Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual — part 39

3C-51 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

Inspection of 4WD Control Module and Its Circuits

S5JB0E3314030

4WD control module and its circuits can be checked at coupler connected to 4WD control module by measuring
voltage, pulse signal.

CAUTION

!

4WD control module cannot be checked by itself. It is strictly prohibited to connect voltmeter or
ohmmeter to 4WD control module with couplers disconnected from it.

Voltage and Signal Check

1) Check voltage using voltmeter (1) connected to each terminal of couplers.
2) Check signal using oscilloscope (2) connected to each terminal of couplers.

NOTE

• As each terminal voltage is affected by the battery voltage, confirm that it is 11 V or more when

ignition switch is turned ON.

• Pulse signal cannot be measured by voltmeter. It can be measured by oscilloscope.
• Item with asterisk (*) in normal voltage column can be read only by oscilloscope.

Terminal arrangement of 4WD control module connector (Viewed from harness side)

1

2

I4JA01332053-01

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

I4JA01332054-01

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-52

Terminal

Number

Wire

Color

Circuit

Normal

Voltage

Condition

E91-1

BLK

Ground

0 – 1 V

—

E91-2

BLU

Transfer actuator
motor 1

10 – 14 V

Ignition switch turned to ON position and transfer shift
actuator being rotated N

→ 4H → 4H-lock direction or 4L-

lock

→ 4H-lock direction

0 – 1 V

Ignition switch turned to ON position and transfer shift
actuator in other than above-mentioned condition

E91-3

YEL

Transfer actuator
motor 2

10 – 14 V

Ignition switch turned to ON position and transfer shift
actuator being rotated 4H-lock

→ 4H → N direction or

4H-lock

→ 4L-lock direction

0 – 1 V

Ignition switch turned to ON position and transfer shift
actuator in other than above-mentioned condition

E91-4

—

—

—

—

E91-5

—

—

—

—

E91-6

—

—

—

—

E91-7

BLK/ORN Clutch switch

10 – 14 V

Ignition switch turned to ON position and clutch pedal
released

0 – 1 V

Ignition switch turned to ON position and clutch pedal
kept depressing

E91-8

PNK

Diagnosis switch

4 – 5 V

Ignition switch turned to ON position

E91-9

—

—

—

—

E91-10

BLK

Ground

0 – 1 V

—

E91-11

WHT

Power source for
internal memory

10 – 14 V

—

E91-12 BLK/WHT Ignition switch

10 – 14 V

Ignition switch turned to ON position

E91-13 BLK/WHT 4L/N switch

10 – 14 V

Ignition switch turned to ON position and transfer shifted
to 4H or 4H-lock position

0 – 1 V

Ignition switch turned to ON position and transfer shifted
to 4L-lock or N position

E91-14 RED/GRN

Center differential lock
switch

10 – 14 V

Ignition switch turned to ON position and transfer shifted
to 4H-lock or 4L-lock position

0 – 1 V

Ignition switch turned to ON position and transfer shifted
to N or 4H position

E91-15

—

—

—

—

E91-16

—

—

—

—

E91-17

—

—

—

—

E91-18

LT GRN Transfer switch 1

10 – 14 V

Ignition switch turned to ON position and transfer switch
at 4H, N or 4L-lock position

0 – 1 V

Ignition switch turned to ON position and transfer switch
at N position

E91-19

BLU/BLK Transfer switch 2

10 – 14 V

Ignition switch turned to ON position and transfer switch
at 4L-lock position

0 – 1 V

Ignition switch turned to ON position and transfer switch
at 4H, 4H-lock or N position

E91-20 BLU/ORN Transfer switch 3

10 – 14 V

Ignition switch turned to ON position and transfer switch
at 4H or N position

0 – 1 V

Ignition switch turned to ON position and transfer switch
at 4H-lock or 4L-lock position

E91-21 PPL/WHT

Data link connector
(DLC)

10 – 14 V

Ignition switch turned to ON position

E91-22

RED

CAN communication
line (High)

*2.5 – 3.5 V Ignition switch turned to ON position

E91-23

WHT

CAN communication
line (Low)

*1.5 – 2.5 V Ignition switch turned to ON position

E91-24

BLK/YEL

Transfer actuator
position switch
(ground)

0 – 1 V

—

3C-53 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

Repair Instructions

Transfer Oil Level Check

S5JB0E3316001

1) Lift up vehicle and check oil leakage.
2) Remove oil level/filler plug (1) and check oil level is

between 0 and 10 mm (0 and 0.394 in.) from the
lower end of oil level / filler plug hole (2).
If oil is insufficient, pour specified oil up to plug hole.

3) Apply sealant to thread of level / filler plug, and then

tighten it to specified torque.

“A”: Sealant 99000–31260 (SUZUKI Bond
No.1217G)

Tightening torque
Transfer oil level / filler plug (a): 23 N·m (2.3 kgf-
m, 17.0 lb-ft)

Transfer Oil Seal Removal and Installation

S5JB0E3316003

Removal

1) Lift up vehicle and drain transfer oil.
2) Remove front propeller shaft and/or rear propeller

shaft referring to “Propeller Shaft Removal and
Installation in Section 3D in related manual”.

3) Remove front oil seal No.1 (1) and/or rear oil seal (2)

using flat end rod or the like.

E91-25

RED

Transfer actuator
position switch 1
(power)

Approx. 4 V

Ignition switch turned to ON position and transfer shifted
to 4H-lock position

Approx. 2 V

Ignition switch turned to ON position and transfer shifted
to 4H position

Approx. 1 V

Ignition switch turned to ON position and transfer shifted
to 4L-lock or N position

Approx. 0 V Ignition switch turned to OFF position

E91-26

RED/BLK

Transfer actuator
position switch 2
(power)

Approx. 4 V

Ignition switch turned to ON position and transfer shifted
to 4L-lock position

Approx. 2 V

Ignition switch turned to ON position and transfer shifted
to N position

Approx. 1 V

Ignition switch turned to ON position and transfer shifted
to 4H or 4H-lock position

Approx. 0 V Ignition switch turned to OFF position

Terminal

Number

Wire

Color

Circuit

Normal

Voltage

Condition

“a”. 0 – 10 mm (0 – 0.394 in.)

I6JB01331003-01

2

1

I5JB0A331031-01

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-54

Installation

1) Install new oil seal using special tool and plastic

hammer, and then apply grease to oil seal lip.

: Grease 99000–25010 (SUZUKI Super Grease
A)

Special tool
(A): 09913–70123

2) Install front propeller shaft and/or rear propeller shaft

referring to “Propeller Shaft Removal and Installation
in Section 3D in related manual”.

3) Fill transfer oil referring to “Transfer Oil Change:

Motor-Shift Type (Transfer with Shift Actuator) in
related manual”.

Transfer Switch Removal and Installation

S5JB0E3316004

Removal
Remove HVAC control module referring to “HVAC
Control Module Removal and Installation in Section 7A
in related manual”, and then remove transfer switch (1)
from center cluster (2).

Installation
Reverse removal procedure.

Transfer Switch Inspection

S5JB0E3316005

Check continuity between following terminals when
transfer switch (1) operated at each position.

4WD Control Module Removal and Installation

S5JB0E3316006

Removal

1) Disconnect negative (–) cable from battery.
2) If the vehicle is equipped with air bag system,

disable air bag system. Refer to “Disabling Air Bag
System in Section 8B in related manual”.

3) Disconnect connectors from 4WD control module

(1).

4) Remove 4WD control module with TCM by removing

its nuts, and then separate 4WD control module and
TCM.

(A)

(A)

I5JB0A331032-01

1

2

I5JB0A331003-02

Switch position

Terminal

†

(2)

1 – 2

N (3)

1 – 2 – 3

4H (4)

1 – 3

4H-lock (5)

1 – 3 – 4

4L-lock (6)

1 – 4

[A]: Transfer switch connector (harness side view)

[A]

6 5 4 3 2 1

6

5

4

3

2

1

I5JB0A331004-04

1

I5JB0A331005-01