Suzuki Grand Vitara JB416 JB420 - Service Manual - Repair Manual

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SUZUKI GRAND VITARA (JB416-JB420) - SERVICE MANUAL

- English Service Manual in PDF format to vehicles Suzuki Grand Vitara JB416 JB420.


INDEX:

IMPORTANT

FOREWORD

TABLE OF CONTENTS

PRECAUTIONS

- Precautions
- Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
- General Precautions
- Precaution in Servicing Full-Time 4WD Vehicle
- Precautions for Catalytic Converter
- Precaution for CAN Communication System
- Precautions for Electrical Circuit Service
- Precautions for Installing Mobile Communication Equipment
- Air Bag Warning
- Discharge Headlight Warning
- A/C System Caution
- Fastener Caution
- Suspension Caution
- Wheels and Tires Caution
- Brakes Caution and Note
- Differential Gear Oil Note
- Repair Instructions
- Electrical Circuit Inspection Procedure
- Intermittent and Poor Connection Inspection

GENERAL INFORMATION

- General Information
- General Description
- Abbreviations
- Symbols

- Wire Color Symbols
- Fastener Information
- Vehicle Lifting Points
- Engine Supporting Points
- Vehicle Identification Number
- Engine Identification Number
- Transmission Identification Number
- Component Location
- Warning, Caution and Information Label Location
- Maintenance and Lubrication
- Precautions
- Precautions for Maintenance and Lubrication
- Scheduled Maintenance
- Maintenance Schedule under Normal Driving Conditions
- Maintenance Recommended under Severe Driving Conditions
- Repair Instructions
- Engine Accessory Drive Belt Inspection
- Engine Accessory Drive Belt Replacement
- Valve Lash (Clearance) Inspection
- Engine Oil and Filter Change
- Engine Coolant Change
- Exhaust system Inspection
- Spark Plugs Replacement
- Air Cleaner Filter Inspection
- Air Cleaner Filter Replacement
- Fuel Lines and Connections Inspection
- Fuel Filter Replacement
- Fuel Tank Inspection
- Crankcase Ventilation Hoses and Connections Inspection (Vehicle without A/F Sensor)
- PCV Valve Inspection
- Fuel Evaporative Emission Control System Inspection
- Brake Discs and Pads Inspection
- Brake Drums and Shoes Inspection
- Brake Hoses and Pipes Inspection
- Brake Fluid Change
- Parking Brake Lever and Cable Inspection
- Clutch Fluid Inspection
- Tire / Wheel Inspection and Rotation
- Wheel Discs Inspection
- Wheel Bearing Inspection
- Suspension System Inspection
- Steering System Inspection
- Propeller Shafts and Drive Shafts Inspection
- Manual Transmission Oil Inspection
- Manual Transmission Oil Change
- Automatic Transmission Fluid Inspection
- Automatic Transmission Fluid Change
- Automatic Transmission Fluid Cooler Hose Inspection
- Transfer Oil Inspection (If Equipped)
- Differential Oil Inspection
- Transfer (If Equipped) and Differential Oil Change
- Power Steering (P/S) System Inspection
- All Hinges, Latches and Locks Inspection
- HVAC Air Filter Inspection (If Equipped)
- HVAC Air Filter Replacement (If Equipped)
- Final Inspection for Maintenance Service
- Specifications
- Tightening Torque Specifications
- Special Tools and Equipment
- Recommended Fluids and Lubricants
- Special Tool

ENGINE

- Precautions
- Precautions for Engine
- Engine General Information and Diagnosis
- Precautions
- Precautions on Engine Service
- Precautions in Diagnosing Trouble
- Precautions For DTC Troubleshooting
- Precautions of ECM Circuit Inspection
- Precautions of Electric Throttle Body System Calibration
- General Description
- Statement on Cleanliness and Care
- Engine Diagnosis General Description
- On-Board Diagnostic System Description
- Engine and Emission Control System Description
- CAN Communication System Description
- Air Intake System Description
- Description of Electric Throttle Body System
- Description of Electric Throttle Body System Calibration
- Generator Control System Description
- A/F Sensor Description
- Electronic Control System Description
- Engine and Emission Control Input / Output Table
- Schematic and Routing Diagram
- Engine and Emission Control System Diagram
- Component Location
- Electronic Control System Components Location
- Diagnostic Information and Procedures
- Engine and Emission Control System Check
- Malfunction Indicator Lamp (MIL) Check
- DTC Check
- DTC Clearance
- DTC Table
- Fail-Safe Table
- Scan Tool Data
- Visual Inspection
- Engine Basic Inspection
- Engine Symptom Diagnosis
- Malfunction Indicator Lamp Does Not Come ON with Ignition Switch ON and Engine Stop (but Engine Can Be Started)
- Malfunction Indicator Lamp Remains ON after Engine Starts
- DTC P0010: Camshaft Position Actuator Circuit (For M16 Engine)
- DTC P0011 / P0012: Camshaft Position - Timing Over-Advanced or System Performance / -Retarded (For M16 Engine)
- DTC P0030: HO2S Heater Control Circuit (Sensor-1)
- DTC P0031 / P0032: HO2S Heater Control Circuit Low / High (Sensor-1)
- DTC P0037 / P0038: HO2S Heater Control Circuit Low / High (Sensor-2)
- DTC P0101: Mass Air Flow Circuit Range / Performance
- DTC P0102: Mass Air Flow Circuit Low Input
- DTC P0103: Mass Air Flow Circuit High Input
- DTC P0106: Manifold Absolute Pressure Range / Performance
- DTC P0107: Manifold Absolute Pressure Circuit Low Input
- DTC P0108: Manifold Absolute Pressure Circuit High Input
- DTC P0111: Intake Air Temperature Circuit Range / Performance
- DTC P0112: Intake Air Temperature Sensor Circuit Low
- DTC P0113: Intake Air Temperature Sensor Circuit High
- DTC P0116: Engine Coolant Temperature Circuit Range / Performance
- DTC P0117: Engine Coolant Temperature Circuit Low
- DTC P0118: Engine Coolant Temperature Circuit High
- DTC P0122: Throttle Position Sensor (Main) Circuit Low
- DTC P0123: Throttle Position Sensor (Main) Circuit High
- DTC P0131 / P0132 / P0134: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage / No Activity Detected (Sensor-1)
- DTC P0133: O2 Sensor (HO2S) Circuit Slow Response (Sensor-1)
- DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)
- DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor-2)
- DTC P0171 / P0172 / P2195 / P2196: Fuel System Too Lean / Rich / Stuck Lean / Stuck Rich
- DTC P0222: Throttle Position Sensor (Sub) Circuit Low
- DTC P0223: Throttle Position Sensor (Sub) Circuit High
- DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4

Misfire Detected
- DTC P0327 / P0328: Knock Sensor Circuit Low / High
- DTC P0335: Crankshaft Position (CKP) Sensor Circuit (For J20 Engine)
- DTC P0335: Crankshaft Position (CKP) Sensor Circuit (For M16 Engine)
- DTC P0340: Camshaft Position (CMP) Sensor Circuit
- DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected
- DTC P0403: Exhaust Gas Recirculation Control Circuit
- DTC P0420: Catalyst System Efficiency below Threshold
- DTC P0443: Evaporative Emission System Purge Control Valve Circuit
- DTC P0462: Fuel Level Sensor Circuit Low
- DTC P0463: Fuel Level Sensor Circuit High
- DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit
- DTC P0500: Vehicle Speed Sensor (VSS) Malfunction
- DTC P0504: Brake Switch “A”/“B” Correlation (For J20 Engine)
- DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low
- DTC P0533: A/C Refrigerant Pressure Sensor Circuit High
- DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control

Module Performance
- DTC P0616: Starter Relay Circuit Low
- DTC P0617: Starter Relay Circuit High
- DTC P0620: Generator Control Circuit
- DTC P0625 / P0626: Generator Field Terminal Circuit Low / High
- DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (For J20 Engine)
- DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High
- DTC P1510: ECM Back-Up Power Supply Malfunction
- DTC P1603: TCM Trouble Code Detected (For J20 Engine)
- DTC P1674: CAN Communication (Bus Off Error)
- DTC P1676: CAN Communication (Reception Error for TCM (for A/T model))
- DTC P1678: CAN Communication (Reception Error for BCM)
- DTC P1685: CAN Communication (Reception Error for ABS Control Module)
- DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance
- DTC P2102: Throttle Actuator Control Motor Circuit Low
- DTC P2103: Throttle Actuator Control Motor Circuit High
- DTC P2111: Throttle Actuator Control System - Stuck Open
- DTC P2119: Throttle Actuator Control Throttle Body Range / Performance
- DTC P2122: Pedal Position Sensor (Main) Circuit Low Input
- DTC P2123: Pedal Position Sensor (Main) Circuit High Input
- DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input
- DTC P2128: Pedal Position Sensor (Sub) Circuit High Input
- DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation
- DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation
- DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction
- Inspection of ECM and Its Circuits
- ECM Power and Ground Circuit Check
- Fuel Injector Circuit Check
- Fuel Pump and Its Circuit Check
- Fuel Pressure Check
- A/C System Circuits Check
- Electric Load Signal Circuit Check
- Radiator Cooling Fan Low Speed Control System Check
- Radiator Cooling Fan High Speed Control System Check
- Repair Instructions
- Idle Speed and IAC Throttle Valve Opening Inspection
- Special Tools and Equipment
- Special Tool
- Aux. Emission Control Devices
- Diagnostic Information and Procedures
- EGR System Inspection
- Repair Instructions
- EVAP Canister Purge Inspection
- EVAP Canister Purge Valve and Its Circuit Inspection
- Vacuum Passage Inspection
- Vacuum Hose and Purge Valve Chamber Inspection
- EVAP Canister Purge Valve Inspection
- EVAP Canister Inspection
- EGR Valve Removal and Installation
- EGR Valve Inspection
- PCV Hose Inspection
- PCV Valve Removal and Installation
- PCV Valve Inspection
- Specifications
- Tightening Torque Specifications
- Special Tools and Equipment
- Recommended Service Material
- Special Tool
- Engine Electrical Devices
- Repair Instructions
- Engine Control Module (ECM) Removal and Installation
- Manifold Absolute Pressure (MAP) Sensor Inspection
- Electric Throttle Body Assembly On-Vehicle Inspection
- Electric Throttle Body System Calibration
- Accelerator Pedal Position (APP) Sensor Assembly On-Vehicle Inspection
- Accelerator Pedal Position (APP) Sensor Assembly Removal and Installation
- Accelerator Pedal Position (APP) Sensor Assembly Inspection
- Engine Coolant Temperature (ECT) Sensor Removal and Installation
- Engine Coolant Temperature (ECT) Sensor Inspection
- Air Fuel Ratio (A/F) Sensor On-Vehicle Inspection
- Heated Oxygen Sensor (HO2S-2) Heater On- Vehicle Inspection
- Air Fuel Ratio (A/F) Sensor, Heated Oxygen Sensor (HO2S-2) Removal and Installation
- Camshaft Position (CMP) Sensor Removal and Installation
- Camshaft Position (CMP) Sensor Inspection
- Crankshaft Position (CKP) Sensor Removal and Installation
- Crankshaft Position (CKP) Sensor Inspection
- Knock Sensor Removal and Installation
- Control Relay Inspection
- Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor On-Vehicle Inspection
- Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Removal and Installation
- Mass Air Flow (MAF) and Intake Air Temperature (IAT) Sensor Inspection
- Vacuum Tank Assembly Inspection (For J20 Engine)
- Electric Load Current Sensor On-Vehicle Inspection (For J20 Engine)
- Electric Load Current Sensor Removal and Installation (For J20 Engine)
- Specifications
- Tightening Torque Specifications
- Engine Mechanical
- For M16A Engine with VVT
- General Description
- Diagnostic Information and Procedures
- Repair Instructions
- Specifications
- Special Tools and Equipment
- For J20 Engine
- General Description
- Diagnostic Information and Procedures
- Repair Instructions
- Specifications
- Special Tools and Equipment
- Engine Lubrication System
- For M16A Engine with VVT
- General Description
- Diagnostic Information and Procedures
- Repair Instructions
- Specifications
- Special Tools and Equipment
- For J20 Engine
- General Description
- Diagnostic Information and Procedures
- Repair Instructions
- Specifications
- Special Tools and Equipment
- Engine Cooling System
- General Description
- Cooling System Description
- Coolant Description
- Schematic and Routing Diagram
- Coolant Circulation
- Diagnostic Information and Procedures
- Engine Cooling Symptom Diagnosis
- Repair Instructions
- Cooling System Components
- Coolant Level Check
- Engine Cooling System Inspection and Cleaning
- Cooling System Draining
- Cooling System Flush and Refill
- Cooling Water Pipes or Hoses Removal and Installation
- Thermostat Removal and Installation (For M16 Engine Model)
- Thermostat Removal and Installation (For J20 Engine Model)
- Thermostat Inspection
- Radiator Cooling Fan Motor On-Vehicle Inspection
- Radiator Cooling Fan Relay Inspection
- Radiator Cooling Fan Assembly Removal and Installation
- Radiator On-Vehicle Inspection and Cleaning
- Radiator Removal and Installation
- Water Pump Removal and Installation (For M16 Engine Model)
- Water Pump Removal and Installation (For J20 Engine Model)
- Water Pump Inspection
- Specifications
- Tightening Torque Specifications
- Special Tools and Equipment
- Recommended Service Material
- Fuel System
- Precautions
- Precautions on Fuel System Service
- General Description
- Fuel System Description
- Fuel Delivery System Description
- Fuel Pump Description
- Schematic and Routing Diagram
- Fuel Delivery System Diagram
- Diagnostic Information and Procedures
- Fuel Pressure Inspection
- Fuel Cut Operation Inspection
- Repair Instructions
- Fuel System Components
- Fuel Hose Disconnecting and Reconnecting
- Fuel Pressure Relief Procedure
- Fuel Leakage Check Procedure
- Fuel Lines On-Vehicle Inspection
- Fuel Pipe Removal and Installation
- Fuel Injector On-Vehicle Inspection
- Fuel Injector Removal and Installation
- Fuel Injector Inspection
- Fuel Pressure Regulator Removal and Installation
- Fuel Pressure Regulator Inspection
- Fuel Filler Cap Inspection
- Fuel Tank Inlet Valve Removal and Installation
- Fuel Tank Inlet Valve Inspection
- Fuel Tank Removal and Installation
- Fuel Tank Inspection
- Fuel Tank Purging Procedure
- Fuel Pump On-Vehicle Inspection
- Fuel Pump Assembly Removal and Installation
- Main Fuel Level Sensor Removal and Installation
- Fuel Pump Inspection
- Sub Fuel Level Sensor Removal and Installation
- Sub Fuel Level Sensor Inspection
- Specifications
- Tightening Torque Specifications
- Special Tools and Equipment
- Recommended Service Material
- Special Tool
- Ignition System
- General Description
- Ignition System Construction
- Schematic and Routing Diagram
- Ignition System Wiring Circuit Diagram
- Component Location
- Ignition System Components Location
- Diagnostic Information and Procedures
- Ignition System Symptom Diagnosis
- Reference Waveform of Ignition System
- Ignition System Check
- Ignition Spark Test
- Repair Instructions
- High-Tension Cord Removal and Installation (For M16 Engine)
- High-Tension Cord Inspection (For M16 Engine)
- Spark Plug Removal and Installation
- Spark Plug Inspection
- Ignition Coil Assembly (Including ignitor) Removal and Installation
- Ignition Coil Assembly (Including ignitor) Inspection
- Ignition Timing Inspection
- Specifications
- Tightening Torque Specifications
- Special Tools and Equipment
- Special Tool
- Starting System
- Precautions
- Cranking System Note
- General Description
- Cranking Circuit Introduction
- Starting Motor Circuit Description
- Diagnostic Information and Procedures
- Cranking System Symptom Diagnosis
- Starting Motor Performance Test
- Repair Instructions
- Starting Motor Dismounting and Remounting
- Starting Motor Components
- Starting Motor Inspection
- Specifications
- Starting Motor Specifications
- Tightening Torque Specifications
- Special Tools and Equipment
- Recommended Service Material
- Charging System
- General Description
- Battery Description
- Generator Description
- Diagnostic Information and Procedures
- Battery Inspection
- Generator Symptom Diagnosis
- Generator Test (Undercharged Battery Check)
- Generator Test (Overcharged Battery Check)
- Repair Instructions
- Jump Starting in Case of Emergency
- Battery Dismounting and Remounting
- Water Pump and Generator Drive Belt Removal and Installation (For M16 Engine)
- Water Pump and Generator Drive Belt Tension Inspection and Adjustment (For M16 Engine)
- Water Pump and Generator Drive Belt On-Vehicle Inspection (For J20 Engine)
- Water Pump and Generator Drive Belt Removal and Installation (For J20 Engine)
- Generator Dismounting and Remounting
- Generator Components
- Generator Inspection
- Specifications
- Charging System Specifications
- Tightening Torque Specifications
- Exhaust System
- General Description
- Exhaust System Description
- Diagnostic Information and Procedures
- Exhaust System Check
- Repair Instructions
- Exhaust System Components
- Exhaust Manifold Removal and Installation (For M16 Engine Model)
- Exhaust Manifold Removal and Installation (For J20 Engine Model)
- Exhaust Pipe and Muffler Removal and Installation
- Specifications
- Tightening Torque Specifications

SUSPENSION

- Precautions
- Precautions on Suspension
- Suspension General Diagnosis
- Diagnostic Information and Procedures
- Suspension, Wheels and Tires Symptom Diagnosis
- Specifications
- Wheel Alignment Specifications
- Front Suspension
- General Description
- Front Suspension Construction
- Front Wheel Alignment Construction
- Repair Instructions
- Front Wheel Alignment Inspection and Adjustment
- Front Strut Assembly Components
- Front Strut Assembly Removal and Installation
- Front Strut Assembly Disassembly and Assembly
- Front Strut Assembly Check
- Front Wheel Hub Assembly and Steering Knuckle Components
- Front Wheel Hub Assembly Removal and Installation
- Steering Knuckle Removal and Installation
- Front Wheel Hub, Disc, Nut and Bearing Check
- Suspension Control Arm Removal and Installation
- Suspension Control Arm / Bushing Disassembly and Assembly
- Suspension Control Arm / Steering Knuckle Check
- Suspension Control Arm Bushing Check
- Suspension Control Arm Joint Check
- Front Suspension Frame, Stabilizer Bar and/or Bushings Components
- Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation
- Front Suspension Frame Check
- Front Stabilizer Bar, Bushing and/or Joint Check
- Front Suspension Fasteners Check
- Specifications
- Tightening Torque Specifications
- Special Tools and Equipment
- Recommended Service Material
- Special Tool
- Rear Suspension
- General Description
- Rear Suspension Construction
- Rear Wheel Alignment Construction
- Repair Instructions
- Rear Wheel Alignment Inspection and Adjustment
- Rear Shock Absorber and Rear Coil Spring Components
- Rear Shock Absorber Removal and Installation
- Shock Absorber Check
- Rear Coil Spring and Bump Stopper Removal and Installation
- Rear Coil Spring Check
- Rod and Arm Components
- Control Rod Removal and Installation
- Control Rod / Bushing Disassembly and Assembly
- Control Rod Check
- Trailing Rod Removal and Installation
- Trailing Rod / Bushing Disassembly and Assembly
- Trailing Rod Check
- Lower Arm Removal and Installation
- Lower Arm / Bushing Disassembly and Assembly
- Lower Arm Check
- Upper Arm Removal and Installation
- Upper Arm / Bushing Disassembly and Assembly
- Upper Arm Check
- Rear Suspension Frame Components
- Rear Suspension Frame Removal and Installation
- Rear Suspension frame / Bushing Disassembly and Assembly
- Rear Suspension Frame, Bushing and Pad Check
- Rear Wheel Hub Assembly and Rear Suspension Knuckle Components
- Rear Wheel Hub Assembly Removal and Installation
- Rear Wheel Hub Assembly, Wheel Bearing and Wheel Stud Inspection
- Rear Wheel Disc, Nut and Bearing Check
- Rear Suspension knuckle Removal and Installation
- Rear Suspension Knuckle Check
- Rear Suspension Fasteners Check
- Specifications
- Tightening Torque Specifications
- Special Tools and Equipment
- Recommended Service Material
- Special Tool
- Wheels and Tires
- General Description
- Tires Description
- Wheels Description
- Irregular and/or Premature Wear Description
- Wear Indicators Description
- Radial Tire Waddle Description
- Radial Tire Lead / Pull Description
- Balancing Wheels Description
- Repair Instructions
- General Balance Procedures
- Tire Rotation
- Wheel Removal and Installation
- Tire Mounting and Dismounting
- Tire Repair
- Specifications
- Wheels and Tires Specifications
- Tightening Torque Specifications

AND MORE....