception Error for BCM)
255
DTC P1685: CAN Communication (Reception Error for ABS or ESP® Control Module)
259
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance
263
DTC P2102: Throttle Actuator Control Motor Circuit Low
265
DTC P2103: Throttle Actuator Control Motor Circuit High
267
DTC P2111: Throttle Actuator Control System - Stuck Open
268
DTC P2119: Throttle Actuator Control Throttle Body Range / Performance
269
DTC P2122: Pedal Position Sensor (Main) Circuit Low Input
271
DTC P2123: Pedal Position Sensor (Main) Circuit High Input
274
DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input
276
DTC P2128: Pedal Position Sensor (Sub) Circuit High Input
279
DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation
281
DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation
284
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
287
Inspection of ECM and Its Circuits
289
ECM Power and Ground Circuit Check
312
Fuel Injector Circuit Check
316
Fuel Pump and Its Circuit Check
318
Fuel Pressure Check
321
A/C System Circuits Check
323
Electric Load Signal Circuit Check
326
Radiator Cooling Fan Low Speed Control System Check
328
Radiator Cooling Fan High Speed Control System Check
331
Idle Speed and IAC Throttle Valve Opening Inspection
333
Repair Instructions
333
Special Tool
334
Special Tools and Equipment
334
For Diesel Engine Model
335
Precautions
335
Precautions in Diagnosing Trouble
335
Precautions on Engine Service
335
Engine Diagnosis General Description
336
General Description
336
On-Board Diagnostic System Description
336
Statement on Cleanliness and Care
336
CAN Communication System Description
338
Diesel Particulate Filter Regeneration Description
340
Electronic Control System Diagram
340
Schematic and Routing Diagram
340
Electronic Control System Wiring Circuit Diagram
342
Component Location
346
Electronic Control System Components Location
346
Diagnostic Information and Procedures
347
Injection Warning Light (Gravity 1 Fault) Check
347
Malfunction Indicator Lamp (MIL) Check
347
Red Stop Warning Light (Gravity 2 Fault) Check
347
Engine and Emission Control System Check
348
DTC Check
350
DTC Clearance
350
DTC Table
351
Indicator Light Operation Table
354
Scan Tool Data
356
Engine Basic Inspection
358
Visual Inspection
358
DTC P0016: CKP - CMP Correlation
359
DTC P0033: Boost Pressure Control Solenoid Valve Control Circuit
360
DTC P0089: Fuel Flow Actuator Performance 1A-292
361
DTC P0100: Mass or Volume Air Flow Circuit 1A-296
365
DTC P0105: Barometric Pressure Circuit
367
DTC P0110: IAT Sensor Circuit Malfunction
367
DTC P0115: ECT Circuit
369
DTC P0190: Fuel Pressure Sensor Circuit
370
DTC P0201: Fuel Injector No.1 Circuit
372
DTC P0202: Fuel Injector No.2 Circuit
373
DTC P0203: Fuel Injector No.3 Circuit
374
DTC P0204: Fuel Injector No.4 Circuit
375
DTC P0225: APP Sensor (Main) Circuit
376
DTC P0235: Boost Pressure Sensor Circuit
378
DTC P0243: Boost Pressure Malfunction
379
DTC P0297: Vehicle Overspeed Condition
381
DTC P0301: Cylinder No.1 Misfire Detected
381
DTC P0302: Cylinder No.2 Misfire Detected
382
DTC P0303: Cylinder No.3 Misfire Detected
382
DTC P0304: Cylinder No.4 Misfire Detected
383
DTC P0335: CKP Sensor Circuit
383
DTC P0340: CMP Sensor Circuit
384
DTC P0380: Glow Plug Control Module Circuit
385
DTC P0403: EGR Control Circuit
386
DTC P0409: EGR Motor Malfunction
387
DTC P0470: Differential Sensor Circuit
388
DTC P0480: Radiator Fan Low Control Circuit 1A-320
389
DTC P0481: Radiator Fan High Control Circuit
390
DTC P0486: EGR Stroke Sensor Circuit
391
DTC P0500: VSS Malfunction
392
DTC P0530: A/C Refrigerant Pressure Sensor Circuit
393
DTC P0544: Exhaust Gas Temperature Sensor 3 Circuit
394
DTC P0560: System Voltage
395
DTC P0571: Brake Light Switch Circuit
396
DTC P0575: Cruise Control Input Circuit
397
DTC P0606: ECM Processor
397
DTC P0611: ECM Performance
399
DTC P0615: Ignition Switch Circuit
400
DTC P0627: Fuel Pump Control Circuit
401
DTC P0638: Inlet Throttle Valve Control Range / Performance
402
DTC P0641: Sensor Reference Voltage 1 Circuit
404
DTC P0645: A/C Compressor Relay Control Circuit
406
DTC P0651: Sensor Reference Voltage 2 Circuit
407
DTC P0670: Glow Plug Control Circuit
409
DTC P0685: Main Relay Control Circuit
410
DTC P0697: Sensor Reference Voltage 3 Circuit
410
DTC P0830: CPP Switch Circuit
412
DTC P1431: Clogged Diesel Particulate Filter Failures
413
DTC P1436: Diesel Particulate Filter Regeneration Request Failures
413
DTC P1480: Upstream Side Differential Pressure Sensor Failure
414
DTC P1641: Additional Heater Relay No.1 Control Circuit
414
DTC P1642: Additional Heater Relay No.2 and 3 Control Circuit
415
DTC P2002: Diesel Particulate Filter Efficiency below Threshold
416
DTC P2031: Exhaust Gas Temperature 2 Sensor Circuit
417
DTC P2120: APP Sensor (Sub) Circuit
418
DTC P2141: EGR Motor Control Circuit Low
420
DTC P2142: EGR Motor Control Circuit High .1A-352
421
DTC P2264: Fuel Filter Water Detection Sensor Circuit
422
DTC P2413: EGR System Performance
423
DTC P242A: Exhaust Gas Temperature Sensor 1 Circuit
424
DTC P242B: Exhaust Gas Temperature Sensor 1 Regulation Failure
425
DTC P2600: Turbocharger Electric Water Pump Control Circuit
426
DTC P3031: Exhaust Gas Temperature Sensor 2 Threshold Overshoot Failures During After-Sales Regeneration
427
Fault Finding-Customer Complaints
427
Fault Finding-Tests
436
Test 1: Exhaust System Check
436
Test 2: Low Pressure Circuit Check
438
Test 3: Checking the Turbocharged Air Inlet Circuit
439
Test 4: MAF Sensor
440
Test 5: Variable Geometry Turbocharger Control
440
Test 6: Rotating Part of a Turbocharger
441
Test 7: Exhaust Gas Recirculation Valve
442
Test 8: Injector Malfunction
443
Special Tool
446
Special Tools and Equipment
446
Aux. Emission Control Devices
447
Diagnostic Information and Procedures
447
EGR System Inspection
447
EVAP Canister Purge Inspection
447
For Petrol Engine Model
447
Repair Instructions
447
EVAP Canister Purge Valve and Its Circuit Inspection
448
EVAP Canister Purge Valve Inspection
449
Vacuum Hose and Purge Valve Chamber Inspection
449
Vacuum Passage Inspection
449
EGR Valve Inspection
450
EGR Valve Removal and Installation
450
EVAP Canister Inspection
450
PCV Hose Inspection
451
PCV Valve Inspection
451
PCV Valve Removal and Installation
451
Recommended Service Material
452
Special Tool
452
Special Tools and Equipment
452
Specifications
452
Tightening Torque Specifications
452
EGR Valve Inspection
453
For Diesel Engine Model
453
Repair Instructions
453
Exhaust Gas Temperature Sensor 1, 2 and 3
454
Removal and Installation
454
Exhaust Gas Temperature Sensor 1, 2 and
455
Installation (with Diesel Particulate Filter)
455
Specifications
456
Tightening Torque Specifications
456
Engine Control Module (ECM) Removal and Installation
457
Engine Electrical Devices
457
For Petrol Engine Model
457
Repair Instructions
457
Electric Throttle Body Assembly On-Vehicle Inspection
458
Manifold Absolute Pressure (MAP) Sensor Inspection
458
Electric Throttle Body System Calibration
461
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection
462
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation
462
Accelerator Pedal Position (APP) Sensor Assembly Inspection
463
Engine Coolant Temperature (ECT) Sensor Inspection
464
Engine Coolant Temperature (ECT) Sensor Removal and Installation
464
Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection
465
Heated Oxygen Sensor (HO2S-2) Heater On-Vehicle Inspection
465
Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S-2) Removal and Installation
466
Camshaft Position (CMP) Sensor Removal and Installation
466
Camshaft Position (CMP) Sensor Inspection
467
Crankshaft Position (CKP) Sensor Removal and Installation
468
Crankshaft Position (CKP) Sensor Inspection
469
Control Relay Inspection
470
Knock Sensor Removal and Installation
470
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection
471
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation
472
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection
473
Vacuum Tank Assembly Inspection (for J20 Engine)
473
Electric Load Current Sensor On-Vehicle Inspection (for J20 Engine)
475
Electric Load Current Sensor Removal and Installation (for J20 Engine)
475
Specifications
476
Tightening Torque Specifications
476
Description of ECM Registration
477
For Diesel Engine Model
477
General Description
477
Precaution in Replacing ECM
477
Precautions
477
Engine Control Module (ECM) Removal and Installation
478
Idle Speed Inspection
478
Registration Procedure for the ECM
478
Repair Instructions
478
EGR Valve Data Initialization
479
Registration Procedure for the Fuel Injector Calibration Code
479
Diesel Particulate Filter After-Sales Regeneration Procedure
480
Diesel Particulate Filter Data Initialization
480
Inlet Throttle Valve Data Initialization
480
Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection
482
Glow Plug Inspection
482
Glow Plug Removal and Installation
482
Accelerator Pedal Position (APP) Sensor Assembly Inspection
483
Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation
483
Engine Coolant Temperature (ECT) Sensor Removal and Installation
484
Camshaft Position (CMP) Sensor Removal and Installation
485
Crankshaft Position (CKP) Sensor (Engine Speed Sensor) Removal and Installation
485
Engine Coolant Temperature (ECT) Sensor Inspection
485
Boost Pressure Sensor Removal and Installation
486
Crankshaft Position (CKP) (Engine Speed Sensor) Sensor Inspection
486
Boost Pressure Control Solenoid Valve Removal and Installation
487
Glow Plug Control Module Removal and Installation
487
Main Relay and Fuel Heater Relay Inspection
487
Boost Pressure Control Solenoid Valve Inspection
488
Turbocharger Electric Water Pump Removal and Installation
488
Inlet Throttle Valve Removal and Installation
489
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Removal and Installation
489
Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection
489
Turbocharger Electric Water Pump Inspection
489
Special Tool
490
Special Tools and Equipment
490
Specifications
490
Engine Construction Description
491
Engine Mechanical
491
For M16A Engine with VVT
491
General Description
491
Camshaft Position Control (VVT Variable Valve Timing) System Description
492
Compression Check
494
Diagnostic Information and Procedures
494
Engine Vacuum Check
495
Valve Lash (Clearance) Inspection
496
Air Cleaner Filter Inspection and Cleaning
499
Air Cleaner Filter Removal and Installation
499
Cylinder Head Cover Removal and Installation
499
Repair Instructions
499
Throttle Body and Intake Manifold Components
501
Electric Throttle Body Assembly Removal and Installation
502
Throttle Body On-Vehicle Inspection
502
Intake Manifold Removal and Installation
503
Throttle Body Cleaning
503
Engine Assembly Removal and Installation
504
Engine Mountings Components
504
Timing Chain Cover Components
508
Timing Chain Cover Removal and Installation
509
Oil Control Valve Removal and Installation
511
Timing Chain Cover Inspection
511
Oil Control Valve Inspection
512
Timing Chain and Chain Tensioner Components
513
Timing Chain and Chain Tensioner Removal and Installation
513
Timing Chain and Chain Tensioner Inspection
516
Camshaft, Tappet and Shim Components
517
Camshaft, Tappet and Shim Removal and Installation
517
Camshaft, Tappet and Shim Inspection
520
Valves and Cylinder Head Components
523
Valves and Cylinder Head Removal and Installation
524
Valves and Cylinder Head Disassembly and Assembly
525
Valves and Valve Guides Inspection
528
Cylinder Head Inspection
530
Valve Spring Inspection
531
Pistons, Piston Rings, Connecting Rods and Cylinders Components
532
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
532
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
534
Cylinders, Pistons and Piston Rings Inspection
535
Piston Pins and Connecting Rods Inspection
537
Crank Pin and Connecting Rod Bearings Inspection
538
Main Bearings, Crankshaft and Cylinder Block Components
541
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
542
Crankshaft Inspection
545
Main Bearings Inspection
546
Cylinder Block Inspection
551
Flywheel Inspection
551
Rear Oil Seal Inspection
551
Sensor Plate Inspection
551
Specifications
552
Tightening Torque Specifications
552
Recommended Service Material
553
Special Tool
553
Special Tools and Equipment
553
Engine Construction Description
555
For J20 Engine
555
General Description
555
Air Cleaner Element Introduction
557
Compression Check
559
Diagnostic Information and Procedures
559
Engine Vacuum Check
560
Valve Lash (Clearance) Inspection
561
Air Cleaner Assembly Removal and Installation
564
Air Cleaner Filter Inspection and Cleaning
564
Air Cleaner Filter Removal and Installation
564
Repair Instructions
564
Throttle Body and Intake Manifold Components
565
Electric Throttle Body Assembly Removal and Installation
566
Intake Manifold Removal and Installation
566
Throttle Body Cleaning
566
Throttle Body On-Vehicle Inspection
566
Cylinder Head Cover Removal and Installation
567
Engine Mountings Components
569
Engine Assembly Removal and Installation
570
Timing Chain Cover Components
573
Timing Chain Cover Removal and Installation
573
2Nd Timing Chain and Chain Tensioner Components
576
Timing Chain Cover Cleaning and Inspection
576
2Nd Timing Chain and Chain Tensioner Removal and Installation
577
2Nd Timing Chain and Chain Tensioner Inspection
580
1St Timing Chain and Chain Tensioner Components
581
1St Timing Chain and Chain Tensioner Removal and Installation
581
Inspection
583
Camshafts, Tappet and Shim Components
584
Camshafts, Tappet and Shim Removal and Installation
585
Camshaft, Tappet and Shim Inspection
586
Valves and Cylinder Head Components
589
Valves and Cylinder Head Removal and Installation
590
Valves and Cylinder Head Disassembly and Assembly
592
Valves and Valve Guides Inspection
595
Cylinder Head Inspection
597
Valve Spring Inspection
598
Pistons, Piston Rings, Connecting Rods and Cylinders Components
599
Pistons, Piston Rings, Connecting Rods and Cylinders Removal and Installation
599
Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly
600
Pistons, Piston Rings, Connecting Rods and Cylinders Inspection and Cleaning
602
Main Bearings, Crankshaft and Cylinder Block Components
609
Main Bearings, Crankshaft and Cylinder Block Removal and Installation
610
Main Bearings, Crankshaft and Cylinder Block Inspection
613
Specifications
619
Tightening Torque Specifications
619
Recommended Service Material
620
Special Tool
620
Special Tools and Equipment
620
Compression Check
623
Diagnostic Information and Procedures
623
For F9Q Engine
623
Valve Lash (Clearance) Inspection
624
Valve Lash (Clearance) Adjustment
625
Air Cleaner Components
626
Air Cleaner Filter Removal and Installation
626
Air Cleaner Removal and Installation
626
Repair Instructions
626
Air Cleaner Filter Inspection and Cleaning
627
Intercooler and Air Intake Pipe Components
627
Air Intake Pipe Removal and Installation
628
Installation
628
Intercooler Removal and Installation
628
Oil Separator Removal and Installation
632
Vacuum Pump Removal and Installation
632
Timing Belt and Belt Tensioner Components
633
Vacuum Pump Inspection
633
Timing Belt and Belt Tensioner Removal and Installation
634
Timing Belt and Belt Tensioner Inspection
639
Engine Mounting Components
640
EGR Valve Components
646
EGR Valve Removal and Installation
647
EGR Pipe and EGR Cooler Removal and Installation
648
Turbocharger Components
650
Turbocharger Assembly Removal and Installation
651
Turbocharger Assembly Inspection
653
Intake Manifold and Exhaust Manifold Components
654
Turbocharger Assembly Adjustment
654
Intake Manifold and Exhaust Manifold Removal and Installation
655
Camshaft and Tappet Components
656
Camshaft and Tappet Removal and Installation
657
Camshaft and Tappet Inspection
660
Valve and Cylinder Head Assembly Components
661
Valve and Cylinder Head Assembly Removal and Installation
662
Valve and Cylinder Head Assembly Inspection
664
Valve and Cylinder Head Disassembly and Reassembly
664
Valves and Valve Guides Inspection
666
Cylinder Head Inspection
668
Valve Spring Inspection
669
Piston, Piston Ring and Connecting Rod Removal and Installation
670
Piston, Piston Ring, Connecting Rod and Cylinder Components
670
Cylinders, Pistons and Piston Rings Inspection
673
Piston Pins and Connecting Rods Inspection .1D-184
674
Crank Pin and Connecting Rod Bearings Inspection
675
Main Bearing, Crankshaft and Cylinder Block Component
677
Main Bearing, Crankshaft and Cylinder Block Removal and Installation
678
Crankshaft Inspection
682
Main Bearings Inspection
683
Specifications
684
Tightening Torque Specifications
684
Recommended Service Material
685
Special Tool
685
Special Tools and Equipment
685
Engine Lubrication Description
688
Engine Lubrication System
688
For M16A Engine with VVT
688
General Description
688
Diagnostic Information and Procedures
690
Oil Pressure Check
690
Oil Pan and Oil Pump Strainer Components
691
Repair Instructions
691
Oil Pan and Oil Pump Strainer Removal and Installation
692
Oil Pan and Oil Pump Strainer Cleaning
693
Oil Pump Components
694
Oil Pump Disassembly and Reassembly
694
Oil Pump Removal and Installation
694
Oil Pump Inspection
695
Recommended Service Material
697
Special Tool
697
Special Tools and Equipment
697
Specifications
697
Tightening Torque Specifications
697
Engine Lubrication Description
698
For J20 Engine
698
General Description
698
Diagnostic Information and Procedures
700
Oil Pressure Check
700
Oil Pan and Oil Pump Strainer Components
701
Repair Instructions
701
Oil Pan and Oil Pump Strainer Removal and Installation
702
Oil Pan and Oil Pump Strainer Cleaning
703
Oil Pump Components
704
Oil Pump Removal and Installation
704
Oil Pump Disassembly and Assembly
705
Oil Pump Inspection
706
Recommended Service Material
707
Special Tool
707
Special Tools and Equipment
707
Specifications
707
Tightening Torque Specifications
707
Diagnostic Information and Procedures
708
Engine Lubrication Description
708
For F9Q Engine
708
General Description
708
Oil Pressure Check
708
Oil Pan and Oil Pump Strainer Components
709
Repair Instructions
709
Oil Pan and Oil Pump Strainer Removal and Installation
710
Oil Pump, Oil Pump Chain and Gasket Holder Plate Component
715
Oil Pump, Oil Pump Chain and Gasket Holder Plate Removal and Installation
715
Oil Pump, Oil Pump Chain and Gasket Holder Plate Inspection
717
Heat Exchanger Removal and Installation
718
Specifications
718
Tightening Torque Specifications
718
Recommended Service Material
719
Special Tool
719
Special Tools and Equipment
719
Coolant Description
720
Cooling System Description
720
Engine Cooling System
720
For Petrol Engine Model
720
General Description
720
Coolant Circulation
721
Schematic and Routing Diagram
721
Diagnostic Information and Procedures
722
Engine Cooling Symptom Diagnosis
722
Cooling System Components
723
Repair Instructions
723
Coolant Level Check
725
Engine Cooling System Inspection and Cleaning
725
Cooling System Draining
726
Cooling System Flush and Refill
726
Cooling Water Pipes or Hoses Removal and Installation
727
Thermostat Removal and Installation (for M16 Engine Model)
727
Thermostat Inspection
728
Thermostat Removal and Installation (for J20 Engine Model)
728
Radiator Cooling Fan Motor On-Vehicle Inspection
729
Radiator Cooling Fan Relay Inspection
729
Radiator Cooling Fan Assembly Removal and Installation
730
Radiator On-Vehicle Inspection and Cleaning
730
Radiator Removal and Installation
730
Water Pump Removal and Installation (for J20 Engine Model)
731
Water Pump Removal and Installation (for M16 Engine Model)
731
Recommended Service Material
732
Special Tools and Equipment
732
Specifications
732
Tightening Torque Specifications
732
Water Pump Inspection
732
Coolant Description
733
Cooling System Description
733
For Diesel Engine Model
733
General Description
733
Coolant Circulation
734
Schematic and Routing Diagram
734
Diagnostic Information and Procedures
735
Engine Cooling Symptom Diagnosis
735
Cooling System Components
736
Repair Instructions
736
Coolant Level Check
737
Cooling System Draining
737
Engine Cooling System Inspection and Cleaning
737
Cooling System Refilling
738
Cooling System Flushing
739
Cooling Water Pipe or Hose Removal and Installation
739
Thermostat Assembly Removal and Installation
739
Radiator Cooling Fan Motor On-Vehicle Inspection
740
Radiator Cooling Fan Assembly Removal and Installation
742
Radiator On-Vehicle Inspection and Cleaning
742
Radiator Removal and Installation
742
Water Pump Removal and Installation
742
Recommended Service Material
743
Special Tools and Equipment
743
Specifications
743
Tightening Torque Specifications
743
Water Pump Inspection
743
For Petrol Engine Model
744
Fuel Delivery System Description
744
Fuel System
744
Fuel System Description
744
General Description
744
Precautions
744
Precautions on Fuel System Service
744
Fuel Delivery System Diagram
745
Fuel Pump Description
745
Schematic and Routing Diagram
745
Diagnostic Information and Procedures
746
Fuel Pressure Inspection
746
Fuel Cut Operation Inspection
747
Fuel System Components
748
Repair Instructions
748
Fuel Hose Disconnecting and Reconnecting
751
Fuel Leakage Check Procedure
753
Fuel Lines On-Vehicle Inspection
753
Fuel Pipe Removal and Installation
753
Fuel Pressure Relief Procedure
753
Fuel Injector On-Vehicle Inspection
754
Fuel Injector Removal and Installation
754
Fuel Injector Inspection
755
Fuel Pressure Regulator Inspection
757
Fuel Pressure Regulator Removal and Installation
757
Fuel Filler Cap Inspection
758
Fuel Tank Inlet Valve Removal and Installation
758
Fuel Tank Inlet Valve Inspection
759
Fuel Tank Removal and Installation
759
Fuel Pump On-Vehicle Inspection
761
Fuel Tank Inspection
761
Fuel Tank Purging Procedure
761
Fuel Pump Assembly Removal and Installation
762
Fuel Pump Inspection
763
Main Fuel Level Sensor Removal and Installation
763
Sub Fuel Level Sensor Removal and Installation
763
Specifications
764
Sub Fuel Level Sensor Inspection
764
Tightening Torque Specifications
764
Recommended Service Material
765
Special Tool
765
Special Tools and Equipment
765
For Diesel Engine Model
766
Precautions
766
Precautions on Fuel System Service
766
Fuel System Description
770
General Description
770
Fuel System Components
771
Repair Instructions
771
Fuel Leakage Check Procedure
772
Fuel Pressure Relief Procedure
772
Air Bleeding of Fuel System
773
Fuel Filter and Fuel Heater Removal and Installation
773
Water Draining of Fuel Filter
773
Fuel Heater Inspection
774
Fuel Hose Disconnecting and Reconnecting
775
Fuel Lines Inspection
777
Fuel Pipe Removal and Installation
777
High Pressure Pipe Removal and Installation
778
Fuel Injector On-Vehicle Inspection
781
Fuel Injector Removal and Installation
781
Injection Pump Components
783
Injection Pump Removal and Installation
784
Fuel Flow Actuator Inspection (Type 2)
787
Fuel Flow Actuator Removal and Installation (Type 2)
787
Common Rail (High Pressure Fuel Injection Rail) Removal and Installation
788
Fuel Filler Cap Inspection
789
Fuel Rail Presser Sensor Inspection
789
Fuel Tank Removal and Installation
789
Fuel Tank Inlet Valve Removal and Installation
791
Fuel Tank Inspection
791
Fuel Tank Purging Procedure
791
Fuel Pump Assembly Removal and Installation
792
Fuel Tank Inlet Valve Inspection
792
Fuel Pump Inspection
793
Main Fuel Level Gauge Removal and Installation
793
Main Fuel Level Gauge Inspection
794
Sub Fuel Level Gauge Inspection
794
Sub Fuel Level Gauge Removal and Installation
794
Specifications
795
Tightening Torque Specifications
795
Recommended Service Material
796
Special Tool
796
Special Tools and Equipment
796
For Petrol Engine Model
797
General Description
797
Ignition System
797
Ignition System Construction
797
Ignition System Wiring Circuit Diagram
798
Schematic and Routing Diagram
798
Component Location
800
Ignition System Components Location
800
Diagnostic Information and Procedures
801
Ignition Spark Test
801
Ignition System Check
801
Ignition System Symptom Diagnosis
801
Reference Waveform of Ignition System
801
High-Tension Cord Inspection (for M16 Engine)
804
High-Tension Cord Removal and Installation (for M16 Engine)
804
Repair Instructions
804
Spark Plug Removal and Installation
804
Ignition Coil Assembly (Including Ignitor) Removal and Installation
805
Spark Plug Inspection
805
Ignition Coil Assembly (Including Ignitor) Inspection
806
Ignition Timing Inspection
806
Special Tools and Equipment
808
Specifications
808
Tightening Torque Specifications
808
Cranking Circuit Introduction
809
Cranking System Note
809
For Petrol Engine Model
809
General Description
809
Precautions
809
Starting Motor Circuit Description
809
Starting System
809
Cranking System Symptom Diagnosis
810
Diagnostic Information and Procedures
810
Starting Motor Performance Test
811
Repair Instructions
813
Starting Motor Dismounting and Remounting
813
Starting Motor Components
814
Starting Motor Inspection
815
Recommended Service Material
818
Special Tools and Equipment
818
Specifications
818
Starting Motor Specifications
818
Tightening Torque Specifications
818
Cranking Circuit Introduction
819
For Diesel Engine Model
819
General Description
819
Starting Motor Circuit Description
819
Cranking System Symptom Diagnosis
820
Diagnostic Information and Procedures
820
Starting Motor Performance Test
821
Repair Instructions
822
Starting Motor Components
822
Starting Motor Disassembly and Assembly
823
Starting Motor Dismounting and Remounting
823
Starting Motor Inspection
825
Specifications
826
Starting Motor Specifications
826
Tightening Torque Specifications
826
Battery Description
827
Charging System
827
For Petrol Engine Model
827
General Description
827
Generator Description
828
Battery Inspection
829
Diagnostic Information and Procedures
829
Generator Symptom Diagnosis
830
Generator Test (Undercharged Battery Check)
830
Generator Test (Overcharged Battery Check)
831
Jump Starting in Case of Emergency
832
Repair Instructions
832
Battery Dismounting and Remounting
833
Water Pump and Generator Drive Belt Removal and Installation (for M16 Engine)
833
Water Pump and Generator Drive Belt Tension Inspection and Adjustment (for M16 Engine)
834
Water Pump and Generator Drive Belt On-Vehicle Inspection (for J20 Engine)
835
Water Pump and Generator Drive Belt Removal and Installation (for J20 Engine)
836
Generator Dismounting and Remounting
837
Generator Components
838
Generator Inspection
839
Charging System Specifications
842
Specifications
842
Tightening Torque Specifications
842
Battery Description
843
For Diesel Engine Model
843
General Description
843
Generator Description
844
Battery Inspection
845
Diagnostic Information and Procedures
845
Generator Symptom Diagnosis
846
Generator Test (Undercharged Battery Check)
846
Generator Test (Overcharged Battery Check)
847
Battery Dismounting and Remounting
848
Jump Starting in Case of Emergency
848
Repair Instructions
848
Generator Components
849
Generator Disassembly and Assembly
850
Generator Dismounting and Remounting
850
Drive End Frame / Bearing Disassembly and Assembly
852
Generator Inspection
852
Accessory Drive Belt and Idler Pulley Removal and Installation
854
Accessory Drive Belt Inspection
855
Accessory Drive Belt Tensioner Removal and Installation
855
Charging System Specifications
855
Specifications
855
Special Tool
856
Special Tools and Equipment
856
Tightening Torque Specifications
856
Diagnostic Information and Procedures
857
Exhaust System
857
Exhaust System Check
857
Exhaust System Components
857
Exhaust System Description
857
For Petrol Engine Model
857
General Description
857
Repair Instructions
857
Exhaust Manifold Removal and Installation (for J20 Engine Model)
860
Exhaust Manifold Removal and Installation (for M16 Engine Model)
860
Exhaust Pipe and Muffler Removal and Installation
861
Specifications
862
Tightening Torque Specifications
862
Diagnostic Information and Procedures
863
Diesel Particurate Filter Description
863
Exhaust System Check
863
Exhaust System Description
863
For Diesel Engine Model
863
General Description
863
Exhaust System Components
864
Repair Instructions
864
Diesel Particulate Filter Removal and Installation
865
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Suzuki GRAND VITARA 2008 Owner's Manual (309 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 4.05 MB
Table of Contents
Service Station Guide
7
Table of Contents
9
Exterior
10
Interior
11
Instrument Panel
12
Fuel Recommendation
15
Fuel Recommendation
16
Before Driving
19
Immobilizer System
20
Keys
20
Door Locks
21
Ignition Key Reminder
21
Central Door Locking System
22
Child-Proof Locks
23
Tailgate
23
Keyless Entry System Transmitter
24
Keyless Start System Remote Controller
24
Keyless Unlocking/Locking Using the Request Switches
25
Reminder Function
27
Replacement of the Battery
28
Replacement of the Battery (Transmitter)
29
Theft Deterrent Light
30
Electric Window Controls
31
Windows
31
Inside Rearview Mirror
32
Mirrors
32
Electric Mirrors
33
Outside Rearview Mirrors
33
Front Seats
34
Seat Adjustment
34
Adjustable Head Restraints
35
Adjusting Seatbacks
35
Front Seat Heater
36
Rear Seats
37
Folding Rear Seats
39
Seat Belts and Child Restraint Systems: 3
40
Seat Belts and Child Restraint Systems
41
Lap-Shoulder Belt
43
Driver’s Seat Belt Reminder
45
Child Restraint Systems
46
Seat Belt Inspection
46
Shoulder Anchor Height Adjuster
46
Child Restraint
47
Installation with Lap-Shoulder Seat Belts
48
A-ELR Type Belt
49
Installation with ISO-FIX Type Anchorages
51
Installation of Child Restraint with Top Strap
53
Seat Belt Pretensioner System
54
Supplemental Restraint System (Air Bags) (if Equipped)
55
Front Air Bags
57
Frontal Collision Range
57
Air Bag Symbol
58
Side Air Bags and Side Curtain Air Bags
59
Side Collision Range
59
How the Air Bag System Works
60
Servicing the Air Bag System
62
Instrument Cluster
63
Anti-Lock Brake System (ABS) Warning Light
64
Brake System Warning Light
64
Warning and Indicator Lights
64
SLIP Indicator Light
65
“ESP” (Electronic Stability Program) Warning Light
65
Hill Descent Control Indicator Light
66
“ESP OFF” Indicator Light
66
Charging Light
67
Oil Pressure Light
67
Seat Belt Reminder Light
67
“AIR BAG” Light
67
Immobilizer System Light
68
Low Fuel Warning Light
68
Malfunction Indicator Light
68
Fuel Filter Warning Light
69
Glow Plug Indicator Light
69
Injection Warning Light
69
Red Stop Warning Light
69
Diesel Particulate Filter (DPF) Warning Light
70
Open Door Warning Light
70
“CRUISE” Indicator Light
70
“SET” Indicator Light
70
Automatic Headlight Leveling System Warning Light
71
Keyless Start System Indicator Light
71
Main Beam (High Beam) Indicator Light
71
Transmission Warning Light
71
4WD Mode Indicator Lights
72
Illumination Indicator Light
72
Master Warning Indicator Light
72
Fuel Gauge
73
Speedometer
73
Tachometer (if Equipped)
73
Illumination Control
74
Temperature Gauge
74
Information Display (if Equipped)
75
A/T Selector Position (for Automatic Transmission)
76
Fuel Consumption/Driving Range/ Average Speed
76
Odometer/Trip Meter/Thermometer
78
Master Warning Indicator
79
Warning and Indicator Messages
79
Lighting Control Lever
82
Front Fog Light Switch (if Equipped)
83
Headlight Leveling Switch (if Equipped)
83
Head Light Washer Switch (if Equipped)
84
Turn Signal Control Lever
84
Hazard Warning Switch
85
Windshield Wiper and Washer Lever
85
Windshield Washer
86
Windshield Wipers
86
Rear Window Wiper/Washer Switch
87
Tilt Steering Lock Lever (if Equipped)
87
Heated Rear Window and Heated Outside Rearview Mirrors (if Equipped) Switch
88
Horn
88
Suzuki GRAND VITARA 2008 Manual (35 pages)
Brand:
Suzuki
| Category:
Automobile
| Size: 0.49 MB
Table of Contents
Precautions
3
Table of Contents
3
Precautions
4
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
4
General Precautions
7
Precaution in Servicing Full-Time 4WD Vehicle
10
Precaution for Vehicle Equipped with ESP® System
12
Precautions for Catalytic Converter (Petrol Engine Model)
12
Precautions for Catalytic Converter and Diesel Particulate Filter (Diesel Engine Model)
12
Precaution for CAN Communication System
12
Precautions for Electrical Circuit Service
12
Precautions for Installing Mobile Communication Equipment
14
Air Bag Warning
14
Discharge Headlight Warning
14
A/C System Caution
15
Fastener Caution
15
Suspension Caution
15
Wheels and Tires Caution
15
Brakes Caution and Note
16
Differential Gear Oil Note
16
Repair Instructions
16
Electrical Circuit Inspection Procedure
16
Intermittent and Poor Connection Inspection
19
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
Maintenance Schedule under Normal Driving Conditions (Petrol Engine Model)
34
Model)
34
Sensor
34
Fuel Evaporative Emission Control System
34
Change
35
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