Suzuki Grand Vitara JB416 / JB420. Service manual - part 11

0B-16 Maintenance and Lubrication: 

Table of Contents 1- i

1

Section 1

CONTENTS

Engine

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

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

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

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

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

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

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

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

Statement on Cleanliness and Care ................... 1A-2
Engine Diagnosis General Description ............... 1A-3
On-Board Diagnostic System Description........... 1A-3
Engine and Emission Control System 

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

CAN Communication System Description........... 1A-6
Air Intake System Description............................. 1A-9
Electric Throttle Body System Description ........ 1A-10
Description of Electric Throttle Body System 

Calibration.......................................................1A-11

Generator Control System Description .............1A-11
A/F Sensor Description ..................................... 1A-12
Electronic Control System Description.............. 1A-13
Engine and Emission Control Input / Output 

Table ............................................................... 1A-14

Schematic and Routing Diagram......................1A-15

Engine and Emission Control System 

Diagram ..........................................................1A-15

Engine and Emission Control System Flow 

Diagram ..........................................................1A-17

ECM Input / Output Circuit Diagram..................1A-18

Component Location .........................................1A-24

Electronic Control System Components 

Location ..........................................................1A-24

Diagnostic Information and Procedures..........1A-26

Engine and Emission Control System Check.... 1A-26
Malfunction Indicator Lamp (MIL) Check .......... 1A-29
DTC Check .......................................................1A-29
DTC Clearance ................................................. 1A-30
DTC Table.........................................................1A-31

Fail-Safe Table..................................................1A-36
Scan Tool Data .................................................1A-38
Visual Inspection ...............................................1A-44
Engine Basic Inspection....................................1A-45
Engine Symptom Diagnosis ..............................1A-49
Malfunction Indicator Lamp Does Not Come 

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

Malfunction Indicator Lamp Remains ON after 

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

DTC P0010: Camshaft Position Actuator 

Circuit (For M16 Engine) .................................1A-61

DTC P0011 / P0012: Camshaft Position - 

Timing Over-Advanced or System 
Performance / -Retarded (For M16 Engine)....1A-63

DTC P0030: HO2S Heater Control Circuit 

(Sensor-1) .......................................................1A-65

DTC P0031 / P0032: HO2S Heater Control 

Circuit Low / High (Sensor-1) ..........................1A-66

DTC P0037 / P0038: HO2S Heater Control 

Circuit Low / High (Sensor-2) ..........................1A-70

DTC P0101: Mass Air Flow Circuit Range / 

Performance....................................................1A-73

DTC P0102: Mass Air Flow Circuit Low Input ...1A-76
DTC P0103: Mass Air Flow Circuit High Input ..1A-78
DTC P0106: Manifold Absolute Pressure 

Range / Performance ......................................1A-80

DTC P0107: Manifold Absolute Pressure 

Circuit Low Input .............................................1A-81

DTC P0108: Manifold Absolute Pressure 

Circuit High Input.............................................1A-83

DTC P0111: Intake Air Temperature Circuit 

Range / Performance ......................................1A-85

DTC P0112: Intake Air Temperature Sensor 

Circuit Low ......................................................1A-88

DTC P0113: Intake Air Temperature Sensor 

Circuit High......................................................1A-90

DTC P0116: Engine Coolant Temperature 

Circuit Range / Performance...........................1A-92

DTC P0117: Engine Coolant Temperature 

Circuit Low ......................................................1A-95

DTC P0118: Engine Coolant Temperature 

Circuit High......................................................1A-96

DTC P0122: Throttle Position Sensor (Main) 

Circuit Low ......................................................1A-99

1-ii Table of Contents

DTC P0123: Throttle Position Sensor (Main) 

Circuit High ...................................................1A-102

DTC P0131 / P0132 / P0134: O2 Sensor 

(HO2S) Circuit Low Voltage / High Voltage / 
No Activity Detected (Sensor-1)....................1A-105

DTC P0133: O2 Sensor (HO2S) Circuit Slow 

Response (Sensor-1) ....................................1A-106

DTC P0137 / P0138: O2 Sensor (HO2S) 

Circuit Low Voltage / High Voltage (Sensor-
2)...................................................................1A-108

DTC P0140: O2 Sensor (HO2S) Circuit No 

Activity Detected (Sensor-2) .........................1A-111

DTC P0171 / P0172 / P2195 / P2196: Fuel 

System Too Lean / Rich / Stuck Lean / Stuck 
Rich ...............................................................1A-112

DTC P0222: Throttle Position Sensor (Sub) 

Circuit Low ....................................................1A-116

DTC P0223: Throttle Position Sensor (Sub) 

Circuit High ...................................................1A-119

DTC P0300 / P0301 / P0302 / P0303 / P0304: 

Random Misfire Detected / Cylinder 1 / 
Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire 
Detected........................................................1A-122

DTC P0327 / P0328: Knock Sensor Circuit 

Low / High .....................................................1A-124

DTC P0335: Crankshaft Position (CKP) 

Sensor Circuit (For J20 Engine)....................1A-126

DTC P0335: Crankshaft Position (CKP) 

Sensor Circuit (For M16 Engine)...................1A-128

DTC P0340: Camshaft Position (CMP) 

Sensor Circuit ...............................................1A-131

DTC P0401 / P0402: Exhaust Gas 

Recirculation Flow Insufficient Detected / 
Excessive Detected ......................................1A-134

DTC P0403: Exhaust Gas Recirculation 

Control Circuit ...............................................1A-137

DTC P0420: Catalyst System Efficiency 

below Threshold............................................1A-139

DTC P0443: Evaporative Emission System 

Purge Control Valve Circuit...........................1A-141

DTC P0462: Fuel Level Sensor Circuit Low....1A-143
DTC P0463: Fuel Level Sensor Circuit High...1A-145
DTC P0480: Fan 1 (Radiator Cooling Fan) 

Control Circuit ...............................................1A-147

DTC P0500: Vehicle Speed Sensor (VSS) 

Malfunction....................................................1A-151

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

(For J20 Engine) ...........................................1A-153

DTC P0532: A/C Refrigerant Pressure 

Sensor Circuit Low ........................................1A-155

DTC P0533: A/C Refrigerant Pressure 

Sensor Circuit High .......................................1A-157

DTC P0601 / P0602 / P0607: Internal Control 

Module Memory Check Sum Error / Control 
Module Programming Error / Control Module 
Performance .................................................1A-158

DTC P0616: Starter Relay Circuit Low............1A-159
DTC P0617: Starter Relay Circuit High...........1A-160
DTC P0620: Generator Control Circuit ...........1A-162

DTC P0625 / P0626: Generator Field 

Terminal Circuit Low / High ...........................1A-164

DTC P0660: Intake Manifold Tuning Valve 

Control Circuit / Open (For J20 Engine)........1A-166

DTC P1501 / P1502: Electric Load Current 

Sensor Circuit Low / High..............................1A-168

DTC P1510: ECM Back-Up Power Supply 

Malfunction....................................................1A-170

DTC P1603: TCM Trouble Code Detected 

(For J20 Engine) ...........................................1A-172

DTC P1674: CAN Communication (Bus Off 

Error) .............................................................1A-173

DTC P1676: CAN Communication (Reception 

Error for TCM (for A/T model)) ......................1A-178

DTC P1678: CAN Communication (Reception 

Error for BCM)...............................................1A-182

DTC P1685: CAN Communication (Reception 

Error for ABS Control Module) ......................1A-186

DTC P2101: Throttle Actuator Control Motor 

Circuit Range / Performance.........................1A-189

DTC P2102: Throttle Actuator Control Motor 

Circuit Low ....................................................1A-191

DTC P2103: Throttle Actuator Control Motor 

Circuit High....................................................1A-193

DTC P2111: Throttle Actuator Control System 

- Stuck Open .................................................1A-194

DTC P2119: Throttle Actuator Control Throttle 

Body Range / Performance...........................1A-195

DTC P2122: Pedal Position Sensor (Main) 

Circuit Low Input ...........................................1A-197

DTC P2123: Pedal Position Sensor (Main) 

Circuit High Input...........................................1A-200

DTC P2127: Pedal Position Sensor (Sub) 

Circuit Low Input ...........................................1A-202

DTC P2128: Pedal Position Sensor (Sub) 

Circuit High Input...........................................1A-204

DTC P2135: Throttle Position Sensor (Main / 

Sub) Voltage Correlation...............................1A-207

DTC P2138: Pedal Position Sensor (Main / 

Sub) Voltage Correlation...............................1A-210

DTC P2227 / P2228 / P2229: Barometric 

Pressure Circuit Malfunction .........................1A-212

Inspection of ECM and Its Circuits ..................1A-214
ECM Power and Ground Circuit Check...........1A-236
Fuel Injector Circuit Check ..............................1A-240
Fuel Pump and Its Circuit Check.....................1A-242
Fuel Pressure Check.......................................1A-245
A/C System Circuits Check .............................1A-247
Electric Load Signal Circuit Check ..................1A-250
Radiator Cooling Fan Low Speed Control 

System Check ...............................................1A-252

Radiator Cooling Fan High Speed Control 

System Check ...............................................1A-255

Repair Instructions ..........................................1A-257

Idle Speed and IAC Throttle Valve Opening 

Inspection......................................................1A-257

Special Tools and Equipment .........................1A-258

Special Tool ....................................................1A-258

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

Table of Contents 1-iii

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

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

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

EVAP Canister Purge Inspection ........................ 1B-1
EVAP Canister Purge Valve and Its Circuit 

Inspection.......................................................... 1B-2

Vacuum Passage Inspection .............................. 1B-3
Vacuum Hose and Purge Valve Chamber 

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

EVAP Canister Purge Valve Inspection .............. 1B-3
EVAP Canister Inspection................................... 1B-4
EGR Valve Removal and Installation .................. 1B-4
EGR Valve Inspection......................................... 1B-5
PCV Hose Inspection.......................................... 1B-5
PCV Valve Removal and Installation .................. 1B-5
PCV Valve Inspection ......................................... 1B-5

Specifications.......................................................1B-6

Tightening Torque Specifications........................ 1B-6

Special Tools and Equipment .............................1B-6

Recommended Service Material......................... 1B-6
Special Tool ........................................................ 1B-6

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

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

Engine Control Module (ECM) Removal and 

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

Manifold Absolute Pressure (MAP) Sensor 

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

Electric Throttle Body Assembly On-Vehicle 

Inspection..........................................................1C-2

Electric Throttle Body System Calibration...........1C-4
Accelerator Pedal Position (APP) Sensor 

Assembly On-Vehicle Inspection ......................1C-5

Accelerator Pedal Position (APP) Sensor 

Assembly Removal and Installation ..................1C-5

Accelerator Pedal Position (APP) Sensor 

Assembly Inspection .........................................1C-6

Engine Coolant Temperature (ECT) Sensor 

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

Engine Coolant Temperature (ECT) Sensor 

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

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

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

Heated Oxygen Sensor (HO2S-2) Heater On-

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

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

Sensor (HO2S-2) Removal and Installation......1C-8

Camshaft Position (CMP) Sensor Removal 

and Installation..................................................1C-8

Camshaft Position (CMP) Sensor Inspection......1C-9
Crankshaft Position (CKP) Sensor Removal 

and Installation..................................................1C-9

Crankshaft Position (CKP) Sensor Inspection ..1C-10
Knock Sensor Removal and Installation ...........1C-11
Control Relay Inspection ...................................1C-12
Mass Air Flow (MAF) and Intake Air 

Temperature (IAT) Sensor On-Vehicle 
Inspection........................................................1C-13

Mass Air Flow (MAF) and Intake Air 

Temperature (IAT) Sensor Removal and 
Installation .......................................................1C-13

Mass Air Flow (MAF) and Intake Air 

Temperature (IAT) Sensor Inspection.............1C-14

Vacuum Tank Assembly Inspection (For J20 

Engine)............................................................1C-14

Electric Load Current Sensor On-Vehicle 

Inspection (For J20 Engine) ............................1C-16

Electric Load Current Sensor Removal and 

Installation (For J20 Engine) ...........................1C-16

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

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

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

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

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

Engine Construction Description.........................1D-1
Camshaft Position Control (VVT Variable 

Valve Timing) System Description ....................1D-2

Diagnostic Information and Procedures............1D-4

Compression Check............................................1D-4
Engine Vacuum Check........................................1D-5
Valve Lash (Clearance) Inspection .....................1D-6

Repair Instructions ..............................................1D-9

Air Cleaner Filter Removal and Installation.........1D-9
Air Cleaner Filter Inspection and Cleaning..........1D-9
Cylinder Head Cover Removal and 

Installation .........................................................1D-9

Throttle Body and Intake Manifold 

Components....................................................1D-11

Throttle Body On-Vehicle Inspection.................1D-11
Electric Throttle Body Assembly Removal and 

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

Throttle Body Cleaning......................................1D-12
Intake Manifold Removal and Installation .........1D-13
Engine Mountings Components ........................1D-14
Engine Assembly Removal and Installation ......1D-14
Timing Chain Cover Components .....................1D-18
Timing Chain Cover Removal and Installation ..1D-19
Timing Chain Cover Inspection .........................1D-21
Oil Control Valve Removal and Installation.......1D-21
Oil Control Valve Inspection..............................1D-22
Timing Chain and Chain Tensioner 

Components....................................................1D-23

Timing Chain and Chain Tensioner Removal 

and Installation ................................................1D-23

Timing Chain and Chain Tensioner Inspection ..1D-26
Camshaft, Tappet and Shim Components ........1D-27
Camshaft, Tappet and Shim Removal and 

Installation .......................................................1D-27

Camshaft, Tappet and Shim Inspection ............1D-30
Valves and Cylinder Head Components ...........1D-33
Valves and Cylinder Head Removal and 

Installation .......................................................1D-34

Valves and Cylinder Head Disassembly and 

Assembly.........................................................1D-35

Valves and Valve Guides Inspection.................1D-38
Cylinder Head Inspection ..................................1D-40