Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 1

 

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Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 1

 

 

Table of Contents 1- i

1

Section 1

CONTENTS

Engine

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-*
Electric Throttle Body System Description ...........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-8

Schematic and Routing Diagram........................1A-9

Engine and Emission Control System 

Diagram ............................................................ 1A-9

Engine and Emission Control System Flow 

Diagram ..........................................................1A-11

ECM Input / Output Circuit Diagram..................1A-12

Component Location .........................................1A-18

Electronic Control System Components 

Location ..........................................................1A-18

Diagnostic Information and Procedures..........1A-20

Engine and Emission Control System Check.......1A-*
Malfunction Indicator Lamp (MIL) Check .............1A-*
DTC Check ..........................................................1A-*
DTC Clearance ....................................................1A-*

DTC Table.........................................................1A-20

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-26

Malfunction Indicator Lamp Remains ON after 

Engine Starts...................................................1A-28

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-*

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.

Engine General Information and Diagnosis:  1A-1

Engine

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.)

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

3. DLC

1

2

3

I5JB0A110002-01

Engine General Information and Diagnosis:  1A-3

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”.

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.

6. Diagnosis connector

1

5

6

2

3

4

I5JB0A110003-01

 

 

 

 

 

 

 

 

 

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