Suzuki Grand Vitara JB627. Manual — part 11

0B-14 Maintenance and Lubrication:

Specifications

Tightening Torque Specifications

S6JB0B0207001

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

Special Tools and Equipment

Recommended Fluids and Lubricants

S6JB0B0208001

Fluids / Lubricants List

Special Tool

S6JB0B0208002

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Engine oil drain plug

35

3.5

25.5

)

Oil filter

14

1.4

10.5

)

Engine oil

Refer to “Engine Oil and Filter Change”.

Engine coolant
(Ethylene glycol base coolant)

“Antifreeze / Anticorrosion coolant”

Brake fluid

Refer to reservoir cap of brake master cylinder.

Manual transmission oil

Refer to “Manual Transmission Oil Change in Section 5B”.

Transfer oil

Refer to “Transfer Oil Change in Section 3C”.

Differential oil (front & rear)

Refer to “Front Differential Oil Change: Front in Section 3B”, or “Rear
Differential Oil Change: Rear in Section 3B”.

Automatic transmission fluid

Refer to “A/T Fluid Change in Section 5A”.

Power steering fluid

An equivalent of DEXRON

®

-II

Door hinges

Engine oil or water resistance chassis grease

Hood latch assembly
Key lock cylinder

Spray lubricant

09915–47320
Oil filter wrench cap (79 mm)
)

Table of Contents 1- i

1

Section 1

CONTENTS

Engine

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

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

Precautions for Engine. . . . . . . . . . .. 1-1

Engine General Information and
Diagnosis . . . . . . . . . . . . . 1A-1

Precautions. . . . . . . . . . . . . . ...1A-1

Precautions on Engine Service . . . . . . ... 1A-1
Precautions in Diagnosing Trouble . . . . . . 1A-1
Precautions for DTC Troubleshooting. . . . . 1A-2
Precautions of ECM Circuit Inspection. . . . 1A-2
Precautions of Electric Throttle Body System

Calibration. . . . . . . . . . . . . . . 1A-2

General Description . . . . . . . . . . . .1A-3

Statement of Cleanliness and Care . . . . . 1A-3
Engine Diagnosis General Description . . . ... 1A-3
On-Board Diagnostic System Description. . ... 1A-3
Engine and Emission Control System

Description . . . . . . . . . . . . . . 1A-6

Air Intake System Description. . . . . . . . 1A-7
Electric Throttle Body System Description . . .. 1A-7
Description of Electric Throttle Body System

Calibration. . . . . . . . . . . . . . . 1A-8

A/F Sensor Description . . . . . . . . . ... 1A-9
CAN Communication System Description. . .1A-10
Electronic Control System Description. . . .. 1A-13

Schematic and Routing Diagram. . . . . ..1A-16

Engine and Emission Control System

Diagram . . . . . . . . . . . . . . ..1A-16

Electronic Control System Diagram . . . . ..1A-17
Electronic Control System Wiring Circuit

Diagram . . . . . . . . . . . . . . ..1A-18

Component Location . . . . . . . . . . .1A-23

Electronic Control System Location . . . . ..1A-23

Diagnostic Information and Procedures. . ..1A-24

Engine and Emission Control System Check. 1A-24
Visual Inspection. . . . . . . . . . . ...1A-28
Engine Basic Check. . . . . . . . . . ..1A-29
Malfunction Indicator Lamp (MIL) Check . . .. 1A-30
DTC Table. . . . . . . . . . . . . . .1A-30
DTC Check . . . . . . . . . . . . . ...1A-41
DTC Clearance . . . . . . . . . . . . . 1A-41
Fail-Safe Table. . . . . . . . . . . . .. 1A-42
Scan Tool Data . . . . . . . . . . . . . 1A-44

Engine Symptom Diagnosis . . . . . . . ..1A-51
Malfunction Indicator Lamp Does Not Come

ON with Ignition Switch ON and Engine Stop
(but Engine Can Be Started) . . . . . . ...1A-58

Malfunction Indicator Lamp Remains ON after

Engine Starts. . . . . . . . . . . . ...1A-60

DTC P0031 / P0032: HO2S Heater Control

Circuit Low / High (Sensor-1, Bank-1). . . .1A-61

DTC P0037 / P0038: HO2S Heater Control

Circuit Low / High (Sensor-2, Bank-1). . . .1A-65

DTC P0051 / P0052: HO2S Heater Control

Circuit Low / High (Sensor-1, Bank-2). . . .1A-68

DTC P0057 / P0058: HO2S Heater Control

Circuit Low / High (Sensor-2, Bank-2). . . .1A-72

DTC P0101: Mass Air Flow Circuit Range /

Performance. . . . . . . . . . . . . 1A-75

DTC P0102 / P0103: Mass Air Flow Circuit

Low / High Input . . . . . . . . . . . ..1A-77

DTC P0107 / P0108: Manifold Absolute

Pressure Sensor Circuit Low / High Input . ...1A-78

DTC P0111: Intake Air Temperature Sensor

Circuit Performance . . . . . . . . . . 1A-81

DTC P0112 / P0113: Intake Air Temperature

Sensor Circuit Low / High Input. . . . . ...1A-82

DTC P0116: Engine Coolant Temperature

Circuit Range / Performance. . . . . . ...1A-84

DTC P0117 / P0118: Engine Coolant

Temperature Circuit Low / High Input . . . .1A-86

DTC P0122 / P0123: Throttle Position Sensor

(Main) Circuit Low / High Input. . . . . . 1A-87

DTC P0133 / P2A00: O2 Sensor Circuit Slow

Response / Performance (Sensor-1, Bank-
1) . . . . . . . . . . . . . . . . . .1A-89

DTC P0134: O2 Sensor Circuit No Activity

(Sensor-1, Bank-1). . . . . . . . . . ..1A-91

DTC P0137 / P0138: O2 Sensor Circuit Low

Voltage / High Voltage (Sensor-2, Bank-1) . .1A-93

DTC P0140: O2 Sensor Circuit No Activity

Detected (Sensor-2, Bank-1) . . . . . . ..1A-95

DTC P0153 / P2A03: O2 Sensor Circuit Slow

Response / Performance (Sensor-1, Bank-
2) . . . . . . . . . . . . . . . . . .1A-97

DTC P0154: O2 Sensor Circuit No Activity

(Sensor-1, Bank-2). . . . . . . . . . ..1A-99

1-ii Table of Contents

DTC P0157 / P0158: O2 Sensor Circuit Low

Voltage / High Voltage (Sensor-2, Bank-2) ...1A-101

DTC P0160: O2 Sensor Circuit No Activity

Detected (Sensor-2, Bank-2) . . . . . . 1A-103

DTC P0171 / P0172: System Too Lean / Too

Rich (Sensor-1, Bank-1) . . . . . . . ...1A-105

DTC P0174 / P0175: System Too Lean / Too

Rich (Sensor-1, Bank-2) . . . . . . . ...1A-108

DTC P0222 / P0223: Throttle Position Sensor

(Sub) Circuit Low/High . . . . . . . . ..1A-111

DTC P0300 / P0301 / P0302 / P0303 / P0304

/ P0305 / P0306: Misfire Detected . . . . 1A-113

DTC P0327 / P0328: Knock Sensor Circuit

Low / High . . . . . . . . . . . . . .1A-115

DTC P0335: Crankshaft Position Sensor

Circuit. . . . . . . . . . . . . . . 1A-117

DTC P0336: Crankshaft Position Sensor

Circuit Range / Performance. . . . . . .1A-119

DTC P0340: Camshaft Position Sensor

Circuit. . . . . . . . . . . . . . . 1A-120

DTC P0341: Camshaft Position Sensor

Circuit Range / Performance. . . . . . .1A-122

DTC P0401 / P0402: Exhaust Gas

Recirculation Flow Insufficient Detected /
Excessive Detected . . . . . . . . . ..1A-123

DTC P0403: Exhaust Gas Recirculation

Control Circuit . . . . . . . . . . . ...1A-125

DTC P0420 / P0430: Catalyst System

Efficiency Below Threshold (Bank-1 / -2) . ..1A-127

DTC P0444 / P0445: EVAP Emission System

Purge Control Valve Circuit Open / Shorted .1A-129

DTC P0462 / P0463: Fuel Level Sensor

Circuit Low / High . . . . . . . . . . ..1A-131

DTC P0480 / P0481 / P0482: Fan 1 / Fan 2 /

Fan 3 Control Circuit . . . . . . . . . .1A-133

DTC P0500: Vehicle Speed Sensor. . . . 1A-135
DTC P0532 / P0533: A/C Refrigerant

Pressure Sensor Circuit Low / High . . . ..1A-136

DTC P0601 / P0602 / P0607: Internal Control

Module Memory Check Sum Error / Control
Module Programming Error / Control Module
Performance . . . . . . . . . . . . .1A-137

DTC P0616 / P0617: Starter Relay Circuit

Low / High . . . . . . . . . . . . . .1A-138

DTC P0645: A/C Clutch Relay Control Circuit 1A-140
DTC P0661 / P0662: Intake Manifold Tuning

Valve Control Circuit Low / High . . . . ...1A-142

DTC P1107 / P1108: Manifold Absolute

Pressure Sensor Rationality Check - Low /
High. . . . . . . . . . . . . . . ...1A-144

DTC P1510: ECM Back-Up Power Supply

Malfunction. . . . . . . . . . . . . 1A-145

DTC P1603: TCM Trouble Code Detected . .1A-146
DTC P2101: Throttle Actuator Control Motor

Circuit Range / Performance. . . . . . .1A-147

DTC P2102: Throttle Actuator Control Motor

Circuit Low . . . . . . . . . . . . . 1A-149

DTC P2103: Throttle Actuator Control Motor

Circuit High . . . . . . . . . . . . ...1A-151

DTC P2108: Throttle Actuator Control Module

Performance. . . . . . . . . . . . ..1A-152

DTC P2119: Throttle Actuator Control Throttle

Body Range / Performance. . . . . . ...1A-152

DTC P2122 / P2123: Pedal Position Sensor

(Main) Circuit Low / High. . . . . . . ...1A-153

DTC P2127 / P2128: Pedal Position Sensor

(Sub) Circuit Low / High . . . . . . . . 1A-155

DTC P2135: Throttle Position Sensor (Main /

Sub) Voltage Correction. . . . . . . . 1A-157

DTC P2138: Pedal Position Sensor (Main /

Sub) Voltage Correction. . . . . . . . 1A-159

DTC P2195 / P2196: O2 Sensor Signal Stuck

Lean / Stuck Rich (Sensor-1, Bank-1). . ...1A-161

DTC P2197 / P2198: O2 Sensor Signal Stuck

Lean / Stuck Rich (Sensor-1, Bank-2). . ...1A-163

DTC P2227/ P2228 / P2229: Barometric

Pressure Circuit Malfunction . . . . . . .1A-165

DTC P2237: O2 Sensor Positive Current

Control Circuit / Open (Sensor-1, Bank-1) . 1A-166

DTC P2238 / P2239: O2 Sensor Positive

Current Control Circuit Low / High (Sensor-
1, Bank-1). . . . . . . . . . . . . ..1A-168

DTC P2240: O2 Sensor Positive Current

Control Circuit / Open (Sensor-1, Bank-2) . 1A-170

DTC P2241 / P2242: O2 Sensor Positive

Current Control Circuit Low / High (Sensor-
1, Bank-2). . . . . . . . . . . . . ..1A-172

DTC P2252 / P2253: O2 Sensor Negative

Current Control Circuit Low/High (Sensor-1,
Bank-1). . . . . . . . . . . . . . ..1A-174

DTC P2255 / P2256: O2 Sensor Negative

Current Control Circuit Low/High (Sensor-1,
Bank-2). . . . . . . . . . . . . . ..1A-176

DTC P2627 / P2628: O2 Sensor Pumping

Current Trim Circuit Low / High (Sensor-1,
Bank-1). . . . . . . . . . . . . . ..1A-178

DTC P2630 / P2631: O2 Sensor Pumping

Current Trim Circuit Low / High (Sensor-1,
Bank-2). . . . . . . . . . . . . . ..1A-180

DTC P2A01: O2 Sensor Circuit Performance

(Sensor-2, Bank-1). . . . . . . . . . 1A-182

DTC P2A04: O2 Sensor Circuit Performance

(Sensor-2, Bank-2). . . . . . . . . . 1A-184

DTC U0073: Control Module Communication

Bus Off . . . . . . . . . . . . . . ..1A-186

DTC U0101: Lost Communication with TCM ..1A-190
DTC U0121: Lost Communication with

Electronic Stability Program / ABS Control
Module . . . . . . . . . . . . . . ..1A-194

DTC U0140: Lost Communication with Body

Control Module. . . . . . . . . . . ..1A-197

Inspection of ECM and Its Circuits . . . . ..1A-201
ECM Power and Ground Circuit Check. . ...1A-223
Fuel Injector Circuit Check . . . . . . . ..1A-226
Fuel Pump and Its Circuit Check. . . . . .1A-228
Fuel Pressure Check. . . . . . . . . ...1A-230
A/C System Circuits Check . . . . . . . .1A-232
Electric Load Signal Circuit Check . . . . ..1A-235

Table of Contents 1-iii

Radiator Cooling Fan Low Speed Control

System Check. . . . . . . . . . . ... 1A-237

Radiator Cooling Fan High Speed Control

System Check. . . . . . . . . . . ... 1A-240

Repair Instructions . . . . . . . . . . ..1A-242

Idle Speed and IAC Throttle Valve Opening

Inspection. . . . . . . . . . . . . .. 1A-242

Special Tools and Equipment . . . . . . .1A-243

Special Tool . . . . . . . . . . . . . 1A-243

Aux. Emission Control Devices . . . . 1B-1

Component Location . . . . . . . . . . ...1B-1

PCV System Location . . . . . . . . . . . 1B-1

Diagnostic Information and Procedures. . . 1B-2

EGR System Inspection (If Equipped) . . . . 1B-2
EVAP Canister Purge System Inspection . . ... 1B-2

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

EVAP Canister Purge Valve and Its Circuit

Inspection. . . . . . . . . . . . . . .. 1B-3

EVAP Canister Purge Valve Inspection . . . .. 1B-4
EVAP Canister Removal and Installation. . . 1B-5
EVAP Canister Inspection. . . . . . . . ... 1B-5
Vacuum Passage Inspection . . . . . . . .. 1B-5
PCV Hose Inspection. . . . . . . . . . .. 1B-5
PCV Valve Removal and Installation . . . . .. 1B-6
PCV Valve Inspection . . . . . . . . . . . 1B-6
EGR Valve Assembly Removal and

Installation (If Equipped) . . . . . . . . ... 1B-6

EGR Valve Assembly Inspection (If

Equipped). . . . . . . . . . . . . . .. 1B-7

Specifications. . . . . . . . . . . . . ...1B-7

Tightening Torque Specifications. . . . . . 1B-7

Special Tools and Equipment . . . . . . . .1B-8

Recommended Service Material. . . . . . . 1B-8
Special Tool . . . . . . . . . . . . . . 1B-8

Engine Electrical Devices . . . . . ... 1C-1

Repair Instructions . . . . . . . . . . . ..1C-1

Engine Control Module (ECM) Removal and

Installation. . . . . . . . . . . . . . .1C-1

Mass Air Flow (MAF) and Intake Air

Temperature (IAT) Sensor On-Vehicle
Inspection. . . . . . . . . . . . . . ..1C-2

Mass Air Flow (MAF) and Intake Air

Temperature (IAT) Sensor Removal and
Installation. . . . . . . . . . . . . . .1C-3

Electric Throttle Body Assembly On-Vehicle

Inspection. . . . . . . . . . . . . . ..1C-3

Electric Throttle Body System Calibration. . ...1C-5
Accelerator Pedal Position (APP) Sensor

Assembly On-Vehicle Inspection . . . . . ..1C-6

Accelerator Pedal Position (APP) Sensor

Assembly Removal and Installation . . . . ..1C-6

Accelerator Pedal Position (APP) Sensor

Assembly Inspection . . . . . . . . . . .1C-7

Engine Coolant Temperature (ECT) Sensor

Removal and Installation. . . . . . . . ...1C-7

Engine Coolant Temperature (ECT) Sensor

Inspection. . . . . . . . . . . . . . ..1C-8

Manifold Absolute Pressure (MAP) Sensor

Removal and Installation (If Equipped) . . . .1C-8

Manifold Absolute Pressure (MAP) Sensor

Inspection. . . . . . . . . . . . . . ..1C-9

Air Fuel Ratio (A/F) Sensor On-Vehicle

Inspection. . . . . . . . . . . . . . ..1C-9

Heated Oxygen Sensor (HO2S-2) Heater On-

Vehicle Inspection (If Equipped) . . . . . .1C-10

Air Fuel Ratio (A/F) Sensor (Sensor-1)

Removal and Installation. . . . . . . . .1C-11

Heated Oxygen Sensor (Sensor-2) Removal

and Installation (If Equipped) . . . . . . ..1C-12

Camshaft Position (CMP) Sensor Removal

and Installation . . . . . . . . . . . . 1C-12

Crankshaft Position (CKP) Sensor Removal

and Installation . . . . . . . . . . . . 1C-13

Camshaft Position (CMP) Sensor and

Crankshaft Position (CKP) Sensor
Inspection. . . . . . . . . . . . . . 1C-13

Knock Sensor Removal and Installation . . ...1C-14
Engine and Emission Control System Relay

Inspection. . . . . . . . . . . . . . 1C-14

IMT Vacuum Tank Assembly Inspection. . ...1C-15

Specifications. . . . . . . . . . . . . .1C-17

Tightening Torque Specifications. . . . . ..1C-17

Engine Mechanical . . . . . . . . .. 1D-1

General Description . . . . . . . . . . . .1D-1

Engine General Information . . . . . . . . 1D-1
Air Cleaner Filter Introduction . . . . . . . .1D-2
IMT (Intake Manifold Tuning) System

Description . . . . . . . . . . . . . . 1D-2

Diagnostic Information and Procedures. . . 1D-3

Compression Check. . . . . . . . . . . 1D-3
Engine Vacuum Check. . . . . . . . . . 1D-4
Valve Lash (Clearance) Inspection . . . . . .1D-5

Repair Instructions . . . . . . . . . . . ..1D-8

Air Intake System Components. . . . . . ...1D-8
Air Cleaner Filter Removal and Installation. . .1D-9
Air Cleaner Filter Inspection and Cleaning. . ..1D-9
Intake Collector and Intake Manifold

Components. . . . . . . . . . . . . ..1D-9

Electric Throttle Body Assembly On-Vehicle

Inspection. . . . . . . . . . . . . . 1D-10

Electric Throttle Body Assembly Removal and

Installation . . . . . . . . . . . . . ...1D-10

IMT (Intake Manifold Tuning) Valve Removal

and Installation . . . . . . . . . . . . 1D-11

IMT (Intake Manifold Tuning) Valve

Inspection. . . . . . . . . . . . . . 1D-11

Intake Collector and Intake Manifold Removal

and Installation . . . . . . . . . . . . 1D-12

Cylinder Head Covers Removal and

Installation . . . . . . . . . . . . . ...1D-14

Engine Mounting Components. . . . . . ..1D-16
Engine Assembly Removal and Installation . ..1D-17
Timing Chain Cover Components . . . . . .1D-20
Engine Block Heater (If Equipped) Removal

and Installation . . . . . . . . . . . . 1D-20