Suzuki GRAND VITARA JB416, GRAND VITARA JB420 SERVICE MANUAL

IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words

WARNING

lighted by these signal words.

WARNING

Indicates a potential hazard that could result in death or injury.

CAUTION

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

WARNING

This service manual is intended for authorized Suzuki dealers and qualified service technicians only. Inexperienced technicians or technicians without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver and passengers.

, and NOTE have special meanings. Pay special attention to the messages high-

CAUTION

WARNING

For vehicles equipped with a Supplemental Restraint (Air Bag) System:

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury.

• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.

• Do not modify the steering wheel, instrument panel or any other air bag system component on or around air bag system components or wiring. Modifications can adversely affect air bag system performance and lead to injury.

• If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat belt with pretensioner, beforehand to avoid component damage or unintended activation.

The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.

FOREWORD

This SUPPLEMENTARY SERVICE MANUAL is a supplement to GRAND VITARA (JB416/JB420) SERVICE MANUAL. It has been prepared exclusively for the following applicable model.

Applicable model: GRAND VITARA (JB416/JB420) vehicles

This supplementary ser vice manual describes only different service information of the above applicable model as compared with GRAND VITARA (JB416/JB420) SERVICE MANUAL. Therefore, whenever servicing the above applicable models, consult this supplement first. And for any section, item or description not found in this supplement, refer to the related manual below.

When replacing parts or servicing by disassemb ling , it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.

All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approv al. And used as the main subject of description is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice.

Related Manuals:

Manual Name Manual No.

GRAND VITARA (JB416/JB420 ) SERVICE MANUAL 99500-64J00-01E

RECOMMENDATON OF GENUINE SUZUKI PARTS AND ACCESSORIES USE

SUZUKI strongly recommends the use of genuine SUZUKI parts* and accessories. Genuine SUZUKI parts and accessories are built to the highest standards of quality and performance, and are designed to fit the vehicle's exact specifications.

A wide variety of non-genuine replacement parts and accessories for SUZUKI vehicles are currently availabl e in the market. Using these par ts and accessories can affect the vehicle performance and shorten its useful life. Therefore, installation of non-genuine SUZUKI parts and accessories is not covered under warranty.

Non-Genuine SUZUKI Parts and Accessories

Some parts and accessories may be approved by certain authorities in your country. Some parts and accessories are sold as SUZUKI a uthorized replacement par ts and accessor ies. Some genuine SUZUKI parts and accessor ies are sold as re-use parts and accessories. These par ts and acce ssories are non-genuine Suzuki parts and accessories and use of these parts are not covered under warranty.

Re-use of Genuine SUZUKI Parts and Accessories

The resale or re-use of the following items which could give rise to safety hazards for users is expressly forbidden:

1) Air bag components and all other pyrotechnic items, including their components (e.g. cushion, control devices and sensors)

2) Seatbelt system, including their components (e.g. webbing, buckles, and retractors)

The air bag and seat belt pretensioner components contain explosive chemicals. These components should be removed and disposed of properly by SUZUKI authorized service shop or scrap yard to avoid unintended explosion before scrapping.

*The parts remanufactured under SUZUKI's approval can be used as genuine SUZUKI parts in Europe.

NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same

sections of the service manual mentioned in the “FOREWORD” of this manual.

Precautions............................................................... 00-i

Precautions ............................................................ 00-1

General Information ................................................... 0-i

General Information ............................................... 0A-1

Maintenance and Lubrication ..................................0B-*

Engine ......................................................................... 1-i

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

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

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

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

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

Engine Lubrication System .....................................1E-*

Engine Cooling System...........................................1F-*

Fuel System ........................................................... 1G-*

Ignition System....................................................... 1H-*

Starting System........................................................ 1I-*

Charging System..................................................... 1J-*

Exhaust System ......................................................1K-*

Suspension................................................................. 2-i

Precautions ............................................................... 2-*

Suspension General Diagnosis...............................2A-*

Front Suspension ................................................... 2B-1

Rear Suspension.................................................... 2C-*

Wheels and Tires ................................................... 2D-*

Driveline / Axle ........................................................... 3-i

Precautions ............................................................... 3-*

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

Differential ...............................................................3B-*

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

Propeller Shafts...................................................... 3D-*

Brakes ......................................................................... 4-i

Precautions .............................................................. 4-1

Brake Control System and Diagnosis ....................4A-1

Front Brakes........................................................... 4B-1

Rear Brakes ........................................................... 4C-*

Parking Brake......................................................... 4D-*

ABS ........................................................................ 4E-1

Electronic Stability Program ................................... 4F-1

Transmission / Transaxle .......................................... 5-i

Precautions ............................................................... 5-*

Automatic Transmission/Transaxle ........................5A-1

Manual Transmission/Transaxle ............................ 5B-*

Clutch ..................................................................... 5C-*

Steering....................................................................... 6-i

Precautions ............................................................... 6-*

Steering General Diagnosis ................................... 6A-*

Steering Wheel and Column ..................................6B-1

Power Assisted Steering System ........................... 6C-*

HVAC ........................................................................... 7-i

Precautions ............................................................... 7-*

Heater and Ventilation............................................ 7A-1

Air Conditioning System.........................................7B-1

Restraint...................................................................... 8-*

Precautions ............................................................... 8-*

Seat Belts............................................................... 8A-*

Air Bag System ...................................................... 8B-*

Body, Cab and Accessories ...................................... 9-i

Precautions .............................................................. 9-1

Wiring Systems ...................................................... 9A-*

Lighting Systems.................................................... 9B-1

Instrumentation / Driver Info. / Horn .......................9C-1

Wipers / Washers...................................................9D-1

Glass / Windows / Mirrors ...................................... 9E-*

Security and Locks..................................................9F-*

Seats ...................................................................... 9G-*

Interior Trim............................................................ 9H-*

Sun Roof / T-Top / Convertible Top .........................9I-*

Hood / Fenders / Doors........................................... 9J-*

Body Structure ....................................................... 9K-*

Paint / Coatings....................................................... 9L-*

Exterior Trim...........................................................9M-*

Control systems ....................................................... 10-i

Precautions ............................................................. 10-*

Cruise Control System .........................................10A-1

Body Electrical Control System ............................10B-1

Immobilizer Control System .................................10C-1

Keyless Start System ........................................... 10E-1

Table of Contents 00- i

Section 00

Precautions

CONTENTS

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.

Precautions ...............................................00-1

Precautions........................................................... 00-1

Precautions for Vehicles Equipped with

a Supplemental Restraint (Air Bag) System ...... 00-*

General Precautions ............................................ 00-*

Precaution in Servicing Full-Time 4WD

Vehicle ............................................................... 00-*

Precaution for Vehicle Equipped with ESP®

System ............................................................. 00-1

Precautions for Catalytic Converter .....................00-*

Precaution for CAN Communication System ....... 00-*

Precautions for Electrical Circuit Service .............00-*

Precautions for Installing Mobile

Communication Equipment ................................ 00-*

Air Bag Warning ...................................................00-*

Discharge Headlight Warning ..............................00-*

A/C System Caution.............................................00-*

Fastener Caution.................................................. 00-*

Suspension Caution ............................................. 00-*

Wheels and Tires Caution....................................00-*

Brakes Caution and Note .................................... 00-1

Differential Gear Oil Note .....................................00-*

Repair Instructions ...............................................00-*

Electrical Circuit Inspection Procedure ................00-*

Intermittent and Poor Connection Inspection .......00-*

00-1 Precautions:

Precautions

Precaution for Vehicle Equipped with ESP® System

S5JB0E0000020

• When testing with any of the following equipments (when vehicle is tested by rotating wheels (tires) under vehicle stop), be sure to deactivate ESP® system referring to “Precautions in Speedometer Test or Other Tests: in Section 4F” to obtain correct data. When vehicle acceleration is not sensed and wheels are rotating, ESP® control module judges that wheels are in slip condition and controls engine torque to reduce by TCS control.

– 2 or 4-wheel chassis dynamometer

– Speedometer tester

– Brake tester

–Etc.

ESP® control module

• When ESP® control module is removed / installed, do not use impact wrenches which generate shock or impact to avoid damaging sensors in ESP® control module.

• When any of the following operation is done, calibrate steering angle sensor, G sensor and master cylinder pressure sensor (in ESP® control module) referring to “Sensor Calibration: in Section 4F”.

– When battery or dome fuse is removed.

– When steering angle sensor is replaced. – When ESP® control module is removed.

– When yaw rate / G sensor assembly is removed.

Brakes Caution and Note

CAUTION

All brake fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/ or could result in major repair expense. They must be replaced with one of same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of all parts. There is to be no welding as it may result in extensive damage and weakening of the metal.

NOTE

Before inspecting and servicing brakes for vehicle equipped with ABS (ESP®), make sure that ABS (ESP®) is in good condition.

S5JB0E0000014

Table of Contents 0- i

Section 0

General Information

CONTENTS

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.

General Information ................................ 0A-1

General Description .............................................0A-1

Abbreviations ...................................................... 0A-1

Symbols ...............................................................0A-*

Wire Color Symbols .............................................0A-*

Fastener Information............................................0A-*

Vehicle Lifting Points............................................0A-*

Engine Supporting Points ....................................0A-*

Vehicle Identification Number ..............................0A-*

Engine Identification Number ...............................0A-*

Transmission Identification Number.....................0A-*

Component Location ........................................... 0A-*

Warning, Caution and Information Label

Location .............................................................0A-*

Maintenance and Lubrication..................0B-*

Precautions........................................................... 0B-*

Precautions for Maintenance and

Lubrication .........................................................0B-*

Scheduled Maintenance ...................................... 0B-*

Maintenance Schedule under Normal

Driving Conditions..............................................0B-*

Maintenance Recommended under Severe

Driving Conditions..............................................0B-*

Repair Instructions .............................................. 0B-*

Engine Accessory Drive Belt Inspection ..............0B-*

Engine Accessory Drive Belt Replacement..........0B-*

Valve Lash (Clearance) Inspection ......................0B-*

Engine Oil and Filter Change ...............................0B-*

Engine Coolant Change .......................................0B-*

Exhaust system Inspection ..................................0B-*

Spark Plugs Replacement ...................................0B-*

Air Cleaner Filter Inspection.................................0B-*

Air Cleaner Filter Replacement ............................0B-*

Fuel Lines and Connections Inspection ...............0B-*

Fuel Filter Replacement.......................................0B-*

Fuel Tank Inspection............................................0B-*

Crankcase Ventilation Hoses and

Connections Inspection (Vehicle without

A/F Sensor) ....................................................... 0B-*

PCV Valve Inspection ......................................... 0B-*

Fuel Evaporative Emission Control System

Inspection.......................................................... 0B-*

Brake Discs and Pads Inspection ....................... 0B-*

Brake Drums and Shoes Inspection.................... 0B-*

Brake Hoses and Pipes Inspection ..................... 0B-*

Brake Fluid Change ............................................ 0B-*

Parking Brake Lever and Cable Inspection......... 0B-*

Clutch Fluid Inspection........................................ 0B-*

Tire / Wheel Inspection and Rotation .................. 0B-*

Wheel Discs Inspection....................................... 0B-*

Wheel Bearing Inspection ................................... 0B-*

Suspension System Inspection ........................... 0B-*

Steering System Inspection ................................ 0B-*

Propeller Shafts and Drive Shafts

Inspection.......................................................... 0B-*

Manual Transmission Oil Inspection ................... 0B-*

Manual Transmission Oil Change ....................... 0B-*

Automatic Transmission Fluid Inspection............ 0B-*

Automatic Transmission Fluid Change ............... 0B-*

Automatic Transmission Fluid Cooler Hose

Inspection.......................................................... 0B-*

Transfer Oil Inspection (If Equipped) .................. 0B-*

Differential Oil Inspection .................................... 0B-*

Transfer (If Equipped) and Differential Oil

Change.............................................................. 0B-*

Power Steering (P/S) System Inspection ............ 0B-*

All Hinges, Latches and Locks Inspection........... 0B-*

HVAC Air Filter Inspection (If Equipped)............. 0B-*

HVAC Air Filter Replacement (If Equipped) ........ 0B-*

Final Inspection for Maintenance Service ........... 0B-*

Specifications....................................................... 0B-*

Tightening Torque Specifications........................ 0B-*

Special Tools and Equipment ............................. 0B-*

Recommended Fluids and Lubricants................. 0B-*

Special Tool ........................................................ 0B-*

0A-1 General Information:

General Information

General Description

Abbreviations

S5JB0E0101001

A: ABDC: After Bottom Dead Center ABS: Anti-lock Brake System AC: Alternating Current A/C: Air Conditioning A-ELR: Automatic-Emergency Locking Retractor A/F: Air Fuel Mixture Ratio ALR: Automatic Locking Retractor API: American Petroleum Institute ATDC: After Top Dead Center ATF: Automatic Transmission Fluid A/T: Automatic Transmission AWD: All Wheel Drive B: BBDC: Before Bottom Dead Center BCM: Body Electrical Control Module BTDC: Before Top Dead Center B+: Battery Positive Voltage C: CAN: Controller Area Network CKP Sensor: Crankshaft Position Sensor CKT: Circuit CMP Sensor: Camshaft Position Sensor CO: Carbon Monoxide CPP Switch: Clutch Pedal Position Switch (Clutch

Switch, Clutch Start Switch)

CPU: Central Processing Unit CRS: Child Restraint System D: DC: Direct Current DLC: Data Link Connector (Assembly Line Diag. Link,

ALDL, Serial Data Link, SDL)

DOHC: Double Over Head Camshaft DOJ: Double Offset Joint DRL: Daytime Running Light DTC: Diagnostic Trouble Code (Diagnostic Code) E: EBCM: Electronic Brake Control Module, ABS Control

Module

EBD: Electronic Brake Force Distribution ECM: Engine Control Module ECT Sensor: Engine Coolant Temperature Sensor

(Water Temp. Sensor, WTS)

EFE Heater: Early Fuel Evaporation Heater (Positive

Temperature Coefficient, PTC Heater)

EGR: Exhaust Gas Recirculation EGRT Sensor: EGR Temperature Sensor (Recirculated

Exhaust Gas Temp. Sensor, REGTS)

ELR: Emergency Locking Retractor EPS: Electronic Power Steering ESP®: Electronic Stability Program EVAP: Evaporative Emission EVAP Canister: Evaporative Emission Canister

(Charcoal Canister)

F: FWD: Front Wheel Drive 4WD: 4 Wheel Drive G: GEN: Generator GND: Ground H: HC: Hydrocarbons HO2S: Heated Oxygen Sensor HVAC: Heating, Ventilating and Air Conditioning I: IAC Valve: Idle Air Control Valve (Idle Speed Control

Solenoid Valve, ISC Solenoid Valve)

IAT Sensor: Intake Air Temperature Sensor (Air

temperature Sensor, ATS)

ICM: Immobilizer Control Module IG: Ignition IMT: Intake Manifold Tuning ISC Actuator: Idle Speed Control Actuator (Motor) L: LH: Left Hand LSPV: Load Sensing Proportioning Valve M: MAF Sensor: Mass Air Flow Sensor (Air Flow Sensor,

AFS, Air Flow Meter, AFM)

MAP Sensor: Manifold Absolute Pressure Sensor

(Pressure Sensor, PS)

Max: Maximum MFI: Multiport Fuel Injection (Multipoint Fuel Injection) MIL: Malfunction Indicator Lamp (“SERVICE ENGINE

SOON” Light)

Min: Minimum M/T: Manual Transmission N: NOx: Nitrogen Oxides O: OBD: On-Board Diagnostic System (Self-Diagnosis

Function)

OCM: Occupant Classification module O/D: Overdrive OHC: Over Head Camshaft O2S: Oxygen Sensor P: PCM: Powertrain Control Module PCV: Positive Crankcase Ventilation PNP: Park / Neutral Position PSP Switch: Power Steering Pressure Switch (P/S

Pressure Switch)

P/S: Power Steering R: RH: Right Hand S: SAE: Society of Automotive Engineers SDM: Sensing and Diagnostic Module (Air Bag

Controller, Air bag Control Module)

SFI: Sequential Multiport Fuel Injection SOHC: Single Over Head Camshaft T: TBI: Throttle Body Fuel Injection (Single-Point Fuel

Injection, SPI)

TCC: Torque Converter Clutch TCM: Transmission Control Module (A/T Controller, A/T

Control Module)

TPMS: Tire Pressure Monitoring System TP Sensor: Throttle Position Sensor TVV: Thermal Vacuum Valve (Thermal Vacuum

Switching Valve, TVSV, Bimetal Vacuum Switching Valve, BVSV)

TWC: Three Way Catalytic Converter (Three Way

Catalyst)

2WD: 2 Wheel Drive V: VIN: Vehicle Identification Number VSS: Vehicle Speed Sensor VVT: Variable Valve Timing (Camshaft Position Control) W: WU-OC: Warm Up Oxidation Catalytic Converter WU-TWC: Warm Up Three Way Catalytic Converter

General Information: 0A-2

0A-3 General Information:

Section 1

Engine

CONTENTS

Table of Contents 1- i

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.

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

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

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

Engine General Information and

Diagnosis ................................................. 1A-1

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

Precautions on Engine Service ............................1A-*

Precautions in Diagnosing Trouble ..................... 1A-1

Precautions For DTC Troubleshooting.................1A-*

Precautions of ECM Circuit Inspection.................1A-*

Precautions of Electric Throttle Body

System Calibration.............................................1A-*

General Description .............................................1A-2

Statement on Cleanliness and Care ....................1A-*

Engine Diagnosis General Description ................1A-*

On-Board Diagnostic System Description........... 1A-2

Engine and Emission Control System

Description ........................................................1A-5

CAN Communication System Description........... 1A-5

Air Intake System Description ..............................1A-*

Description of Electric Throttle Body System .......1A-*

Description of Electric Throttle Body

System Calibration.............................................1A-*

Generator Control System Description ................1A-*

A/F Sensor Description ........................................1A-*

Electronic Control System Description................ 1A-7

Engine and Emission Control Input / Output

Table ...............................................................1A-15

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

Engine and Emission Control System

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

Component Location .........................................1A-17

Electronic Control System Components

Location .......................................................... 1A-17

Diagnostic Information and Procedures..........1A-19

Engine and Emission Control System

Check.................................................................1A-*

Malfunction Indicator Lamp (MIL) Check .............1A-*

DTC Check ..........................................................1A-*

DTC Clearance ....................................................1A-*

DTC Table......................................................... 1A-19

Fail-Safe Table.....................................................1A-*

Scan Tool Data ....................................................1A-*

Visual Inspection ................................................. 1A-*

Engine Basic Inspection...................................... 1A-*

Engine Symptom Diagnosis ................................ 1A-*

Malfunction Indicator Lamp Does Not Come

ON with Ignition Switch ON and Engine

Stop (but Engine Can Be Started)................... 1A-25

Malfunction Indicator Lamp Remains ON

after Engine Starts ..........................................1A-27

DTC P0010: Camshaft Position Actuator

Circuit (For M16 Engine) ................................... 1A-*

DTC P0011 / P0012: Camshaft Position -

Timing Over-Advanced or System Performance

/ -Retarded (For M16 Engine) ........................... 1A-*

DTC P0030: HO2S Heater Control Circuit

(Sensor-1) ......................................................... 1A-*

DTC P0031 / P0032: HO2S Heater Control

Circuit Low / High (Sensor-1) ............................ 1A-*

DTC P0037 / P0038: HO2S Heater Control

Circuit Low / High (Sensor-2) ............................ 1A-*

DTC P0101: Mass Air Flow Circuit Range

/ Performance.................................................... 1A-*

DTC P0102: Mass Air Flow Circuit Low

Input .................................................................. 1A-*

DTC P0103: Mass Air Flow Circuit High

Input .................................................................. 1A-*

DTC P0106: Manifold Absolute Pressure

Range / Performance ........................................ 1A-*

DTC P0107: Manifold Absolute Pressure

Circuit Low Input ............................................... 1A-*

DTC P0108: Manifold Absolute Pressure

Circuit High Input............................................... 1A-*

DTC P0111: Intake Air Temperature Circuit

Range / Performance ........................................ 1A-*

DTC P0112: Intake Air Temperature

Sensor Circuit Low ............................................ 1A-*

DTC P0113: Intake Air Temperature

Sensor Circuit High ........................................... 1A-*

DTC P0116: Engine Coolant Temperature

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

DTC P0117: Engine Coolant Temperature

Circuit Low ........................................................ 1A-*

DTC P0118: Engine Coolant Temperature

Circuit High........................................................ 1A-*

DTC P0122: Throttle Position Sensor

(Main) Circuit Low ............................................. 1A-*

1-ii Table of Contents

DTC P0123: Throttle Position Sensor

(Main) Circuit High ............................................ 1A-*

DTC P0131 / P0132 / P0134: O2 Sensor

(HO2S) Circuit Low Voltage / High Voltage

/ No Activity Detected (Sensor-1)...................... 1A-*

DTC P0133: O2 Sensor (HO2S) Circuit

Slow Response (Sensor-1) ............................... 1A-*

DTC P0137 / P0138: O2 Sensor (HO2S)

Circuit Low Voltage / High Voltage

(Sensor-2) ......................................................... 1A-*

DTC P0140: O2 Sensor (HO2S) Circuit No

Activity Detected (Sensor-2) ............................. 1A-*

DTC P0171 / P0172 / P2195 / P2196: Fuel

System Too Lean / Rich / Stuck Lean /

Stuck Rich ......................................................... 1A-*

DTC P0222: Throttle Position Sensor (Sub)

Circuit Low ........................................................ 1A-*

DTC P0223: Throttle Position Sensor (Sub)

Circuit High ....................................................... 1A-*

DTC P0300 / P0301 / P0302 / P0303 /

P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4

Misfire Detected ................................................ 1A-*

DTC P0327 / P0328: Knock Sensor Circuit Low

/ High................................................................. 1A-*

DTC P0335: Crankshaft Position (CKP)

Sensor Circuit (For J20 Engine)........................ 1A-*

DTC P0335: Crankshaft Position (CKP)

Sensor Circuit (For M16 Engine)....................... 1A-*

DTC P0340: Camshaft Position (CMP)

Sensor Circuit ................................................... 1A-*

DTC P0401 / P0402: Exhaust Gas

Recirculation Flow Insufficient Detected /

Excessive Detected .......................................... 1A-*

DTC P0403: Exhaust Gas Recirculation

Control Circuit ................................................... 1A-*

DTC P0420: Catalyst System Efficiency

below Threshold................................................ 1A-*

DTC P0443: Evaporative Emission System

Purge Control Valve Circuit............................... 1A-*

DTC P0462: Fuel Level Sensor Circuit Low........ 1A-*

DTC P0463: Fuel Level Sensor Circuit High....... 1A-*

DTC P0480: Fan 1 (Radiator Cooling Fan)

Control Circuit ................................................... 1A-*

DTC P0500: Vehicle Speed Sensor

(VSS) Malfunction ...........................................1A-28

DTC P0504: Brake Switch “A”/“B” Correlation

(For J20 Engine) ............................................... 1A-*

DTC P0532: A/C Refrigerant Pressure

Sensor Circuit Low ............................................ 1A-*

DTC P0533: A/C Refrigerant Pressure

Sensor Circuit High ........................................... 1A-*

DTC P0601 / P0602 / P0607: Internal

Control Module Memory Check Sum Error

/ Control Module Programming Error /

Control Module Performance ............................ 1A-*

DTC P0616: Starter Relay Circuit Low................ 1A-*

DTC P0617: Starter Relay Circuit High............... 1A-*

DTC P0620: Generator Control Circuit ............... 1A-*

DTC P0625 / P0626: Generator Field

Terminal Circuit Low / High ............................... 1A-*

DTC P0660: Intake Manifold Tuning Valve

Control Circuit / Open (For J20 Engine)............ 1A-*

DTC P1501 / P1502: Electric Load Current

Sensor Circuit Low / High.................................. 1A-*

DTC P1510: ECM Back-Up Power Supply

Malfunction........................................................ 1A-*

DTC P1603: TCM Trouble Code Detected

(For J20 Engine) ............................................. 1A-29

DTC P1674: CAN Communication (Bus Off

Error) ...............................................................1A-31

DTC P1676: CAN Communication

(Reception Error for TCM (for A/T model))......1A-35

DTC P1678: CAN Communication

(Reception Error for BCM) ..............................1A-38

DTC P1685: CAN Communication

(Reception Error for ABS or ESP® Control

Module) ..........................................................1A-42

DTC P2101: Throttle Actuator Control

Motor Circuit Range / Performance................... 1A-*

DTC P2102: Throttle Actuator Control

Motor Circuit Low .............................................. 1A-*

DTC P2103: Throttle Actuator Control

Motor Circuit High ............................................. 1A-*

DTC P2111: Throttle Actuator Control System

- Stuck Open ..................................................... 1A-*

DTC P2119: Throttle Actuator Control

Throttle Body Range / Performance.................. 1A-*

DTC P2122: Pedal Position Sensor (Main)

Circuit Low Input ............................................... 1A-*

DTC P2123: Pedal Position Sensor (Main)

Circuit High Input............................................... 1A-*

DTC P2127: Pedal Position Sensor (Sub)

Circuit Low Input ............................................... 1A-*

DTC P2128: Pedal Position Sensor (Sub)

Circuit High Input............................................... 1A-*

DTC P2135: Throttle Position Sensor (Main

/ Sub) Voltage Correlation................................. 1A-*

DTC P2138: Pedal Position Sensor (Main /

Sub) Voltage Correlation................................... 1A-*

DTC P2227 / P2228 / P2229: Barometric

Pressure Circuit Malfunction ............................. 1A-*

Inspection of ECM and Its Circuits ....................1A-46

ECM Power and Ground Circuit Check............... 1A-*

Fuel Injector Circuit Check .................................. 1A-*

Fuel Pump and Its Circuit Check......................... 1A-*

Fuel Pressure Check........................................... 1A-*

A/C System Circuits Check ...............................1A-68

Electric Load Signal Circuit Check ....................1A-71

Radiator Cooling Fan Low Speed Control

System Check ................................................... 1A-*

Radiator Cooling Fan High Speed Control

System Check ................................................... 1A-*

Repair Instructions .............................................. 1A-*

Idle Speed and IAC Throttle Valve Opening

Inspection.......................................................... 1A-*

Special Tools and Equipment ...........................1A-72

Special Tool ......................................................1A-72

Table of Contents 1-iii

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

Diagnostic Information and Procedures............ 1B-*

EGR System Inspection .......................................1B-*

Repair Instructions .............................................. 1B-*

EVAP Canister Purge Inspection .........................1B-*

EVAP Canister Purge Valve and Its Circuit

Inspection...........................................................1B-*

Vacuum Passage Inspection ...............................1B-*

Vacuum Hose and Purge Valve Chamber

Inspection...........................................................1B-*

EVAP Canister Purge Valve Inspection ...............1B-*

EVAP Canister Inspection....................................1B-*

EGR Valve Removal and Installation ...................1B-*

EGR Valve Inspection ..........................................1B-*

PCV Hose Inspection ...........................................1B-*

PCV Valve Removal and Installation ...................1B-*

PCV Valve Inspection ..........................................1B-*

Specifications....................................................... 1B-*

Tightening Torque Specifications.........................1B-*

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

Recommended Service Material ..........................1B-*

Special Tool .........................................................1B-*

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

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

Engine Control Module (ECM) Removal

and Installation.................................................. 1C-*

Manifold Absolute Pressure (MAP) Sensor

Inspection.......................................................... 1C-*

Electric Throttle Body Assembly

On-Vehicle Inspection....................................... 1C-*

Electric Throttle Body System Calibration........... 1C-*

Accelerator Pedal Position (APP) Sensor

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

Accelerator Pedal Position (APP) Sensor

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

Accelerator Pedal Position (APP) Sensor

Assembly Inspection ......................................... 1C-*

Engine Coolant Temperature (ECT) Sensor

Removal and Installation................................... 1C-*

Engine Coolant Temperature (ECT)

Sensor Inspection ............................................. 1C-*

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

Inspection.......................................................... 1C-*

Heated Oxygen Sensor (HO2S-2) Heater

On-Vehicle Inspection....................................... 1C-*

Air Fuel Ratio (A/F) Sensor, Heated Oxygen

Sensor (HO2S-2) Removal and Installation ...... 1C-*

Camshaft Position (CMP) Sensor Removal

and Installation.................................................. 1C-*

Camshaft Position (CMP) Sensor

Inspection.......................................................... 1C-*

Crankshaft Position (CKP) Sensor

Removal and Installation................................... 1C-*

Crankshaft Position (CKP) Sensor

Inspection.......................................................... 1C-*

Knock Sensor Removal and Installation ............. 1C-*

Control Relay Inspection ..................................... 1C-*

Mass Air Flow (MAF) and Intake Air

Temperature (IAT) Sensor On-Vehicle

Inspection.......................................................... 1C-*

Mass Air Flow (MAF) and Intake Air

Temperature (IAT) Sensor Removal and

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

Mass Air Flow (MAF) and Intake Air

Temperature (IAT) Sensor Inspection............... 1C-*

Vacuum Tank Assembly Inspection (For

J20 Engine) ....................................................... 1C-*

Electric Load Current Sensor On-Vehicle

Inspection (For J20 Engine) .............................. 1C-*

Electric Load Current Sensor Removal

and Installation (For J20 Engine) ...................... 1C-*

Specifications....................................................... 1C-*

Tightening Torque Specifications........................ 1C-*

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

For M16A Engine with VVT..................................... 1D-*

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

Engine Construction Description......................... 1D-*

Camshaft Position Control (VVT Variable

Valve Timing) System Description .................... 1D-*

Diagnostic Information and Procedures............ 1D-*

Compression Check............................................ 1D-*

Engine Vacuum Check........................................ 1D-*

Valve Lash (Clearance) Inspection ..................... 1D-*

Repair Instructions .............................................. 1D-*

Air Cleaner Filter Removal and Installation......... 1D-*

Air Cleaner Filter Inspection and Cleaning.......... 1D-*

Cylinder Head Cover Removal and

Installation ......................................................... 1D-*

Throttle Body and Intake Manifold

Components...................................................... 1D-*

Throttle Body On-Vehicle Inspection................... 1D-*

Electric Throttle Body Assembly Removal

and Installation .................................................. 1D-*

Throttle Body Cleaning........................................ 1D-*

Intake Manifold Removal and Installation ........... 1D-*

Engine Mountings Components .......................... 1D-*

Engine Assembly Removal and Installation ........ 1D-*

Timing Chain Cover Components ....................... 1D-*

Timing Chain Cover Removal and

Installation ......................................................... 1D-*

Timing Chain Cover Inspection ........................... 1D-*

Oil Control Valve Removal and Installation......... 1D-*

Oil Control Valve Inspection................................ 1D-*

Timing Chain and Chain Tensioner

Components...................................................... 1D-*

Timing Chain and Chain Tensioner

Removal and Installation................................... 1D-*

Timing Chain and Chain Tensioner

Inspection.......................................................... 1D-*

Camshaft, Tappet and Shim Components .......... 1D-*

Camshaft, Tappet and Shim Removal and

Installation ......................................................... 1D-*

Camshaft, Tappet and Shim Inspection .............. 1D-*

Valves and Cylinder Head Components ............. 1D-*

1-iv Table of Contents

Valves and Cylinder Head Removal and

Installation......................................................... 1D-*

Valves and Cylinder Head Disassembly

and Assembly ................................................... 1D-*

Valves and Valve Guides Inspection................... 1D-*

Cylinder Head Inspection .................................... 1D-*

Valve Spring Inspection ...................................... 1D-*

Pistons, Piston Rings, Connecting Rods

and Cylinders Components............................... 1D-*

Pistons, Piston Rings, Connecting Rods

and Cylinders Removal and Installation............ 1D-*

Pistons, Piston Rings, Connecting Rods

and Cylinders Disassembly and Assembly ....... 1D-*

Cylinders, Pistons and Piston Rings

Inspection.......................................................... 1D-*

Piston Pins and Connecting Rods

Inspection.......................................................... 1D-*

Crank Pin and Connecting Rod Bearings

Inspection.......................................................... 1D-*

Main Bearings, Crankshaft and Cylinder

Block Components............................................ 1D-*

Main Bearings, Crankshaft and Cylinder

Block Removal and Installation ......................... 1D-*

Crankshaft Inspection ......................................... 1D-*

Main Bearings Inspection.................................... 1D-*

Sensor Plate Inspection ...................................... 1D-*

Rear Oil Seal Inspection ..................................... 1D-*

Flywheel Inspection............................................. 1D-*

Cylinder Block Inspection.................................... 1D-*

Specifications....................................................... 1D-*

Tightening Torque Specifications........................ 1D-*

Special Tools and Equipment ............................. 1D-*

Recommended Service Material ......................... 1D-*

Special Tool ........................................................ 1D-*

For J20 Engine ........................................................ 1D-*

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

Engine Construction Description......................... 1D-*

Air Cleaner Element Introduction ........................ 1D-*

IMT (Intake Manifold Tuning) System ................. 1D-*

Diagnostic Information and Procedures............ 1D-*

Compression Check............................................ 1D-*

Engine Vacuum Check........................................ 1D-*

Valve Lash (Clearance) Inspection ..................... 1D-*

Repair Instructions .............................................. 1D-*

Air Cleaner Assembly Removal and

Installation......................................................... 1D-*

Air Cleaner Filter Removal and Installation......... 1D-*

Air Cleaner Filter Inspection and Cleaning.......... 1D-*

Throttle Body and Intake Manifold

Components...................................................... 1D-*

Throttle Body On-Vehicle Inspection................... 1D-*

Electric Throttle Body Assembly Removal

and Installation .................................................. 1D-*

Throttle Body Cleaning........................................ 1D-*

Intake Manifold Removal and Installation ........... 1D-*

Cylinder Head Cover Removal and

Installation......................................................... 1D-*

Engine Mountings Components .......................... 1D-*

Engine Assembly Removal and Installation ........ 1D-*

Timing Chain Cover Components ....................... 1D-*

Timing Chain Cover Removal and

Installation ......................................................... 1D-*

Timing Chain Cover Cleaning and

Inspection.......................................................... 1D-*

2nd Timing Chain and Chain Tensioner

Components...................................................... 1D-*

2nd Timing Chain and Chain Tensioner

Removal and Installation................................... 1D-*

2nd Timing Chain and Chain Tensioner

Inspection.......................................................... 1D-*

1st Timing Chain and Chain Tensioner

Components...................................................... 1D-*

1st Timing Chain and Chain Tensioner

Removal and Installation................................... 1D-*

1st Timing Chain and Chain Tensioner

Inspection.......................................................... 1D-*

Camshafts, Tappet and Shim Components ........ 1D-*

Camshafts, Tappet and Shim Removal

and Installation .................................................. 1D-*

Camshaft, Tappet and Shim Inspection .............. 1D-*

Valves and Cylinder Head Components ............. 1D-*

Valves and Cylinder Head Removal and

Installation ......................................................... 1D-*

Valves and Cylinder Head Disassembly

and Assembly.................................................... 1D-*

Valves and Valve Guides Inspection................... 1D-*

Cylinder Head Inspection .................................... 1D-*

Valve Spring Inspection ...................................... 1D-*

Pistons, Piston Rings, Connecting Rods

and Cylinders Components............................... 1D-*

Pistons, Piston Rings, Connecting Rods

and Cylinders Removal and Installation............ 1D-*

Pistons, Piston Rings, Connecting Rods

and Cylinders Disassembly and Assembly ....... 1D-*

Pistons, Piston Rings, Connecting Rods

and Cylinders Inspection and Cleaning............. 1D-*

Main Bearings, Crankshaft and Cylinder

Block Components ............................................ 1D-*

Main Bearings, Crankshaft and Cylinder

Block Removal and Installation ......................... 1D-*

Main Bearings, Crankshaft and Cylinder

Block Inspection ................................................ 1D-*

Specifications....................................................... 1D-*

Tightening Torque Specifications........................ 1D-*

Special Tools and Equipment ............................. 1D-*

Recommended Service Material ......................... 1D-*

Special Tool ........................................................ 1D-*

Engine Lubrication System ..................... 1E-*

For M16A Engine with VVT..................................... 1E-*

General Description ............................................. 1E-*

Engine Lubrication Description ........................... 1E-*

Diagnostic Information and Procedures............ 1E-*

Oil Pressure Check ............................................. 1E-*

Repair Instructions .............................................. 1E-*

Oil Pan and Oil Pump Strainer Components....... 1E-*

Oil Pan and Oil Pump Strainer Removal

and Installation .................................................. 1E-*

Table of Contents 1-v

Oil Pan and Oil Pump Strainer Cleaning..............1E-*

Oil Pump Components .........................................1E-*

Oil Pump Removal and Installation......................1E-*

Oil Pump Disassembly and Reassembly .............1E-*

Oil Pump Inspection .............................................1E-*

Specifications........................................................1E-*

Tightening Torque Specifications.........................1E-*

Special Tools and Equipment ..............................1E-*

Recommended Service Material ..........................1E-*

Special Tool .........................................................1E-*

For J20 Engine .........................................................1E-*

General Description ..............................................1E-*

Engine Lubrication Description ............................1E-*

Diagnostic Information and Procedures.............1E-*

Oil Pressure Check ..............................................1E-*

Repair Instructions ...............................................1E-*

Oil Pan and Oil Pump Strainer Components........1E-*

Oil Pan and Oil Pump Strainer Removal

and Installation...................................................1E-*

Oil Pan and Oil Pump Strainer Cleaning..............1E-*

Oil Pump Components .........................................1E-*

Oil Pump Removal and Installation......................1E-*

Oil Pump Disassembly and Assembly .................1E-*

Oil Pump Inspection .............................................1E-*

Specifications........................................................1E-*

Tightening Torque Specifications.........................1E-*

Special Tools and Equipment ..............................1E-*

Recommended Service Material ..........................1E-*

Special Tool .........................................................1E-*

Engine Cooling System ........................... 1F-*

General Description ..............................................1F-*

Cooling System Description .................................1F-*

Coolant Description..............................................1F-*

Schematic and Routing Diagram.........................1F-*

Coolant Circulation...............................................1F-*

Diagnostic Information and Procedures.............1F-*

Engine Cooling Symptom Diagnosis....................1F-*

Repair Instructions ...............................................1F-*

Cooling System Components ..............................1F-*

Coolant Level Check............................................1F-*

Engine Cooling System Inspection and

Cleaning.............................................................1F-*

Cooling System Draining ..................................... 1F-*

Cooling System Flush and Refill ..........................1F-*

Cooling Water Pipes or Hoses Removal

and Installation...................................................1F-*

Thermostat Removal and Installation (For

M16 Engine Model)............................................1F-*

Thermostat Removal and Installation (For

J20 Engine Model) .............................................1F-*

Thermostat Inspection .........................................1F-*

Radiator Cooling Fan Motor On-Vehicle

Inspection...........................................................1F-*

Radiator Cooling Fan Relay Inspection................1F-*

Radiator Cooling Fan Assembly Removal

and Installation...................................................1F-*

Radiator On-Vehicle Inspection and

Cleaning.............................................................1F-*

Radiator Removal and Installation .......................1F-*

Water Pump Removal and Installation (For

M16 Engine Model) ............................................1F-*

Water Pump Removal and Installation (For

J20 Engine Model) .............................................1F-*

Water Pump Inspection........................................1F-*

Specifications........................................................1F-*

Tightening Torque Specifications.........................1F-*

Special Tools and Equipment ..............................1F-*

Recommended Service Material ..........................1F-*

Fuel System ..............................................1G-*

Precautions........................................................... 1G-*

Precautions on Fuel System Service ..................1G-*

General Description ............................................. 1G-*

Fuel System Description ..................................... 1G-*

Fuel Delivery System Description ....................... 1G-*

Fuel Pump Description........................................ 1G-*

Schematic and Routing Diagram........................ 1G-*

Fuel Delivery System Diagram............................ 1G-*

Diagnostic Information and Procedures............ 1G-*

Fuel Pressure Inspection .................................... 1G-*

Fuel Cut Operation Inspection ............................ 1G-*

Repair Instructions .............................................. 1G-*

Fuel System Components................................... 1G-*

Fuel Hose Disconnecting and Reconnecting ......1G-*

Fuel Pressure Relief Procedure .......................... 1G-*

Fuel Leakage Check Procedure.......................... 1G-*

Fuel Lines On-Vehicle Inspection ....................... 1G-*

Fuel Pipe Removal and Installation..................... 1G-*

Fuel Injector On-Vehicle Inspection .................... 1G-*

Fuel Injector Removal and Installation ................ 1G-*

Fuel Injector Inspection ....................................... 1G-*

Fuel Pressure Regulator Removal and

Installation ......................................................... 1G-*

Fuel Pressure Regulator Inspection.................... 1G-*

Fuel Filler Cap Inspection ................................... 1G-*

Fuel Tank Inlet Valve Removal and

Installation ......................................................... 1G-*

Fuel Tank Inlet Valve Inspection ......................... 1G-*

Fuel Tank Removal and Installation.................... 1G-*

Fuel Tank Inspection........................................... 1G-*

Fuel Tank Purging Procedure ............................. 1G-*

Fuel Pump On-Vehicle Inspection....................... 1G-*

Fuel Pump Assembly Removal and

Installation ......................................................... 1G-*

Main Fuel Level Sensor Removal and

Installation ......................................................... 1G-*

Fuel Pump Inspection ......................................... 1G-*

Sub Fuel Level Sensor Removal and

Installation ......................................................... 1G-*

Sub Fuel Level Sensor Inspection ...................... 1G-*

Specifications....................................................... 1G-*

Tightening Torque Specifications........................ 1G-*

Special Tools and Equipment .............................1G-*

Recommended Service Material ......................... 1G-*

Special Tool ........................................................ 1G-*

Ignition System.........................................1H-*

1-vi Table of Contents

General Description ............................................. 1H-*

Ignition System Construction .............................. 1H-*

Schematic and Routing Diagram........................ 1H-*

Ignition System Wiring Circuit Diagram............... 1H-*

Component Location ........................................... 1H-*

Ignition System Components Location................ 1H-*

Diagnostic Information and Procedures............ 1H-*

Ignition System Symptom Diagnosis................... 1H-*

Reference Waveform of Ignition System............. 1H-*

Ignition System Check ........................................ 1H-*

Ignition Spark Test .............................................. 1H-*

Repair Instructions .............................................. 1H-*

High-Tension Cord Removal and Installation

(For M16 Engine) .............................................. 1H-*

High-Tension Cord Inspection (For M16

Engine).............................................................. 1H-*

Spark Plug Removal and Installation .................. 1H-*

Spark Plug Inspection ......................................... 1H-*

Ignition Coil Assembly (Including ignitor)

Removal and Installation................................... 1H-*

Ignition Coil Assembly (Including ignitor)

Inspection.......................................................... 1H-*

Ignition Timing Inspection ................................... 1H-*

Specifications....................................................... 1H-*

Tightening Torque Specifications........................ 1H-*

Special Tools and Equipment ............................. 1H-*

Starting System ..........................................1I-*

Precautions.............................................................1I-*

Cranking System Note ..........................................1I-*

General Description ............................................... 1I-*

Cranking Circuit Introduction................................. 1I-*

Starting Motor Circuit Description ......................... 1I-*

Diagnostic Information and Procedures.............. 1I-*

Cranking System Symptom Diagnosis.................. 1I-*

Starting Motor Performance Test .......................... 1I-*

Repair Instructions ................................................ 1I-*

Starting Motor Dismounting and

Remounting......................................................... 1I-*

Starting Motor Components .................................. 1I-*

Starting Motor Inspection ...................................... 1I-*

Specifications......................................................... 1I-*

Starting Motor Specifications ................................1I-*

Tightening Torque Specifications.......................... 1I-*

Special Tools and Equipment ...............................1I-*

Recommended Service Material ........................... 1I-*

Charging System...................................... 1J-*

General Description .............................................. 1J-*

Battery Description............................................... 1J-*

Generator Description .......................................... 1J-*

Diagnostic Information and Procedures............. 1J-*

Battery Inspection ................................................ 1J-*

Generator Symptom Diagnosis ............................ 1J-*

Generator Test (Undercharged Battery

Check)................................................................ 1J-*

Generator Test (Overcharged Battery

Check)................................................................ 1J-*

Repair Instructions ...............................................1J-*

Jump Starting in Case of Emergency................... 1J-*

Battery Dismounting and Remounting ................. 1J-*

Water Pump and Generator Drive Belt

Removal and Installation (For M16 Engine)....... 1J-*

Water Pump and Generator Drive Belt

Tension Inspection and Adjustment (For

M16 Engine)....................................................... 1J-*

Water Pump and Generator Drive Belt

On-Vehicle Inspection (For J20 Engine) ............ 1J-*

Water Pump and Generator Drive Belt

Removal and Installation (For J20 Engine) ........ 1J-*

Generator Dismounting and Remounting............. 1J-*

Generator Components........................................ 1J-*

Generator Inspection............................................ 1J-*

Specifications........................................................ 1J-*

Charging System Specifications .......................... 1J-*

Tightening Torque Specifications......................... 1J-*

Exhaust System........................................1K-*

General Description ............................................. 1K-*

Exhaust System Description ............................... 1K-*

Diagnostic Information and Procedures............ 1K-*

Exhaust System Check ....................................... 1K-*

Repair Instructions .............................................. 1K-*

Exhaust System Components............................. 1K-*

Exhaust Manifold Removal and Installation

(For M16 Engine Model) ................................... 1K-*

Exhaust Manifold Removal and Installation

(For J20 Engine Model)..................................... 1K-*

Exhaust Pipe and Muffler Removal and

Installation ......................................................... 1K-*

Specifications....................................................... 1K-*

Tightening Torque Specifications........................ 1K-*

Special Tool ........................................................ 1H-*

Engine General Information and Diagnosis: 1A-1

Engine General Information and Diagnosis

Precautions

Precautions in Diagnosing Trouble

S5JB0E1100002

• Don’t disconnect couplers from ECM, battery cable from battery, ECM ground wire harness from engine or main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in ECM memory. Such disconnection will erase memorized information in ECM memory.

• Diagnostic information stored in ECM memory can be cleared as well as checked by using SUZUKI scan tool or OBD generic scan tool (Vehicle without diagnosis connector). Before using scan tool, read its Operator’s (Instruction) Manual carefully to have good understanding as to what functions are available and how to use it. It is indistinguishable which module turns on MIL because not only ECM but also TCM (for A/T model) turns on MIL (For details of on-board diagnostic system for A/T model, refer to “On-Board Diagnostic System Description: in Section 5A in related manual”. Therefore, check both ECM and TCM (for A/T model) for DTC when MIL lights on. When checking ECM for DTC, keep in mind that DTC is displayed on the scan tool as follows depending on the scan tool used.

– SUZUKI scan tool displays DTC detected by ECM.

– OBD generic scan tool displays DTC detected by

each of ECM and TCM (for A/T model) simultaneously.

• Priorities for diagnosing troubles If two or more DTCs are stored, proceed to the DTC flow which has been detected earliest in the order and follow the instruction in that flow. If no instructions are given, troubleshoot DTCs according to the following priorities.

a. DTCs other than DTC P0171 / P0172 (Fuel

system too lean / too rich), DTC P0300 / P0301 / P0302 / P0303 / P0304 (Misfire detected) and DTC P0401 / P0402 (EGR flow malfunction)

b. DTC P0171 / P0172 (Fuel system too lean / too

rich) and DTC P0401 / P0402 (EGR flow malfunction)

c. DTC P0300 / P0301 / P0302 / P0303 / P0304

(Misfire detected)

• Be sure to read “Precautions for Electrical Circuit Service: in Section 00 in related manual” before inspection and observe what is written there.

• ECM replacement: When substituting a known-good ECM, check for the following conditions. Neglecting this check may cause damage to a known-good ECM.

– Resistance value of all relays and actuators is as

specified respectively.

– MAP sensor, electric load current sensor (for J20

engine), A/C refrigerant pressure sensor (if equipped with A/C), accelerator pedal position (APP) sensor, TP sensor and CO adjust resistor (if not equipped with A/F sensor) are in good condition and none of power circuits of these sensors is shorted to ground.

• Communication of ECM, BCM, combination meter, keyless start control module (if equipped), ABS / ESP® control module, 4WD control module (if equipped), steering angle sensor (if equipped) and TCM (for A/T model) is established by CAN (Controller Area Network). (For more detail of CAN communication for ECM, refer to “CAN Communication System Description: ”). Therefore, handle CAN communication line with care referring to “Precaution for CAN Communication System: in Section 00 in related manual”.

• Immobilizer transponder code registration after replacing ECM: When ECM is replaced with new one or with another one, make sure to register immobilizer transponder code with ECM correctly according to “Procedure after ECM Replacement: in Section 10C in related manual”.

1A-2 Engine General Information and Diagnosis:

General Description

On-Board Diagnostic System Description

S5JB0E1101003

Vehicle not Equipped with Diagnosis Connector

ECM in this vehicle has the following functions.

• When the ignition switch is turned ON with the engine at a stop, malfunction indicator lamp (MIL) (1) turns ON to check the circuit of the malfunction indicator lamp (1).

• When ECM detects a malfunction which gives an adverse effect to vehicle emission while the engine is running, it makes the malfunction indicator lamp (1) in the meter cluster of the instrument panel turn ON or flash (flashing only when detecting a misfire which can cause damage to the catalyst) and stores the malfunction area in its memory. (If it detects that continuously 3 driving cycles are normal after detecting a malfunction, however, it makes MIL (1) turn OFF although DTC stored in its memory will remain.)

• As a condition for detecting a malfunction in some areas in the system being monitored by ECM and turning ON the malfunction indicator lamp (1) due to that malfunction, 2 driving cycle detection logic is adopted to prevent erroneous detection.

• When a malfunction is detected, engine and driving conditions then are stored in ECM memory as freeze frame data. (For the details, refer to description on “Freeze Frame Data (Vehicle Not Equipped with Diagnosis Connector): ”.)

• It is possible to communicate by using not only SUZUKI scan tool (2) but also OBD generic scan tool. (Diagnostic information can be accessed by using a scan tool.)

I5JB0A110002-01

3. DLC

Vehicle Equipped with Diagnosis Connector

ECM diagnosis troubles which may occur in the area including the following parts when the ignition switch is ON and the engine is running, and indicates the result by turning on or flashing malfunction indicator lamp (1).

• A/F sensor (if equipped)

• Heated oxygen sensor (if equipped)

• ECT sensor

• TP sensor

• MAF sensor

• IAT sensor

• MAP sensor

• CMP sensor

• CKP sensor

• Knock sensor

• Wheel speed sensor

• CPU (Central Processing Unit) of ECM

• APP sensor

• Oil control valve (for M16 engine)

• Radiator cooling fan relay

ECM and malfunction indicator lamp (1) operate as follows.

• Malfunction indicator lamp (1) lights when the ignition switch is turned ON (but the engine at stop) with the diagnosis switch terminal ungrounded regardless of the condition of Engine and Emission control system. This is only to check the malfunction indicator lamp (1) in the combination meter and its circuit.

• If the above areas of Engine and Emission control system is free from any trouble after the engine start (while engine is running), malfunction indicator lamp (1) turns OFF.

• When ECM detects a trouble which has occurred in the above areas, it makes malfunction indicator lamp (1) turn ON while the engine is running to warn the driver of such occurrence of trouble and at the same time it stores the trouble area in ECM back-up memory. (The memory is kept as it is even if the trouble was only temporary and disappeared immediately. And it is not erased unless the power to ECM is shut off for specified time or it is cleared by SUZUKI scan tool (2).) In addition, DTC can be read by not only using SUZUKI scan tool but also displayed on odometer (5) of the combination meter. (i.e. when diagnosis switch terminal (3) is grounded with a service wire (4) and ignition switch is turned ON.) For further detail of the checking procedure, refer to “DTC Check: in related manual”.

Engine General Information and Diagnosis: 1A-3

I5JB0A110003-01

6. Diagnosis connector

Warm-Up Cycle

A warm-up cycle means sufficient vehicle operation such that the coolant temperature has risen by at least 22 °C (40 °F) from engine starting and reaches a minimum temperature of 70 °C (160 °F).

Driving Cycle

A “Driving Cycle” consists of engine startup and engine shutoff.

2 Driving Cycle Detection Logic

The malfunction detected in the first driving cycle is stored in ECM memory (in the form of pending DTC) but the malfunction indicator lamp does not light at this time. It lights up at the second detection of same malfunction also in the next driving cycle.

Pending DTC

Pending DTC means a DTC detected and stored temporarily at 1 driving cycle of the DTC which is detected in the 2 driving cycle detection logic.

1A-4 Engine General Information and Diagnosis:

Freeze Frame Data (Vehicle Not Equipped with Diagnosis Connector)

ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Freeze frame data”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the vehicle was running or stopped, where air/fuel mixture was lean or rich) when a malfunction was detected by checking the freeze frame data. Also, ECM has a function to store each freeze frame data for three different malfunctions in the order as each malfunction is detected. Utilizing this function, it is possible to know the order of malfunctions that have been detected. Its use is helpful when rechecking or diagnosing a trouble.

[A]

I3RB0A110002-01

[A]: 1st or 2nd in parentheses here represents which position in the order

the malfunction is detected.

Priority of freeze frame data:

ECM has 4 frames where the freeze frame data can be stored. The first frame stores the freeze frame data of the malfunction which was detected first. However, the freeze frame data stored in this frame is updated according to the priority described. (If malfunction as described in the upper square “1” is detected while the freeze frame data in the lower square “2” has been stored, the freeze frame data “2” will be updated by the freeze frame data “1”.)

Priority Freeze frame data in frame 1

Freeze frame data at initial detection of malfunction among misfire detected (P0300 – P0304), fuel system too lean (P0171) and fuel system too rich (P0172)

2 Freeze frame data when a malfunction other than those in “1” is detected

In the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as each malfunction is detected. These data are not updated. Shown in the table are examples of how freeze frame data are stored when two or more malfunctions are detected.

Frame

Malfunction detected order

Frame 1 Frame 2 Frame 3 Frame 4

Freeze frame data to

be updated

1st freeze frame

data

2nd freeze frame

data

3rd freeze frame

data

No malfunction No freeze frame data P0401 (EGR)

detected P0171 (Fuel system)

detected P0300 (Misfire)

detected P0301 (Misfire)

detected

Data at P0401 detection Data at P0171 detection Data at P0171 detection Data at P0171 detection

Data at P0401 detection Data at P0401 detection Data at P0401 detection Data at P0401 detection

——

Data at P0171 detection Data at P0171 detection Data at P0171 detection

—

Data at P0300 detection Data at P0300 detection

Freeze frame data clearance:

The freeze frame data is cleared at the same time as clearance of DTC.

Data Link Connector (DLC)

DLC (1) is in compliance with SAE J1962 in the shape of connector and pin assignment. OBD serial data line (3) (K line of ISO 9141) is used for SUZUKI scan tool or OBD generic scan tool to communicate with ECM, Air bag SDM, immobilizer control module (in ECM), BCM (Body electrical Control Module), TCM (Transmission Control Module (for A/T model)), 4WD control module (if equipped) and ABS / ESP® control module.

Engine General Information and Diagnosis: 1A-5

910111213141516

12345678

2. B + (Unswitched vehicle battery positive)

4. ECM ground (Signal ground)

5. Vehicle body ground (Chassis ground)

I5JB0A110004-01

Engine and Emission Control System Description

S5JB0E1101004

The engine and emission control system is divided into 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control system. Air intake system includes air cleaner, throttle body, and intake manifold. Fuel delivery system includes fuel pump, delivery pipe, etc. Electronic control system includes ECM, various sensors and controlled devices. Emission control system includes EGR, EVAP and PCV system.

CAN Communication System Description

S5JB0E1101005

ECM (1), ABS / ESP® control module (2), TCM (for A/T model) (3), BCM (4), 4WD control module (if equipped) (5), combination meter (6), keyless start control module (if equipped) (7) and steering angle sensor (for vehicle with ESP®) (8) of this vehicle communicate control data between each control module. Communication of each control module is established by CAN (Controller Area Network) communication system.

I6JB01110110-02

1A-6 Engine General Information and Diagnosis:

CAN communication system uses the serial communication in which data is transmitted at a high speed. It uses a twisted pair of two communication lines for the high-speed data transmission. As one of its characteristics, multiple control modules can communicate simultaneously. In addition, it has a function to detect a communication error automatically. Each module reads necessary data from the received data and transmits data. ECM communicates control data with each control module as follows.

ECM Transmission Data

Transmit data of ECM

Engine torque signal

Accelerator pedal position

Engine speed

Throttle position

Stand by to engage air

conditioning compressor

Top gear inhibit

Torque converter clutch

control inhibit

Lock up / slip control

inhibit signal

Immobilizer indication

Engine emissions

related malfunction

Engine coolant

temperature

Fuel level percent

Cruise control signal

(if equipped)

Cruise control system

indication (if equipped)

Vehicle speed

Brake pedal switch

active

Air conditioning compressor

clutch engaged

(if equipped with A/C)

A/C refrigerant pressure

Distance kilometers per

liter of fuel

Engine diagnostic trouble

codes (if equipped with

diagnosis connector)

TCM

(for A/T

model)

ABS hydrauric

unit/control

module assembly

(for vehicle

without ESP )

ESP

control module

(for vehicle with ESP )

BCM

Combination

meter

4WD control

module

(if equipped)

Keyless start

control module

(if equipped)

I5JB0D110001-02

NOTE

In communication between ECM and combination meter, between ECM and keyless start control module (if equipped) and between ECM and 4WD control module (if equipped), data is transmitted only from ECM to combination meter, keyless start control module (if equipped) and 4WD control module (if equipped). (Combination meter, keyless start control module (if equipped) and 4WD control module (if equipped) does not transmit data to ECM.)

ECM Reception Data

Receives data of ECM

Torque reduction request

Slip control signal

Transmission malfunction

indication on

Transmission emissions related

malfunction active

Transmission gear selector

position

Daytime running light active

(if equipped with DRL)

Air conditioning switch ON

(if equipped with A/C)

A/T mode status

Electric load active (low beam)

Electric load active (high beam)

Electric load active (tail light)

Electric load active (rear defogger)

Blower fan step

Torque up request

Wheel speed pulse (rear right)

Wheel speed pulse (rear left)

Electronic stability program

system active

Electronic stability program

system off

Antilock brake system active

TCM

(for A/T model)

Engine General Information and Diagnosis: 1A-7

ABS hydraulic

unit/control module

assmbly (for vehicle

without ESP )

R R

ESP

control module

(for vehicle with ESP )

BCM

I5JB0D110002-02

Electronic Control System Description

S5JB0E1101011

The electronic control system consists of 1) various sensors which detect the state of engine and driving conditions, 2) ECM which controls various devices according to the signals from the sensors and 3) various controlled devices. Functionally, it is divided into the following sub systems:

• Fuel injection control system

• Ignition control system

• Intake manifold tuning valve control system (for J20 engine)

• Electric Throttle Body Control System

• Fuel pump control system

• Radiator cooling fan control system

• Evaporative emission control system (if equipped)

• EGR system

• A/F sensor heater control system (if equipped)

• Oxygen sensor heater control system (if equipped)

• A/C control system (if equipped with A/C)

• Camshaft position control system (for M16 engine)

• Immobilizer control system (if equipped)

• Generator control system (for J20 engine)

• Controller (computer) communication system

Especially, ECM (Engine Control Module), BCM (Body electrical Control Module), combination meter, TCM (Transmission Control Module (For A/T model)), ABS / ESP® control module, 4WD control module (if equipped), keyless start control module (if equipped) and steering angle sensor (for vehicle with ESP®) intercommunicate by means of CAN (Controller Area Network) communication.

1A-8 Engine General Information and Diagnosis:

Engine and Emission Control System Flow Diagram

VAP OR

AIR

FUEL

VACUUM

EXHAUST GAS

PIPE

EXHAUST

CATALYST

THREE WAY

EXHAUST

MANIFOLD

ENGINE

HO2S-2

(IF EQUIPPED)

A/F SENSOR

(IF EQUIPPED)

VALVE

(FOR M16

OIL CONTROL

CMP ACTUATOR

COIL

IGNITION

WITH IGNITER

CKP

SENSOR

CMP

SENSOR

ENGINE)

KNOCK

SENSOR

HEATER

CONTROL

HEATER

CONTROL

ECT

SENSOR

(FOR J20

CURRENT

FUEL

INJECTOR

ENGINE)

SENSOR

PRESSURE

BAROMETRIC

SWITCH

STOP LAMP

SWITCH

PUMP PRESSURE

POWER STEERING

GENERATOR

CLUTCH

A/C COMPRESSOR

(IF EQUIPPED WITH A/C)

FAN

RADIATOR

IMMOBILIZER

(IF EQUIPPED)

COIL ANTENNA

ACCELERATOR PEDAL

POSITION (APP) SENSOR

EGR

VALVE

MAP

SENSOR

INTAKE

MANIFOLD

THROTTLE BODY ASSEMBLY

AIR

CLEANER

IMT VALVE

(FOR J20 ENGINE)

SENSOR

THROTTLE

ACTUATOR

MAF

SENSOR

IAT

SENSOR

FUEL

VALVE

CHECK

EVAP

PURGE

CANISTER

IMT VACUUM

SOLENOID VALVE

(FOR J20 ENGINE)

PUMP

VALVE

FUEL TANK

EVAP

SENSOR

FUEL LEVEL

CANISTER

ECM

A/C REFRIGERANT

PRESSURE SENSOR

(IF EQUIPPED WITH A/C)

COMBINATION METER

TCM (FOR A/T MODEL)

(IF EQUIPPED)

4WD CONTROL MODULE

MODULE

ABS / ESP CONTROL

· MIL

· COOLANT TEMP.

· IMMOBILIZER INDICATOR LAMP

(IF EQUIPPED)

KEYLESS START

CONTROL MODULE

BCM

· TACHOMETER

· SPEEDOMETER

ELECTRIC LOAD

A/C SWITCH ON

SENSOR (VSS)

WHEEL SPEED

(IF EQUIPPED WITH A/C)

DLC

I5JB0D110003-01

ECM Input / Output Circuit Diagram

For J20 engine

Engine General Information and Diagnosis: 1A-9

+BB

WHT

WHT/BLU

ORN

ORN/BLU BLU/GRN

BLUYEL

E23-56 E23-55 E23-54

E23-53 E23-52 E23-51

WHT/RED

BLK/YEL

GRY/GRN

BLU

BLK

RED BLU

LT GR N

GRY/RED GRN/WHT

RED/WHT

PPL/YEL

GRY/BLK

BLU

GRY/GRN

GRN

BRN/BLK

+BB

IG1

BLK/RED

BLK

PNK

BLK

IG1

RED

WHT

+BB

RED/YEL

RED/BLU

WHT

PNK/BLU

BLK/YEL

BLK/WHT

LT GR N

BLK/YEL

YEL/GRN

WHT/RED

WHT/BLU

YEL/RED

GRN/WHT

PNK

RED

BLK

WHT

BLU

C37-52

C37-51 C37-36

C37-26 C37-27

C37-25

C37-14 C37-10

C37-55

C37-24

C37-12

C37-9

C37-57

C37-8

C37-28

C37-11

C37-47

C37-35

C37-34

C37-38

C37-37

C37-32

C37-31 C37-56

E23-6

E23-22

E23-21

E23-8

E23-7

E23-4 E23-19

E23-24

E23-20

PPL/WHT

E23-5

E23-50 E23-17

C37-45

C37-44 C37-53

C37-54

C37-40 C37-41

C37-1

C37-2

C37-16

C37-17

C37-13

C37-5 C37-6 C37-3 C37-4

C37-33

E23-15

E23-46

E23-47

E23-48

E23-49

C37-21

C37-20

C37-19

C37-18

C37-7

E23-29

E23-2

E23-60

E23-1

E23-16

C37-22

E23-28 E23-13

E23-12

C37-15 C37-30 C37-29 C37-48 C37-58

BLU/ORN

GRN

BLU/YEL

BLU/RED WHT

BLK

RED

GRN

PNK

PNK/BLK

PNK/GRN

PNK/BLU

GRN/BLK

YEL/BLK YEL/RED

YEL/GRN

YEL

GRY/RED

WHT/GRN

RED/BLK

RED

RED/YEL

PNK

BRN

BRN/BLK

BRN/WHT

BRN/YEL

BLU/ORN

BLK/WHT

WHT

BLU

BLU/BLK

BLK/YEL

GRY/BLU

PNK/BLU

YEL

BLK/ORN BLK/ORN

BLK/YEL

: 74 : 75

BLU/BLK

BLU/RED

PNKBLK

: 5V

+BB

IG2

IG1

BLU/WHT

BLU/BLK

WHT/GRN

YEL/GRN

IG1

IG2

62 63

66 67

: 12V

I5JB0D110004-01

1A-10 Engine General Information and Diagnosis:

1. Accelerator pedal position (APP) sensor assembly

2. Shield wire 28. Stop lamp 54. Ignition coil assembly (for No.1 spark plug)

3. CMP sensor 29. DLC 55. Ignition coil assembly (for No.2 spark plug)

4. CKP sensor

5. MAF and IAT sensor 31. Barometric pressure sensor 57. Ignition coil assembly (for No.4 spark plug)

6. CO adjust resistor (if equipped) 32. Throttle actuator control relay 58. Power steering pump pressure switch

7. MAP sensor 33. “THR MOT” fuse 59. “IG COIL” fuse

8. ECT sensor 34. Electric throttle body assembly 60. Main relay

9. A/C refrigerant pressure sensor (if equipped with A/C)

10. Electric load current sensor 36. Throttle position sensor 62. “DOME” fuse

11. Generator 37. Fuel injector No.1 63. “FI” fuse

12. “O2 HTR” fuse 38. Fuel injector No.2 64. Ignition switch

13. HO2S heater relay 39. Fuel injector No.3 65. “IGN” fuse

14. HO2S-2 40. Fuel injector No.4 66. “STR MOT” fuse

15. A/F sensor 41. EVAP canister purge valve 67. “ST SIG” fuse

16. Knock sensor 42. EGR valve 68. Starting motor control relay

17. Cruise control switch (if equipped) 43. IMT vacuum solenoid valve 69. Transmission range switch (for A/T model)

18. Brake pedal switch (for cruise control) 44. Fuel pump relay 70. Starting motor

19. Clutch pedal position switch (for cruise control)

20. ABS / ESP® control module 46. Radiator cooling fan relay No.1 72. Diagnosis connector (if equipped)

21. BCM 47. Radiator cooling fan relay No.2 73. Battery

22. TCM (for A/T model) 48. Radiator cooling fan relay No.3 74. Engine ground

23. Combination meter 49. Radiator cooling fan motor No.1 75. Body ground

24. 4WD control module (if equipped) 50. Radiator cooling fan motor No.2 76. Main fuel level sensor

25. Keyless start control module (if equipped) 51. A/C compressor relay (if equipped with A/C) 77. Sub fuel level sensor

26. Steering angle sensor (for vehicle with ESP®)

27. Stop lamp switch 53. “CPRSR” fuse

30. To TCM (for A/T model), BCM, ABS / ESP® control

module and 4WD control module (if equipped)

35. Throttle actuator 61. “IG2 SIG” fuse

45. Fuel pump 71. Immobilizer coil antenna (if equipped)

52. A/C compressor (if equipped with A/C)

56. Ignition coil assembly (for No.3 spark plug)

For M16 engine

Engine General Information and Diagnosis: 1A-11

IG1

+BB

IG2

IG1

BLU/WHT

BLU/BLK

WHT/GRN

YEL/GRN

IG1

54 55

IG2

58 59

RED

YEL

BLU/BLK

BLU/RED

PNKBLK

WHT

WHT/BLU

ORN

ORN/BLU BLU/GRN

BLUYEL

E23-56 E23-55 E23-54

E23-53 E23-52 E23-51

WHT/RED

C37-52

WHT/BLU

BLK/YEL

GRN

RED BLU

LT GRN

GRY/RED

GRN/WHT

RED/WHT

PPL/YEL

GRY/BLK

GRY/GRN

BRN/RED

BRN/BLK

RED

BLK/RED

RED/YEL

RED/BLU

WHT BLK

PNK/BLU

BLK/YEL

WHT

BLU/ORN

GRY/GRN

BLK

PNK

C37-51

C37-26 C37-27

C37-25

C37-14 C37-10

C37-55

C37-24

C37-12

C37-57

C37-8

C37-28

C37-11

C37-47

C37-35

C37-34

C37-38

C37-37

C37-32

C37-31

C37-56

C37-7

RED

WHT

GRY/BLU

PNK/BLU

WHT/RED WHT/BLU

YEL/RED

E23-28 E23-13

E23-4

E23-19

E23-24

E23-50 E23-17

C37-45

C37-44 C37-53

C37-54

C37-40 C37-41

C37-1

C37-2

C37-16

C37-17

C37-13

C37-5 C37-6 C37-3 C37-4

C37-60

C37-59

E23-15

E23-46

E23-47

E23-48

E23-49

C37-21

C37-20

E23-29

E23-2

E23-60

E23-1

E23-16

C37-22

BLU/ORN

GRN

BLU/YEL

BLU/RED WHT

BLK

RED GRN

PNK

PNK/BLK

PNK/GRN

PNK/BLU

GRN/BLK

YEL/BLK

YEL/RED

YEL/GRN

YEL

BRN/WHT

BRN/YEL

WHT/GRN

RED/BLK

RED

RED/YEL

PNK

BRN

BRN/BLK

BLK/WHT

WHT

BLU

BLU/BLK

BLK/YEL

: 5V

: 12V

I5JB0D110005-01

+BB

GRN/WHT

PPL/WHT

E23-20

E23-5

E23-12

C37-15 C37-30 C37-29 C37-48 C37-58

YEL

BLK/ORN BLK/ORN BLK/YEL BLK/YEL BLK/YEL

: 64 : 65

1A-12 Engine General Information and Diagnosis:

1. Accelerator pedal position (APP) sensor assembly

2. Shield wire 25. To BCM and ABS / ESP® control module 48. “CPRSR” fuse

3. CMP sensor 26. Barometric pressure sensor 49. Ignition coil assembly (for No.1 and No.4

4. CKP sensor 27. Throttle actuator control relay 50. Ignition coil assembly (for No.2 and No.3

5. MAF and IAT sensor 28. “THR MOT” fuse 51. “IG COIL” fuse

6. CO adjust resistor (if equipped) 29. Electric throttle body assembly 52. Main relay

7. MAP sensor 30. Throttle actuator 53. “IG2 SIG” fuse

8. ECT sensor 31. Throttle position sensor 54. “DOME” fuse

9. A/C refrigerant pressure sensor (if equipped with A/C)

10. Generator 33. Fuel injector No.2 56. Ignition switch

11. “O2 HTR” fuse 34. Fuel injector No.3 57. “IGN” fuse

12. HO2S heater relay 35. Fuel injector No.4 58. “STR MOT” fuse

13. HO2S-2 36. EVAP canister purge valve 59. “ST SIG” fuse

14. A/F sensor 37. EGR valve 60. Starting motor control relay

15. Knock sensor 38. Oil control valve (Camshaft position control) 61. Starting motor

16. Power steering pump pressure switch 39. Fuel pump relay 62. Diagnosis connector (if equipped)

17. Immobilizer coil antenna (if equipped) 40. Fuel pump 63. Battery

18. ABS / ESP® control module 41. Radiator cooling fan relay No.1 64. Engine ground

19. BCM 42. Radiator cooling fan relay No.2 65. Body ground

20. Combination meter 43. Radiator cooling fan relay No.3 66. Main fuel level sensor

21. Steering angle sensor (for vehicle with ESP®) 44. Radiator cooling fan motor No.1 67. Sub fuel level sensor

22. Stop lamp switch 45. Radiator cooling fan motor No.2

23. Stop lamp 46. A/C compressor relay (if equipped with A/C)

24. DLC 47. A/C compressor (if equipped with A/C)

spark plugs)

32. Fuel injector No.1 55. “FI” fuse

Terminal Arrangement of ECM Coupler (Viewed from Harness Side)

E23 C37

45 43 41 33

60 58

262728

56 48

5557 54 53

5671011

2122

11213

1819

1720

32 31343536374042 39 38

47 46495051

1625924

45 43 41 33

60 58

262728

56 48

5557 54 53

834

5671011

2122

1819

1720

32 31343536374042 39 38

47 46495051

Connector: C37

Terminal Wire color Circuit Terminal Wire color Circuit

1 PNK Fuel injector No.1 31 BLK/YEL Ground for A/F sensor heater 2 PNK/BLK Fuel injector No.2 32 PNK/BLU Heater output of A/F sensor

3YEL/GRN

4 YEL

5 YEL/BLK

6 YEL/RED

7BLU/ORN

EGR valve (stepper motor coil

4) EGR valve (stepper motor coil

EGR valve (stepper motor coil

Power steering pump pressure switch signal

33 GRY/RED

34 RED/BLU

35 RED/YEL

36 PNK

37 BLK A/F sensor signal (–)

Intake manifold tuning vacuum solenoid valve output (for J20 engine) Ground for A/F sensor adjusting resistor A/F sensor adjusting resistor signal Crankshaft position (CKP) sensor (–) (for J20 engine)

BRN/RED

(for M16

engine) Generator field coil monitor

BRN/BLK

signal

38 WHT A/F sensor signal (+)

(for J20 engine)

11213

1625924

I4RS0A110008-01

+ 444 hidden pages

Suzuki GRAND VITARA JB416, GRAND VITARA JB420 SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

IMPORTANT

FOREWORD

TABLE OF CONTENTS

Precautions

Precautions

Precautions

Brakes Caution and Note

General Information

General Information

General Description

Abbreviations

Engine

Engine General Information and Diagnosis

Precautions

Precautions in Diagnosing Trouble

General Description

On-Board Diagnostic System Description

Engine and Emission Control System Description

CAN Communication System Description

Electronic Control System Description