Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 13

 

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Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 13

 

 

Table of Contents 1- i

1

Section 1

CONTENTS

Engine

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

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

Precautions for Engine (Petrol Engine Model) ...... 1-1
Precautions for Engine (Diesel Engine Model) ...... 1-1

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

For Petrol Engine Model.........................................1A-1

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

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

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

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

Statement on Cleanliness and Care ................... 1A-3
Engine Diagnosis General Description ............... 1A-3
On-Board Diagnostic System Description........... 1A-4
Engine and Emission Control System 

Description ........................................................ 1A-7

CAN Communication System Description........... 1A-7
Air Intake System Description........................... 1A-10
Electric Throttle Body System Description ........ 1A-11
Description of Electric Throttle Body System 

Calibration.......................................................1A-12

Generator Control System Description .............1A-12
A/F Sensor Description ..................................... 1A-13
Electronic Control System Description.............. 1A-14
Engine and Emission Control Input / Output 

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

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

Engine and Emission Control System 

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

Engine and Emission Control System Flow 

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

ECM Input / Output Circuit Diagram..................1A-19

Component Location .........................................1A-25

Electronic Control System Components 

Location ..........................................................1A-25

Diagnostic Information and Procedures..........1A-27

Engine and Emission Control System Check.... 1A-27
Malfunction Indicator Lamp (MIL) Check .......... 1A-30
DTC Check .......................................................1A-31

DTC Clearance .................................................1A-32
DTC Table.........................................................1A-33
Fail-Safe Table..................................................1A-39
Scan Tool Data .................................................1A-41
Visual Inspection ...............................................1A-47
Engine Basic Inspection....................................1A-48
Engine Symptom Diagnosis ..............................1A-52
Malfunction Indicator Lamp Does Not Come 

ON with Ignition Switch ON and Engine Stop 
(but Engine Can Be Started) ...........................1A-63

Malfunction Indicator Lamp Remains ON after 

Engine Starts...................................................1A-65

DTC P0010: Camshaft Position Actuator 

Circuit (For M16 Engine) .................................1A-66

DTC P0011 / P0012: Camshaft Position - 

Timing Over-Advanced or System 
Performance / -Retarded (For M16 Engine)....1A-68

DTC P0030: HO2S Heater Control Circuit 

(Sensor-1) .......................................................1A-70

DTC P0031 / P0032: HO2S Heater Control 

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

DTC P0037 / P0038: HO2S Heater Control 

Circuit Low / High (Sensor-2) ..........................1A-75

DTC P0101: Mass Air Flow Circuit Range / 

Performance....................................................1A-79

DTC P0102: Mass Air Flow Circuit Low Input ...1A-83
DTC P0103: Mass Air Flow Circuit High Input ..1A-84
DTC P0106: Manifold Absolute Pressure 

Range / Performance ......................................1A-86

DTC P0107: Manifold Absolute Pressure 

Circuit Low Input .............................................1A-87

DTC P0108: Manifold Absolute Pressure 

Circuit High Input.............................................1A-89

DTC P0111: Intake Air Temperature Circuit 

Range / Performance ......................................1A-91

DTC P0112: Intake Air Temperature Sensor 

Circuit Low ......................................................1A-93

DTC P0113: Intake Air Temperature Sensor 

Circuit High......................................................1A-95

DTC P0116: Engine Coolant Temperature 

Circuit Range / Performance...........................1A-97

DTC P0117: Engine Coolant Temperature 

Circuit Low ....................................................1A-100

DTC P0118: Engine Coolant Temperature 

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

Precautions: 1-1

Engine

Precautions

Precautions

Precautions for Engine (Petrol Engine Model)

S6JB0A1000001

Air Bag Warning
Refer to “Air Bag Warning in Section 00”.

Precautions on Engine Service
Refer to “Precautions on Engine Service: For Petrol 
Engine Model in Section 1A”.

Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble: For Petrol 
Engine Model in Section 1A”.

Precautions for DTC Troubleshooting
Refer to “Precautions for DTC Troubleshooting: For 
Petrol Engine Model in Section 1A”.

Precautions on Fuel System Service
Refer to “Precautions on Fuel System Service: For 
Petrol Engine Model in Section 1G”.

Engine Cooling System Warning
Refer to “Coolant Description: For Petrol Engine Model 
in Section 1F”.

Cranking System Note
Refer to “Cranking System Note: For Petrol Engine 
Model in Section 1I”.

Exhaust System Caution
Refer to “Exhaust System Check: For Petrol Engine 
Model in Section 1K”.

Precaution for CAN Communication System
Refer to “Precaution for CAN Communication System in 
Section 00”
.

Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter (Petrol 
Engine Model) in Section 00”.

Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service in 
Section 00”
.

Precautions of ECM Circuit Inspection
Refer to “Precautions of ECM Circuit Inspection: For 
Petrol Engine Model in Section 1A”.

Precautions of Electric Throttle Body System 
Calibration
Refer to “Precautions of Electric Throttle Body System 
Calibration: For Petrol Engine Model in Section 1A”.

Precaution in Replacing ECM
Refer to “Precaution in Replacing ECM: For Petrol 
Engine Model in Section 10C”.

Precautions for Engine (Diesel Engine Model)

S6JB0A1000002

Air Bag Warning
Refer to “Air Bag Warning in Section 00”.

Precautions on Engine Service
Refer to “Precautions on Engine Service: For Diesel 
Engine Model in Section 1A”
.

Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble: For Diesel 
Engine Model in Section 1A”
.

Statement on Cleanliness and Care
Refer to “Statement on Cleanliness and Care: For Diesel 
Engine Model in Section 1A”
.

Precautions on Fuel System Service
Refer to “Precautions on Fuel System Service: For 
Diesel Engine Model in Section 1G”.

Engine Cooling System Warning
Refer to “Coolant Description: For Diesel Engine Model 
in Section 1F”.

Exhaust System Caution
Refer to “Exhaust System Check: For Diesel Engine 
Model in Section 1K”.

Precaution for CAN Communication System
Refer to “Precaution for CAN Communication System in 
Section 00”
.

Precautions for Catalytic Converter
Refer to “Precautions for Catalytic Converter and Diesel 
Particulate Filter (Diesel Engine Model) in Section 00”.

Precautions for Electrical Circuit Service
Refer to “Precautions for Electrical Circuit Service in 
Section 00”
.

Precaution in Replacing ECM
Refer to “Precaution in Replacing ECM: For Diesel 
Engine Model in Section 1C”
.

1A-1 Engine General Information and Diagnosis: For Petrol Engine Model

Engine

Engine General Information and Diagnosis

For Petrol Engine Model

Precautions

Precautions on Engine Service

S6JB0A1110001

CAUTION

!

 

The following information on engine service 
should be noted carefully, as it is important in 
preventing damage, and in contributing to 
reliable engine performance.

 

• When raising or supporting engine for any reason, do 

not use a jack under oil pan. Due to small clearance 
between oil pan and oil pump strainer, jacking against 
oil pan may cause it to be bent against strainer, 
resulting in damaged oil pick-up unit.

• It should be kept in mind, while working on engine, 

that 12-volt electrical system is capable of violent and 
damaging short circuits.
When performing any work where electrical terminals 
can be grounded, ground cable of the battery should 
be disconnected at battery.

• Any time the air cleaner, throttle body or intake 

manifold is removed, the intake opening should be 
covered. This will protect against accidental entrance 
of foreign material which could follow intake passage 
into cylinder and cause extensive damage when 
engine is started.

Precautions in Diagnosing Trouble

S6JB0A1110002

• 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 (Euro OBD model). 
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”.
 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)

Engine General Information and Diagnosis: For Petrol Engine Model 1A-2

• Be sure to read “Precautions for Electrical Circuit 

Service in Section 00” 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: For Petrol 
Engine Model”). The
refore, handle CAN 
communication line with care referring to “Precaution 
for CAN Communication System in Section 00”.

• 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: For Petrol Engine Model in 
Section 10C”
.

Precautions for DTC Troubleshooting

S6JB0A1110003

• Before troubleshooting, be sure to read the 

“Precautions of ECM Circuit Inspection: For Petrol 
Engine Model”.

• When measuring circuit voltage, resistance and/or 

pulse signal at ECM connector, connect the special 
tool to ECM and/or the ECM connectors referring to 
“Inspection of ECM and Its Circuits: For Petrol Engine 
Model”
.

• Upon completion of inspection and repair work, 

perform “DTC Confirmation Procedure” and confirm 
that the trouble has been corrected.

Precautions of ECM Circuit Inspection

S6JB0A1110004

• ECM connectors are waterproofed. Each terminal of 

the ECM connectors is sealed up with the grommet. 
Therefore, when measuring circuit voltage, resistance 
and/or pulse signal at ECM connector, do not insert 
the tester’s probe into the sealed terminal at the 
harness side. When measuring circuit voltage, 
resistance and/or pulse signal at ECM connector, 
connect the special tool to the ECM connectors. And, 
insert the tester’s probe into the special tool’s 
connectors at the harness side, and then measure 
voltage, resistance and/or pulse signal. Or, ECM and 
its circuits may be damaged by water.

• Wire colors of the special tool’s connectors are 

different from the ones of the ECM connectors. 
However, the circuit arrangement of the special tool’s 
connectors is the same as the one of the ECM 
connectors. Therefore, measure circuit voltage and 
resistance by identifying the terminal location subject 
to the measurement.

Precautions of Electric Throttle Body System 
Calibration

S6JB0A1110005

After performing one of works described below, it is 
necessary to re-register the completely closed throttle 
valve reference position stored in memory of ECM. (For 
detailed information, refer to “Description of Electric 
Throttle Body System Calibration: For Petrol Engine 
Model”.)
 For the procedure to register such data in ECM, 
refer to “Electric Throttle Body System Calibration: For 
Petrol Engine Model in Section 1C”.
• To shut off backup power of ECM for such purposes of 

battery replacement or “DOME” fuse removal

• To erase DTCs P0122, P0123, P0222, P0223, P0607, 

P2101, P2102, P2103, P2111, P2119, P2122, P2123, 
P2127, P2128, P2135 and/or P2138

• To replace ECM
• To replace throttle body and/or accelerator pedal 

position (APP) sensor assembly

 

 

 

 

 

 

 

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