Suzuki Grand Vitara JB416 / JB420. Manual — part 11
0B-16 Maintenance and Lubrication:
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-2
Statement on Cleanliness and Care . . . . ... 1A-2
Engine Diagnosis General Description . . . ... 1A-3
On-Board Diagnostic System Description. . ... 1A-3
Engine and Emission Control System
Description . . . . . . . . . . . . . . 1A-6
CAN Communication System Description. . ... 1A-6
Air Intake System Description. . . . . . . . 1A-9
Electric Throttle Body System Description . . 1A-10
Description of Electric Throttle Body System
Calibration. . . . . . . . . . . . . ...1A-11
Generator Control System Description . . . .1A-11
A/F Sensor Description . . . . . . . . . . 1A-12
Electronic Control System Description. . . .. 1A-13
Engine and Emission Control Input / Output
Table . . . . . . . . . . . . . . . ... 1A-14
Schematic and Routing Diagram. . . . . ..1A-15
Engine and Emission Control System
Diagram . . . . . . . . . . . . . . ..1A-15
Engine and Emission Control System Flow
Diagram . . . . . . . . . . . . . . ..1A-17
ECM Input / Output Circuit Diagram. . . . ..1A-18
Component Location . . . . . . . . . . .1A-24
Electronic Control System Components
Location . . . . . . . . . . . . . . ..1A-24
Diagnostic Information and Procedures. . ..1A-26
Engine and Emission Control System Check. 1A-26
Malfunction Indicator Lamp (MIL) Check . . .. 1A-29
DTC Check . . . . . . . . . . . . . ...1A-29
DTC Clearance . . . . . . . . . . . . . 1A-30
DTC Table. . . . . . . . . . . . . . .1A-31
Fail-Safe Table. . . . . . . . . . . . ..1A-36
Scan Tool Data . . . . . . . . . . . . .1A-38
Visual Inspection . . . . . . . . . . . ...1A-44
Engine Basic Inspection. . . . . . . . . 1A-45
Engine Symptom Diagnosis . . . . . . . ..1A-49
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 P0010: Camshaft Position Actuator
Circuit (For M16 Engine) . . . . . . . . .1A-61
DTC P0011 / P0012: Camshaft Position -
Timing Over-Advanced or System
Performance / -Retarded (For M16 Engine). 1A-63
DTC P0030: HO2S Heater Control Circuit
(Sensor-1) . . . . . . . . . . . . . ...1A-65
DTC P0031 / P0032: HO2S Heater Control
Circuit Low / High (Sensor-1) . . . . . . ..1A-66
DTC P0037 / P0038: HO2S Heater Control
Circuit Low / High (Sensor-2) . . . . . . ..1A-70
DTC P0101: Mass Air Flow Circuit Range /
Performance. . . . . . . . . . . . . 1A-73
DTC P0102: Mass Air Flow Circuit Low Input ...1A-76
DTC P0103: Mass Air Flow Circuit High Input ..1A-78
DTC P0106: Manifold Absolute Pressure
Range / Performance . . . . . . . . . ..1A-80
DTC P0107: Manifold Absolute Pressure
Circuit Low Input . . . . . . . . . . . .1A-81
DTC P0108: Manifold Absolute Pressure
Circuit High Input. . . . . . . . . . . .1A-83
DTC P0111: Intake Air Temperature Circuit
Range / Performance . . . . . . . . . ..1A-85
DTC P0112: Intake Air Temperature Sensor
Circuit Low . . . . . . . . . . . . . ..1A-88
DTC P0113: Intake Air Temperature Sensor
Circuit High. . . . . . . . . . . . . ..1A-90
DTC P0116: Engine Coolant Temperature
Circuit Range / Performance. . . . . . ...1A-92
DTC P0117: Engine Coolant Temperature
Circuit Low . . . . . . . . . . . . . ..1A-95
DTC P0118: Engine Coolant Temperature
Circuit High. . . . . . . . . . . . . ..1A-96
1-ii Table of Contents
DTC P0123: Throttle Position Sensor (Main)
Circuit High . . . . . . . . . . . . ...1A-102
DTC P0131 / P0132 / P0134: O2 Sensor
(HO2S) Circuit Low Voltage / High Voltage /
No Activity Detected (Sensor-1). . . . . 1A-105
DTC P0133: O2 Sensor (HO2S) Circuit Slow
Response (Sensor-1) . . . . . . . . . 1A-106
DTC P0137 / P0138: O2 Sensor (HO2S)
Circuit Low Voltage / High Voltage (Sensor-
2). . . . . . . . . . . . . . . . ...1A-108
DTC P0140: O2 Sensor (HO2S) Circuit No
Activity Detected (Sensor-2) . . . . . . .1A-111
DTC P0171 / P0172 / P2195 / P2196: Fuel
System Too Lean / Rich / Stuck Lean / Stuck
Rich . . . . . . . . . . . . . . . ...1A-112
DTC P0222: Throttle Position Sensor (Sub)
Circuit Low . . . . . . . . . . . . . 1A-116
DTC P0223: Throttle Position Sensor (Sub)
Circuit High . . . . . . . . . . . . ...1A-119
DTC P0300 / P0301 / P0302 / P0303 / P0304:
DTC P0327 / P0328: Knock Sensor Circuit
Low / High . . . . . . . . . . . . . .1A-124
DTC P0335: Crankshaft Position (CKP)
Sensor Circuit (For J20 Engine). . . . . 1A-126
DTC P0335: Crankshaft Position (CKP)
Sensor Circuit (For M16 Engine). . . . ...1A-128
DTC P0340: Camshaft Position (CMP)
Sensor Circuit . . . . . . . . . . . ...1A-131
DTC P0401 / P0402: Exhaust Gas
Recirculation Flow Insufficient Detected /
Excessive Detected . . . . . . . . . ..1A-134
DTC P0403: Exhaust Gas Recirculation
Control Circuit . . . . . . . . . . . ...1A-137
DTC P0420: Catalyst System Efficiency
below Threshold. . . . . . . . . . . 1A-139
DTC P0443: Evaporative Emission System
Purge Control Valve Circuit. . . . . . ...1A-141
DTC P0462: Fuel Level Sensor Circuit Low. 1A-143
DTC P0463: Fuel Level Sensor Circuit High...1A-145
DTC P0480: Fan 1 (Radiator Cooling Fan)
Control Circuit . . . . . . . . . . . ...1A-147
DTC P0500: Vehicle Speed Sensor (VSS)
Malfunction. . . . . . . . . . . . . 1A-151
DTC P0504: Brake Switch “A”/“B” Correlation
(For J20 Engine) . . . . . . . . . . ...1A-153
DTC P0532: A/C Refrigerant Pressure
Sensor Circuit Low . . . . . . . . . . 1A-155
DTC P0533: A/C Refrigerant Pressure
Sensor Circuit High . . . . . . . . . ...1A-157
DTC P0601 / P0602 / P0607: Internal Control
DTC P0616: Starter Relay Circuit Low. . . 1A-159
DTC P0617: Starter Relay Circuit High. . ...1A-160
DTC P0620: Generator Control Circuit . . ...1A-162
DTC P0625 / P0626: Generator Field
Terminal Circuit Low / High . . . . . . ...1A-164
DTC P0660: Intake Manifold Tuning Valve
Control Circuit / Open (For J20 Engine). . 1A-166
DTC P1501 / P1502: Electric Load Current
Sensor Circuit Low / High. . . . . . . ..1A-168
DTC P1510: ECM Back-Up Power Supply
Malfunction. . . . . . . . . . . . . 1A-170
DTC P1603: TCM Trouble Code Detected
(For J20 Engine) . . . . . . . . . . ...1A-172
DTC P1674: CAN Communication (Bus Off
Error) . . . . . . . . . . . . . . . .1A-173
DTC P1676: CAN Communication (Reception
Error for TCM (for A/T model)) . . . . . ..1A-178
DTC P1678: CAN Communication (Reception
Error for BCM). . . . . . . . . . . ...1A-182
DTC P1685: CAN Communication (Reception
Error for ABS Control Module) . . . . . ..1A-186
DTC P2101: Throttle Actuator Control Motor
Circuit Range / Performance. . . . . . .1A-189
DTC P2102: Throttle Actuator Control Motor
Circuit Low . . . . . . . . . . . . . 1A-191
DTC P2103: Throttle Actuator Control Motor
Circuit High. . . . . . . . . . . . . 1A-193
DTC P2111: Throttle Actuator Control System
- Stuck Open . . . . . . . . . . . . .1A-194
DTC P2119: Throttle Actuator Control Throttle
Body Range / Performance. . . . . . ...1A-195
DTC P2122: Pedal Position Sensor (Main)
Circuit Low Input . . . . . . . . . . ...1A-197
DTC P2123: Pedal Position Sensor (Main)
Circuit High Input. . . . . . . . . . ...1A-200
DTC P2127: Pedal Position Sensor (Sub)
Circuit Low Input . . . . . . . . . . ...1A-202
DTC P2128: Pedal Position Sensor (Sub)
Circuit High Input. . . . . . . . . . ...1A-204
DTC P2135: Throttle Position Sensor (Main /
Sub) Voltage Correlation. . . . . . . ...1A-207
DTC P2138: Pedal Position Sensor (Main /
Sub) Voltage Correlation. . . . . . . ...1A-210
DTC P2227 / P2228 / P2229: Barometric
Pressure Circuit Malfunction . . . . . . .1A-212
Inspection of ECM and Its Circuits . . . . ..1A-214
ECM Power and Ground Circuit Check. . ...1A-236
Fuel Injector Circuit Check . . . . . . . ..1A-240
Fuel Pump and Its Circuit Check. . . . . .1A-242
Fuel Pressure Check. . . . . . . . . ...1A-245
A/C System Circuits Check . . . . . . . .1A-247
Electric Load Signal Circuit Check . . . . ..1A-250
Radiator Cooling Fan Low Speed Control
System Check . . . . . . . . . . . ...1A-252
Radiator Cooling Fan High Speed Control
System Check . . . . . . . . . . . ...1A-255
Repair Instructions . . . . . . . . . . ..1A-257
Idle Speed and IAC Throttle Valve Opening
Inspection. . . . . . . . . . . . . ..1A-257
Special Tools and Equipment . . . . . . .1A-258
Table of Contents 1-iii
Diagnostic Information and Procedures. . . 1B-1
EGR System Inspection. . . . . . . . . .. 1B-1
Repair Instructions . . . . . . . . . . . ..1B-1
EVAP Canister Purge Inspection . . . . . . 1B-1
EVAP Canister Purge Valve and Its Circuit
Inspection. . . . . . . . . . . . . . .. 1B-2
Vacuum Passage Inspection . . . . . . . .. 1B-3
Vacuum Hose and Purge Valve Chamber
Inspection. . . . . . . . . . . . . . .. 1B-3
EVAP Canister Purge Valve Inspection . . . .. 1B-3
EVAP Canister Inspection. . . . . . . . ... 1B-4
EGR Valve Removal and Installation . . . . .. 1B-4
EGR Valve Inspection. . . . . . . . . . . 1B-5
PCV Hose Inspection. . . . . . . . . . .. 1B-5
PCV Valve Removal and Installation . . . . .. 1B-5
PCV Valve Inspection . . . . . . . . . . . 1B-5
Specifications. . . . . . . . . . . . . ...1B-6
Tightening Torque Specifications. . . . . . 1B-6
Special Tools and Equipment . . . . . . . .1B-6
Recommended Service Material. . . . . . . 1B-6
Special Tool . . . . . . . . . . . . . . 1B-6
Engine Electrical Devices . . . . . ... 1C-1
Repair Instructions . . . . . . . . . . . ..1C-1
Engine Control Module (ECM) Removal and
Installation. . . . . . . . . . . . . . .1C-1
Manifold Absolute Pressure (MAP) Sensor
Inspection. . . . . . . . . . . . . . ..1C-1
Electric Throttle Body Assembly On-Vehicle
Inspection. . . . . . . . . . . . . . ..1C-2
Electric Throttle Body System Calibration. . ...1C-4
Accelerator Pedal Position (APP) Sensor
Assembly On-Vehicle Inspection . . . . . ..1C-5
Accelerator Pedal Position (APP) Sensor
Assembly Removal and Installation . . . . ..1C-5
Accelerator Pedal Position (APP) Sensor
Assembly Inspection . . . . . . . . . . .1C-6
Engine Coolant Temperature (ECT) Sensor
Removal and Installation. . . . . . . . ...1C-6
Engine Coolant Temperature (ECT) Sensor
Inspection. . . . . . . . . . . . . . ..1C-7
Air Fuel Ratio (A/F) Sensor On-Vehicle
Inspection. . . . . . . . . . . . . . ..1C-7
Heated Oxygen Sensor (HO2S-2) Heater On-
Vehicle Inspection. . . . . . . . . . . .1C-8
Air Fuel Ratio (A/F) Sensor, Heated Oxygen
Sensor (HO2S-2) Removal and Installation. ..1C-8
Camshaft Position (CMP) Sensor Removal
and Installation. . . . . . . . . . . . ..1C-8
Camshaft Position (CMP) Sensor Inspection. ..1C-9
Crankshaft Position (CKP) Sensor Removal
and Installation. . . . . . . . . . . . ..1C-9
Crankshaft Position (CKP) Sensor Inspection ..1C-10
Knock Sensor Removal and Installation . . ...1C-11
Control Relay Inspection . . . . . . . . ...1C-12
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor On-Vehicle
Inspection. . . . . . . . . . . . . . 1C-13
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor Removal and
Installation . . . . . . . . . . . . . ...1C-13
Mass Air Flow (MAF) and Intake Air
Temperature (IAT) Sensor Inspection. . . .1C-14
Vacuum Tank Assembly Inspection (For J20
Engine). . . . . . . . . . . . . . . 1C-14
Electric Load Current Sensor On-Vehicle
Inspection (For J20 Engine) . . . . . . . 1C-16
Electric Load Current Sensor Removal and
Installation (For J20 Engine) . . . . . . ...1C-16
Specifications. . . . . . . . . . . . . .1C-17
Tightening Torque Specifications. . . . . ..1C-17
Engine Mechanical . . . . . . . . .. 1D-1
For M16A Engine with VVT. . . . . . . . . .1D-1
General Description . . . . . . . . . . . .1D-1
Engine Construction Description. . . . . . .1D-1
Camshaft Position Control (VVT Variable
Valve Timing) System Description . . . . . 1D-2
Diagnostic Information and Procedures. . . 1D-4
Compression Check. . . . . . . . . . . 1D-4
Engine Vacuum Check. . . . . . . . . . 1D-5
Valve Lash (Clearance) Inspection . . . . . .1D-6
Repair Instructions . . . . . . . . . . . ..1D-9
Installation . . . . . . . . . . . . . . .1D-9
Throttle Body and Intake Manifold
Components. . . . . . . . . . . . . 1D-11
Throttle Body On-Vehicle Inspection. . . . .1D-11
Electric Throttle Body Assembly Removal and
Installation . . . . . . . . . . . . . ...1D-12
Throttle Body Cleaning. . . . . . . . . ..1D-12
Intake Manifold Removal and Installation . . .1D-13
Engine Mountings Components . . . . . . 1D-14
Engine Assembly Removal and Installation . ..1D-14
Timing Chain Cover Components . . . . . .1D-18
Timing Chain Cover Removal and Installation ..1D-19
Timing Chain Cover Inspection . . . . . . .1D-21
Oil Control Valve Removal and Installation. ...1D-21
Oil Control Valve Inspection. . . . . . . ..1D-22
Timing Chain and Chain Tensioner
Components. . . . . . . . . . . . . 1D-23
Timing Chain and Chain Tensioner Removal
and Installation . . . . . . . . . . . . 1D-23
Timing Chain and Chain Tensioner Inspection ..1D-26
Camshaft, Tappet and Shim Components . . 1D-27
Camshaft, Tappet and Shim Removal and
Installation . . . . . . . . . . . . . ...1D-27
Camshaft, Tappet and Shim Inspection . . . 1D-30
Valves and Cylinder Head Components . . ...1D-33
Valves and Cylinder Head Removal and
Installation . . . . . . . . . . . . . ...1D-34
Valves and Cylinder Head Disassembly and
Assembly. . . . . . . . . . . . . . .1D-35
Valves and Valve Guides Inspection. . . . .1D-38
Cylinder Head Inspection . . . . . . . . ..1D-40
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