Suzuki Grand Vitara JB416 / JB420. Manual — part 159

3-ii Table of Contents

Input / Output Signal Table of 4WD Control

Module . . . . . . . . . . . . . . . ..3C-9

On-Board Diagnostic System Description. . .3C-10
CAN Communication System Description. . .3C-11

Schematic and Routing Diagram. . . . . ..3C-12

4WD Control System Wiring Circuit Diagram. 3C-12

Component Location . . . . . . . . . . .3C-13

Transfer Shift Control System Components. ..3C-13

Diagnostic Information and Procedures. . ..3C-14

4WD Control System Check . . . . . . . .3C-14
Transfer Position Indicator Operation Check . 3C-17
4WD Control System Operation Inspection . ..3C-17
Visual Inspection . . . . . . . . . . . ...3C-18
DTC Check. . . . . . . . . . . . . . 3C-19
DTC Clearance . . . . . . . . . . . . .3C-20
DTC Table. . . . . . . . . . . . . . .3C-21
Fail-Safe Table. . . . . . . . . . . . ..3C-22
Scan Tool Data . . . . . . . . . . . . .3C-22
Scan Tool Data Definitions. . . . . . . . 3C-23
4WD Control Symptom Diagnosis. . . . . .3C-23
Transfer Position Indicator Does Not Come

ON at Ignition Switch ON but Engine Stops. 3C-25

Transfer Position Indicator Remains ON

Steady at Ignition Switch ON . . . . . . ..3C-27

DTC C1213: Transfer Switch Circuit Open . ...3C-28
DTC C1214: Transfer Switch Circuit Short . ...3C-29
DTC C1223 / C1235: Transfer Shift Actuator

Motor Position Switch 1 Circuit Open /
Transfer Shift Actuator Motor Position
Switch 2 Circuit Open . . . . . . . . . .3C-31

DTC C1224 / C1236: Transfer Shift Actuator

Motor Position Switch 1 Circuit Short /
Transfer Shift Actuator Motor Position
Switch 2 Circuit Short. . . . . . . . . ..3C-33

DTC C1227: 4L/N Switch Circuit Open . . . .3C-35
DTC C1228: 4L/N Switch Circuit Short . . . .3C-36
DTC C1230: Transfer Actuator Circuit

Malfunction. . . . . . . . . . . . . ..3C-38

DTC C1237: Center Differential Lock Switch

Circuit Open . . . . . . . . . . . . . 3C-39

DTC C1238: Center Differential Lock Switch

Circuit Short . . . . . . . . . . . . . 3C-41

DTC C1240: 4WD Control Module Power

Supply Circuit Malfunction . . . . . . . ..3C-42

DTC C1243: Internal Circuit Malfunction of

4WD Control Module. . . . . . . . . ...3C-43

DTC C1246: Clutch Pedal Position (CPP)

Switch Circuit Short. . . . . . . . . . .3C-44

DTC U1073: Control Module Communication

Buss Off . . . . . . . . . . . . . . ..3C-45

DTC U1100: Lost Communication with ECM . 3C-47
DTC U1101: Lost Communication with TCM . 3C-49
DTC U1121: Lost Communication with ABS

Hydraulic Unit / Control Module . . . . . ..3C-51

Inspection of 4WD Control Module and Its

Circuits . . . . . . . . . . . . . . . 3C-53

Repair Instructions . . . . . . . . . . . 3C-55

Transfer Oil Level Check. . . . . . . . ...3C-55
Transfer Oil Change. . . . . . . . . . ..3C-55

Transfer Oil Seal Removal and Installation. ...3C-56
Transfer Switch Removal and Installation. . .3C-57
Transfer Switch Inspection. . . . . . . . 3C-57
4WD Control Module Removal and

Installation . . . . . . . . . . . . . ...3C-57

Transfer Assembly Dismounting and

Remounting. . . . . . . . . . . . . .3C-58

Transfer Assembly Components. . . . . ...3C-59
Transfer Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-60

Transfer Assembly Inspection. . . . . . ...3C-68
Input Gear Assembly, Counter Gear

Assembly, Front Output Shaft Assembly and
Rear Output Shaft Assembly Components . .3C-70

Input Gear Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-71

Counter Gear Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-72

Front Output Shaft Assembly Disassembly

and Reassembly . . . . . . . . . . . .3C-72

Rear Output Shaft Assembly Disassembly

and Reassembly . . . . . . . . . . . .3C-73

Specifications . . . . . . . . . . . . . .3C-74

Tightening Torque Specifications. . . . . ..3C-74

Special Tools and Equipment . . . . . . ...3C-74

Recommended Service Material . . . . . ...3C-74
Special Tool . . . . . . . . . . . . . ..3C-75

Non-Shift Type (Transfer without Shift

Actuator) . . . . . . . . . . . . . . . ..3C-76

Precautions. . . . . . . . . . . . . . .3C-76

Transfer Warning . . . . . . . . . . . ..3C-76

General Description . . . . . . . . . . ...3C-76

Transfer Construction. . . . . . . . . . 3C-76

Diagnostic Information and Procedures . . ..3C-77

Transfer Symptom Diagnosis. . . . . . . 3C-77

Repair Instructions . . . . . . . . . . . 3C-78

Transfer Oil Change. . . . . . . . . . ..3C-78
Transfer Oil Level Check. . . . . . . . ...3C-78
Transfer Oil Seal Removal and Installation. ...3C-78
Transfer Assembly Dismounting and

Remounting. . . . . . . . . . . . . .3C-78

Transfer Assembly Components. . . . . ...3C-79
Transfer Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-80

Input Gear Assembly Disassembly and

Reassembly . . . . . . . . . . . . . 3C-87

Front Output Shaft Assembly Disassembly

and Reassembly . . . . . . . . . . . .3C-87

Rear Output Shaft Assembly Disassembly

and Reassembly . . . . . . . . . . . .3C-87

Specifications . . . . . . . . . . . . . .3C-88

Tightening Torque Specifications. . . . . ..3C-88

Special Tools and Equipment . . . . . . ...3C-88

Recommended Service Material . . . . . ...3C-88
Special Tool . . . . . . . . . . . . . ..3C-88

Propeller Shaft . . . . . . . . . . . 3D-1

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

Propeller Shaft Caution . . . . . . . . . ...3D-1

Table of Contents 3-iii

General Description . . . . . . . . . . . .3D-1

Propeller Shaft Construction . . . . . . . ...3D-1

Diagnostic Information and Procedures. . . 3D-2

Propeller Shaft Symptom Diagnosis . . . . ...3D-2

Repair Instructions . . . . . . . . . . . ..3D-2

Propeller Shaft Joint Check . . . . . . . . 3D-2
Propeller Shaft Removal and Installation. . . 3D-2

Propeller Shaft Disassembly and Assembly . ...3D-3
Propeller Shaft Inspection . . . . . . . . ...3D-5

Specifications. . . . . . . . . . . . . ...3D-6

Tightening Torque Specifications. . . . . . 3D-6

Special Tools and Equipment . . . . . . . .3D-6

Recommended Service Material . . . . . . .3D-6
Special Tool . . . . . . . . . . . . . . 3D-6

3-1 Precautions:

Driveline / Axle

Precautions

Precautions

Precautions for Driveline / Axle

S5JB0A3000001

Differential Gear Oil Note
Refer to “Differential Gear Oil Note in Section 00”.

Fastener Caution
Refer to “Fastener Caution in Section 00”.

Precautions for Transfer
Refer to “Precautions in Diagnosing Trouble: Motor-Shift Type (Transfer with Shift Actuator) in Section 3C”.

Drive Shaft / Axle: Front 3A-1

Driveline / Axle

Drive Shaft / Axle

Front

General Description

Front Drive Shaft Construction

S5JB0A3111001

A constant velocity tripod joint is used on the differential side of both the right and left drive shaft assemblies. And, a
constant velocity ball joint is used on the wheel side of both the right and left drive shaft assemblies. The drive shaft
can slide through the tripod joint in the extension / contraction direction.

Diagnostic Information and Procedures

Front Drive Shaft Symptom Diagnosis

S5JB0A3114001

Condition

Possible cause

Correction / Reference Item

Abnormal noise: When
starting

Loose wheel nut(s)

Tighten wheel nut(s) referring to “Wheel
Removal and Installation in Section 2D”.

Loose drive shaft flange bolt(s)

Tighten drive shaft flange bolt(s) referring to
“Front Drive Shaft Assembly Removal and
Installation: Front”.

Broken or damaged wheel bearing

Replace referring to “Front Wheel Hub, Disc,
Nut and Bearing Check in Section 2B”.

Abnormal noise: When
making turns

Grease leakage from boot

Replace boot and apply grease referring to
“Front Drive Shaft Disassembly and Assembly:
Front”.

Worn or broken drive shaft joint

Replace drive shaft joint referring to “Front
Drive Shaft Disassembly and Assembly:
Front”.

Abnormal noise: When
running

Broken drive shaft joint

Replace drive shaft joint referring to “Front
Drive Shaft Disassembly and Assembly:
Front”.

Poorly lubricated or worn joint

Lubricate or replace joint referring to “Front
Drive Shaft Disassembly and Assembly:
Front”.

Loose drive shaft flange bolt(s)

Tighten drive shaft flange bolt(s) referring to
“Front Drive Shaft Assembly Removal and
Installation: Front”.

Vibration

Worn drive shaft joint

Replace drive shaft joint referring to “Front
Drive Shaft Disassembly and Assembly:
Front”.

Deformed drive shaft

Replace referring to “Front Drive Shaft
Disassembly and Assembly: Front”.