Suzuki Grand Vitara JB419. Service manual - part 5

 

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Suzuki Grand Vitara JB419. Service manual - part 5

 

 

Maintenance and Lubrication:  0B-6

Manual Transmission Oil Inspection

S5JB0B0206028

1) Inspect transmission case for evidence of oil 

leakage. Repair leaky point if any.

2) Make sure that vehicle is placed level for oil level 

check.

3) Remove level / filler plug (1) of transmission.
4) Check oil level.

Oil level can be checked roughly by means of level 
plug hole. That is, if oil flows out of level plug hole or 
if oil level is found up to hole when level / filler plug is 
removed, oil is properly filled.
If oil is found insufficient, pour specified amount of 
specified oil.

5) Tighten level / filler plug to specified torque referring 

to “Manual Transmission Oil Change in Section 5B”.

Manual Transmission Oil Change

S5JB0B0206029

Change transmission oil with new specified oil referring 
to “Manual Transmission Oil Change in Section 5B”.

Transfer Oil Inspection (If Equipped)

S5JB0B0206033

1) Check transfer case for evidence of oil leakage. 

Repair leaky point if any.

2) Make sure that vehicle is placed level for oil level 

check.

3) Check oil level referring to “Transfer Oil Level Check 

in Section 3C in related manual”.

Transfer (If Equipped) and Differential Oil 
Change

S5JB0B0206035

Change transfer oil and differential oil (front and rear) 
with new specified oil respectively.
For transfer, refer to “Transfer Oil Change in Section 3C 
in related manual”.
For front differential, refer to “Front Differential Oil 
Change: Front in Section 3B in related manual”.
For rear differential, refer to “Rear Differential Oil 
Change: Rear in Section 3B in related manual”.

Power Steering (P/S) System Inspection

S5JB0B0206036

1) Visually check power steering system for fluid 

leakage and hose for damage and deterioration.
Repair or replace defective parts, if any.

2) Check fluid level with engine stopped. If it is lower 

than LOWER level line, fill fluid up to UPPER level 
line.

NOTE
Fluid level should be checked when fluid is 
cool.

 

2. Drain plug

1

2

I5JB0B020011-01

I5JB0B020012-01

I5JB0B020013-01

0B-7 Maintenance and Lubrication: 

Specifications

Tightening Torque Specifications

S5JB0B0207001

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Recommended Fluids and Lubricants

S5JB0B0208001

Fluids / Lubricants List

Special Tool

S5JB0B0208002

Fastening part

Tightening torque

Note

N

m

kgf-m

lb-ft

Engine oil drain plug

35

3.5 

25.5

)

Engine oil

Refer to “Engine Oil and Filter Change”.

Engine coolant 
(Ethylene glycol base coolant)

“Antifreeze / Anticorrosion coolant”

Brake fluid

Refer to reservoir cap of brake master cylinder.

Manual transmission oil

Refer to “Manual Transmission Oil Change in Section 5B”.

Transfer oil

Refer to “Transfer Oil Change in Section 3C in related manual”.

Differential oil (front & rear)

Refer to “Front Differential Oil Change: Front in Section 3B in related 
manual”, or “Rear Differential Oil Change: Rear in Section 3B in related 
manual”.

Power steering fluid

An equivalent of DEXRON

®-II

Door hinges

Engine oil or water resistance chassis grease

Hood latch assembly
Key lock cylinder

Spray lubricant

09915–46510
Oil filter wrench
)

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

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

Statement on Cleanliness and Care ................... 1A-2
Engine Diagnosis General Description ............... 1A-2
On-Board Diagnostic System Description........... 1A-2
CAN Communication System Description........... 1A-4
Diesel Particulate Filter Regeneration 

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

Schematic and Routing Diagram........................1A-7

Electronic Control System Diagram .................... 1A-7
Electronic Control System Wiring Circuit 

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

Component Location .........................................1A-12

Electronic Control System Components 

Location ..........................................................1A-12

Diagnostic Information and Procedures..........1A-13

Malfunction Indicator Lamp (MIL) Check .......... 1A-13
Injection Warning Light (Gravity 1 Fault) 

Check.............................................................. 1A-13

Red Stop Warning Light (Gravity 2 Fault) 

Check.............................................................. 1A-13

Engine and Emission Control System Check.... 1A-14
DTC Check .......................................................1A-16
DTC Clearance ................................................. 1A-16
DTC Table.........................................................1A-17
Indicator Lamp Operation Table ....................... 1A-20
Scan Tool Data ................................................. 1A-22
Visual Inspection...............................................1A-24
Engine Basic Inspection.................................... 1A-24
DTC P0016: Crankshaft Position-Camshaft 

Position Correlation Malfunction ..................... 1A-25

DTC P0033: Turbo Charger Bypass Valve 

Control Circuit Malfunction.............................. 1A-26

DTC P0089: Fuel Pressure Regulator 1 

Performance Malfunction ................................1A-27

DTC P0100: Mass or Volume Air Flow Circuit 

Malfunction......................................................1A-31

DTC P0105: Manifold Absolute Pressure / 

Barometric Pressure Circuit Malfunction.........1A-33

DTC P0110: Intake Air Temperature Sensor 1 

Circuit Malfunction...........................................1A-33

DTC P0115: Engine Coolant Temperature 

Circuit Malfunction...........................................1A-35

DTC P0190: Fuel Rail Pressure Sensor 

Circuit Malfunction...........................................1A-36

DTC P0201: Fuel Injector Circuit / Open 

Malfunction-Cylinder 1 ....................................1A-37

DTC P0202: Fuel Injector Circuit / Open 

Malfunction-Cylinder 2 ....................................1A-38

DTC P0203: Fuel Injector Circuit / Open 

Malfunction-Cylinder 3 ....................................1A-39

DTC P0204: Fuel Injector Circuit / Open 

Malfunction-Cylinder 4 ....................................1A-40

DTC P0225: Accelerator Pedal Position 

(APP) Sensor Assembly / Switch “C” Circuit 
Malfunction......................................................1A-41

DTC P0235: Turbo / Super Charger Boost 

Sensor “A” Circuit Malfunction ........................1A-43

DTC P0243: Turbo / Super Charger 

Wastegate Solenoid “A” Malfunction...............1A-44

DTC P0297: Vehicle Overspeed Condition 

Malfunction......................................................1A-46

DTC P0301: Cylinder 1 Misfire Detected 

Malfunction......................................................1A-47

DTC P0302: Cylinder 2 Misfire Detected 

Malfunction......................................................1A-47

DTC P0303: Cylinder 3 Misfire Detected 

Malfunction......................................................1A-48

DTC P0304: Cylinder 4 Misfire Detected 

Malfunction......................................................1A-48

DTC P0335: Crankshaft Position Sensor “A” 

Circuit Malfunction...........................................1A-49

DTC P0340: Camshaft Position Sensor “A” 

Circuit Malfunction...........................................1A-50

DTC P0380: Glow Plug / Heater Circuit “A” 

Malfunction......................................................1A-51

DTC P0403: Exhaust Gas Recirculation 

Control Circuit Malfunction ..............................1A-52

DTC P0409: Exhaust Gas Recirculation 

Sensor “A” Circuit Malfunction ........................1A-53

1-1 Precautions: 

Engine

Precautions

Precautions

Precautions for Engine

S5JB0B1000001

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

Precautions on Engine Service
Refer to “Precautions on Engine Service in Section 1A”.

Precautions in Diagnosing Trouble
Refer to “Precautions in Diagnosing Trouble in Section 1A”.

Statement on Cleanliness and Care
Refer to “Statement on Cleanliness and Care in Section 1A”.

Precautions on Fuel System Service
Refer to “Precautions on Fuel System Service in Section 1G”.

Engine Cooling System Warning
Refer to “Coolant Description in Section 1F”.

Exhaust System Caution
Refer to “Exhaust System Check in Section 1K”.

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

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

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

Precaution in Replacing ECM
Refer to “Precaution in Replacing ECM in Section 1C”.

 

 

 

 

 

 

 

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