Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 26

 

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Suzuki Grand Vitara JB416 / JB420 (ESP model). Service manual - part 26

 

 

3-ii Table of Contents

Input / Output Signal Table of 4WD Control 

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

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

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

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

Component Location .........................................3C-14

Transfer Shift Control System Components......3C-14

Diagnostic Information and Procedures..........3C-15

4WD Control System Check .............................3C-15
Transfer Position Indicator Operation Check ....3C-18
4WD Control System Operation Inspection ......3C-18
Visual Inspection ...............................................3C-19
DTC Check........................................................3C-20
DTC Clearance .................................................3C-21
DTC Table.........................................................3C-22
Fail-Safe Table..................................................3C-23

Scan Tool Data ................................................... 3C-*

Scan Tool Data Definitions................................3C-23
4WD Control Symptom Diagnosis.....................3C-24
Transfer Position Indicator Does Not Come 

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

Transfer Position Indicator Remains ON 

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

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

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

DTC C1224 / C1236: Transfer Shift Actuator 

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

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

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

DTC C1237: Center Differential Lock Switch 

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

DTC C1238: Center Differential Lock Switch 

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

DTC C1240: 4WD Control Module Power 

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

DTC C1243: Internal Circuit Malfunction of 

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

DTC C1246: Clutch Pedal Position (CPP) 

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

DTC U1073: Control Module Communication 

Bus Off ............................................................3C-46

DTC U1100: Lost Communication with ECM ....3C-48
DTC U1101: Lost Communication with TCM ....3C-49
DTC U1121: Lost Communication with ABS / 

Electronic Stability Program Hydraulic Unit / 
Control Module................................................3C-50

Inspection of 4WD Control Module and Its 

Circuits ............................................................3C-51

Repair Instructions ............................................3C-53

Transfer Oil Level Check...................................3C-53

Transfer Oil Change............................................ 3C-*

Transfer Oil Seal Removal and Installation.......3C-53
Transfer Switch Removal and Installation.........3C-54
Transfer Switch Inspection................................3C-54
4WD Control Module Removal and 

Installation .......................................................3C-54

Transfer Assembly Dismounting and 

Remounting.....................................................3C-55

Transfer Assembly Components.......................3C-56
Transfer Assembly Disassembly and 

Reassembly ....................................................3C-57

Transfer Assembly Inspection...........................3C-65
Input Gear Assembly, Counter Gear 

Assembly, Front Output Shaft Assembly and 
Rear Output Shaft Assembly Components .....3C-67

Input Gear Assembly Disassembly and 

Reassembly ....................................................3C-68

Counter Gear Assembly Disassembly and 

Reassembly ....................................................3C-69

Front Output Shaft Assembly Disassembly 

and Reassembly .............................................3C-69

Rear Output Shaft Assembly Disassembly 

and Reassembly .............................................3C-70

Specifications .....................................................3C-71

Tightening Torque Specifications......................3C-71

Special Tools and Equipment ...........................3C-71

Recommended Service Material .......................3C-71
Special Tool ......................................................3C-72

Non-Shift Type (Transfer without Shift 

Actuator) ..............................................................3C-73

Precautions.........................................................3C-73

Transfer Warning ..............................................3C-73

General Description ...........................................3C-73

Transfer Construction........................................3C-73

Diagnostic Information and Procedures ..........3C-74

Transfer Symptom Diagnosis............................3C-74

Repair Instructions ............................................3C-74

Transfer Oil Change..........................................3C-74
Transfer Oil Level Check...................................3C-74
Transfer Oil Seal Removal and Installation.......3C-74
Transfer Assembly Dismounting and 

Remounting.....................................................3C-74

Transfer Assembly Components.......................3C-75
Transfer Assembly Disassembly and 

Reassembly ....................................................3C-76

Input Gear Assembly Disassembly and 

Reassembly ....................................................3C-82

Front Output Shaft Assembly Disassembly 

and Reassembly .............................................3C-82

Rear Output Shaft Assembly Disassembly 

and Reassembly .............................................3C-82

Specifications .....................................................3C-83

Tightening Torque Specifications......................3C-83

Special Tools and Equipment ...........................3C-83

Recommended Service Material .......................3C-83
Special Tool ......................................................3C-83

Propeller Shaft ..........................................3D-*

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

Table of Contents 3-iii

Propeller Shaft Caution....................................... 3D-*

General Description ............................................. 3D-*

Propeller Shaft Construction ............................... 3D-*

Diagnostic Information and Procedures............ 3D-*

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

Repair Instructions .............................................. 3D-*

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

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

Specifications....................................................... 3D-*

Tightening Torque Specifications........................ 3D-*

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

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

3C-1 Transfer: Motor-Shift Type (Transfer with Shift Actuator)

Driveline / Axle

Transfer

Motor-Shift Type (Transfer with Shift Actuator)

Precautions

Transfer Warning

S5JB0E3310001

WARNING

!

 

This transfer has a center differential.
When testing with 2-wheel chassis 
dynamometer or speedometer tester (which 
tester roller is driven by vehicle wheels), be 
sure to make the vehicle as rear wheel drive 
or as front wheel drive temporarily as 
follows.
Otherwise, front wheels drive rear wheels or 
vise-versa and personal injury may result.

 

1) Remove front propeller shaft or rear propeller shaft 

referring to “Propeller Shaft Removal and Installation 
in Section 3D in related manual”.

2) Install special tool (cap) to flange yoke cover hole 

(front or rear) of transfer (1) and fix it to transfer or 
hook with string to prevent oil leakage from transfer.

Special tool
(A):  09928–36510

3) Pour specified oil into transfer up to lever plug hole if 

front propeller shaft is removed.

4) Shift transfer to 4H-lock position as follows.

• Non-shift type (Transfer without shift actuator)

– Remove lever bolt (1) on transfer, push down 

lever to 4H-lock position (2) and fix lever with 
bolt.

• Motor-shift type (Transfer with shift actuator)

– Shift transfer to 4H-lock position by turning 

transfer switch.

Precautions in Diagnosing Trouble

S5JB0E3310002

• Do not disconnect the following parts before 

confirming diagnostic information (DTC, etc.) stored in 
4WD control module memory. These actions will 
erase memorized information in 4WD control module 
memory.
– Disconnection of coupler from 4WD control module
– Disconnection of battery cable from battery
– Disconnection of ground wire harness of 4WD 

control module

– Disconnect main fuse from fuse box

• Diagnostic information stored in 4WD control module 

memory can be cleared as well as checked by using 
SUZUKI scan tool. 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.

• Be sure to read “Precautions for Electrical Circuit 

Service:” before inspection and observe what is 
written there.

(A)

1

I5JB0A331107-03

2

1

I5JB0A331108-01

Transfer: Motor-Shift Type (Transfer with Shift Actuator) 3C-2

General Description

Transfer Description

S5JB0E3311001

The aluminum transfer case directly connected to the back of the transmission contains input gear, counter gear, rear 
output shaft, front output shaft, center differential, drive chain and their accompanying gears, hubs, sleeves, fork, etc.
The center differential is installed in the transfer. With the torque induction type LSD used in the center differential, the 
effect of LSD works when a rotation difference between front and rear wheels is occurring.
The transfer has such a selective mechanism as to enable the shift actuator to make selection of high speed (direct 
connection with transmission output: main shaft), low speed (speed reduction by input gear, counter gear and low 
gear) or neutral by way of the reduction shift sleeve located between the input gear and low gear, and selection of 
center differential lock or not by way of the differential lock clutch sleeve located at the center of the rear output shaft.
The case has an oil pump to provide proper lubrication.

4WD Control System Description

S5JB0E3311003

Transfer Shift Control
The 4WD control module controls the transfer shift actuator based on the signal from the transfer switch so that the 
transfer is shifted to the selected position (4H, 4H-lock, N or 4L-lock). (Shifting to the N position requires that the 
switch to “†” position (1) keep it there for about 10 seconds then turn it to “N” position.)
The transfer actuator consists of the actuator motor and the actuator motor position switch. The 4WD control module 
detects the position of the actuator motor using the position switch and controls the actuator motor running / stopping 
operation.
Also, the 4L/N switch and center differential lock switch that detect the each position of the High / Low shift fork and 
the differential lock shift fork are installed the transfer assembly. The 4WD control module detects the transfer actual 
shift position (4H, 4H-lock, N or 4L-lock) by the signals from the 4L/N switch and center differential lock switch as 
follows.

Relationship of transfer shift position and switches

When the transfer shift actuator motor position detected by motor position switch and transfer actual shift position 
detected by the above-mentioned switches match, the 4WD control module judges that the transfer shifting is 
complete.

Retry Control
When 4WD control module cannot judge the shifting to the target position, it commands to retry the shifting up to 3 
times. If retry shifting is not possible, previous shift position is restored and notify failure of the shifting with the 
indicator and buzzer.

Indicator And Buzzer Operation
The 4WD control module output operation signal of the differential lock indicator, 4L indicator, N indicator and the 
buzzer to BCM. Indicators and buzzer as follows in order to inform what state the transfer control system is.

Switch

Transfer shift position

4H

4H-lock

N

4L-lock

4L/N switch

OFF

OFF

ON

ON

Center differential lock switch

ON

OFF

ON

OFF

1

I5JB0A332002-01

 

 

 

 

 

 

 

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