Suzuki Grand Vitara JB419. Service manual — part 74

Exhaust System: 1K-3

Exhaust Manifold Removal and Installation

S5JB0B1B06002

For removal and installation, refer to “Intake Manifold
and Exhaust Manifold Removal and Installation in
Section 1D”.

Diesel Particulate Filter Removal and
Installation

S5JB0B1B06003

WARNING

To avoid the danger of being burned, do not
touch the exhaust system when the system is
hot. Any service on the exhaust system
should be performed when the system is
cool.

CAUTION

When replacing diesel particulate filter,
perform “Initialize diesel PF data” mode of
SUZUKI scan tool referring to “SUZUKI Tech
2 Operator's Manual”.

Removal

1) Disconnect negative (–) cable at battery.
2) Remove exhaust gas temperature sensor 2 and 3

from diesel particulate filter.

3) Remove diesel particulate filter differential pressure

sensor union nut.

4) Remove diesel particulate filter differential pressure

sensor pipe from diesel particulate filter.

5) Remove diesel particulate filter.

Installation
Reverse removal procedure noting the following.
• Tighten bolts and nuts to specified torque referring to

“Exhaust System Components”.

• When replacing diesel particulate filter, perform

“Initialize diesel PF data” mode of SUZUKI scan tool
referring to “SUZUKI Tech 2 Operator's Manual”.

Specifications

Tightening Torque Specifications

S5JB0B1B07001

NOTE
The specified tightening torque is also described in the following.
“Exhaust System Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

1K-4 Exhaust System:

Table of Contents 3- i

Section 3

CONTENTS

Driveline / Axle

Precautions . . . . . . . . . . . . .3-1

Precautions. . . . . . . . . . . . . . . . 3-1

Precautions for Driveline / Axle . . . . . . . . 3-1

Drive Shaft / Axle . . . . . . . . . ..3A-*

Front . . . . . . . . . . . . . . . . . . . 3A-*

General Description . . . . . . . . . . . . 3A-*

Front Drive Shaft Construction. . . . . . . .3A-*

Diagnostic Information and Procedures. . . 3A-*

Front Drive Shaft Symptom Diagnosis. . . . .3A-*

Repair Instructions . . . . . . . . . . . .. 3A-*

Front Drive Shaft Boot and Joint Check. . . ...3A-*
Front Drive Shaft Components . . . . . . . 3A-*
Front Drive Shaft Assembly Removal and

Installation. . . . . . . . . . . . . . ..3A-*

Front Drive Shaft Disassembly and Assembly . .3A-*

Specifications. . . . . . . . . . . . . ... 3A-*

Tightening Torque Specifications. . . . . . .3A-*

Special Tools and Equipment . . . . . . . . 3A-*

Recommended Service Material. . . . . . ..3A-*
Special Tool . . . . . . . . . . . . . . .3A-*

Rear . . . . . . . . . . . . . . . . . . .. 3A-*

General Description . . . . . . . . . . . . 3A-*

Rear Drive Shaft Construction . . . . . . . .3A-*

Repair Instructions . . . . . . . . . . . .. 3A-*

Rear Drive Shaft Components . . . . . . . .3A-*
Rear Drive Shaft Assembly Removal and

Installation. . . . . . . . . . . . . . ..3A-*

Rear Drive Shaft Disassembly and Assembly. ..3A-*

Specifications. . . . . . . . . . . . . ... 3A-*

Tightening Torque Specifications. . . . . . .3A-*

Special Tools and Equipment . . . . . . . . 3A-*

Recommended Service Material. . . . . . ..3A-*
Special Tool . . . . . . . . . . . . . . .3A-*

Differential. . . . . . . . . . . . 3B-1

Front . . . . . . . . . . . . . . . . . . .3B-1

General Description . . . . . . . . . . . . 3B-*

Front Differential Construction . . . . . . . .3B-*

Diagnostic Information and Procedures. . . 3B-*

Front Differential Symptom Diagnosis. . . . ..3B-*

Repair Instructions . . . . . . . . . . . ..3B-1

Front Differential Oil Change . . . . . . . ...3B-*

Front Differential Unit Components. . . . . .3B-1

Front Differential Dismounting and

Remounting. . . . . . . . . . . . . ... 3B-*

Front Differential Components . . . . . . . 3B-*
Front Differential Assembly Disassembly and

Reassembly . . . . . . . . . . . . . .. 3B-*

Front Differential Inspection . . . . . . . . 3B-*

Specifications. . . . . . . . . . . . . ...3B-1

Tightening Torque Specifications. . . . . . 3B-1

Special Tools and Equipment . . . . . . . . 3B-*

Recommended Service Material . . . . . . . 3B-*
Special Tool . . . . . . . . . . . . . . 3B-*

Rear . . . . . . . . . . . . . . . . . . ..3B-2

General Description . . . . . . . . . . . . 3B-*

Rear Differential Construction . . . . . . . . 3B-*

Diagnostic Information and Procedures. . . 3B-*

Rear Differential Symptom Diagnosis . . . . . 3B-*

Repair Instructions . . . . . . . . . . . ..3B-2

Rear Differential Oil Change . . . . . . . ... 3B-*
Rear Differential Unit Components . . . . . . 3B-*

Rear Differential Dismounting and

Remounting. . . . . . . . . . . . . ...3B-2

Rear Differential Components. . . . . . . . 3B-*
Rear Differential Assembly Disassembly and

Reassembly . . . . . . . . . . . . . .. 3B-*

Rear Differential Inspection. . . . . . . . . 3B-*

Specifications. . . . . . . . . . . . . ...3B-2

Tightening Torque Specifications. . . . . . 3B-2

Special Tools and Equipment . . . . . . . . 3B-*

Recommended Service Material . . . . . . . 3B-*
Special Tool . . . . . . . . . . . . . . 3B-*

Transfer . . . . . . . . . . . . . 3C-1

Precautions. . . . . . . . . . . . . . ...3C-1

Transfer Warning . . . . . . . . . . . . 3C-1

Precautions in Diagnosing Trouble . . . . . . 3C-*

General Description . . . . . . . . . . . .3C-2

Transfer Description. . . . . . . . . . . 3C-*
4WD Control System Description. . . . . . 3C-*
Function of 4WD Control System Component . 3C-*
4WD Control System Operation. . . . . . .. 3C-*

Input / Output Signal Table of 4WD Control

Module . . . . . . . . . . . . . . . ..3C-2

On-Board Diagnostic System Description. . ... 3C-*

NOTE
For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual
mentioned in the “FOREWORD” of this manual.

3-ii Table of Contents

CAN Communication System Description. . ...3C-2

Schematic and Routing Diagram. . . . . . 3C-3

4WD Control System Wiring Circuit Diagram. ..3C-3

Component Location . . . . . . . . . . ... 3C-*

Transfer Shift Control System Components. . 3C-*

Diagnostic Information and Procedures. . . 3C-5

4WD Control System Check . . . . . . . ... 3C-*
Transfer Position Indicator Operation Check . .. 3C-*
4WD Control System Operation Inspection . . 3C-*

Visual Inspection . . . . . . . . . . . . .3C-5

DTC Check. . . . . . . . . . . . . . .. 3C-*
DTC Clearance . . . . . . . . . . . . ... 3C-*

DTC Table. . . . . . . . . . . . . . ...3C-5

Fail-Safe Table. . . . . . . . . . . . . 3C-*

Scan Tool Data . . . . . . . . . . . . ...3C-6
Scan Tool Data Definitions. . . . . . . . ..3C-7
4WD Control Symptom Diagnosis. . . . . ...3C-8

Transfer Position Indicator Does Not Come

ON at Ignition Switch ON but Engine Stops. .. 3C-*

Transfer Position Indicator Remains ON

Steady at Ignition Switch ON . . . . . . . 3C-*

DTC C1213: Transfer Switch Circuit Open . . . 3C-*
DTC C1214: Transfer Switch Circuit Short . . . 3C-*
DTC C1223 / C1235: Transfer Shift Actuator

Motor Position Switch 1 Circuit Open /
Transfer Shift Actuator Motor Position
Switch 2 Circuit Open . . . . . . . . . ... 3C-*

DTC C1224 / C1236: Transfer Shift Actuator

Motor Position Switch 1 Circuit Short /
Transfer Shift Actuator Motor Position
Switch 2 Circuit Short. . . . . . . . . . 3C-*

DTC C1227: 4L/N Switch Circuit Open . . . ... 3C-*
DTC C1228: 4L/N Switch Circuit Short . . . ... 3C-*
DTC C1230: Transfer Actuator Circuit

Malfunction. . . . . . . . . . . . . . 3C-*

DTC C1237: Center Differential Lock Switch

Circuit Open . . . . . . . . . . . . . .. 3C-*

DTC C1238: Center Differential Lock Switch

Circuit Short . . . . . . . . . . . . . .. 3C-*

DTC C1240: 4WD Control Module Power

Supply Circuit Malfunction . . . . . . . . 3C-*

DTC C1243: Internal Circuit Malfunction of

4WD Control Module. . . . . . . . . . . 3C-*

DTC C1246: Clutch Pedal Position (CPP)

Switch Circuit Short. . . . . . . . . . ... 3C-*

DTC U1073: Control Module Communication

Buss Off . . . . . . . . . . . . . . . 3C-9

DTC U1100: Lost Communication with ECM . 3C-11
DTC U1121: Lost Communication with ABS /

Electronic Stability Program Hydraulic Unit /
Control Module. . . . . . . . . . . . 3C-12

Inspection of 4WD Control Module and Its

Circuits . . . . . . . . . . . . . . . .. 3C-*

Repair Instructions . . . . . . . . . . . 3C-13

Transfer Oil Level Check. . . . . . . . . . 3C-*
Transfer Oil Change. . . . . . . . . . . 3C-*
Transfer Oil Seal Removal and Installation. . . 3C-*
Transfer Switch Removal and Installation. . ... 3C-*
Transfer Switch Inspection. . . . . . . . .. 3C-*
4WD Control Module Removal and

Installation . . . . . . . . . . . . . . . 3C-*

Transfer Assembly Dismounting and

Remounting. . . . . . . . . . . . . ... 3C-*

Transfer Assembly Components. . . . . ...3C-13
Transfer Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-14

Transfer Assembly Inspection. . . . . . . . 3C-*
Input Gear Assembly, Counter Gear

Assembly, Front Output Shaft Assembly and
Rear Output Shaft Assembly Components . ... 3C-*

Input Gear Assembly Disassembly and

Reassembly . . . . . . . . . . . . . .. 3C-*

Counter Gear Assembly Disassembly and

Reassembly . . . . . . . . . . . . . .. 3C-*

Front Output Shaft Assembly Disassembly