Suzuki GRAND VITARA Service Manual

Suzuki GRAND VITARA

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Fuel System: 1G-5

Repair Instructions

Fuel System Components

S5JB0A1706001

I5JB0A170001-03

www.CarGarage.ir

www.CarGarage.ir

www.CarGarage.ir

Table of Contents

Default Chapter1
- Table of Contents1
Precautions7
- Precautions for Engine7
Engine General Information and Diagnosis8
- Precautions8
- General Description9
- Schematic and Routing Diagram29
  - Engine and Emission Control System Diagram29
- Component Location30
  - Electronic Control System Components Location30
- Diagnostic Information and Procedures32
1 II Table of Contents114
- DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-2)114
- DTC P0140: O2 Sensor (HO2S) Circuit no Activity Detected (Sensor-2)117
- DTC P0171 / P0172 / P2195 / P2196: Fuel System too Lean / Rich / Stuck Lean / Stuck Rich118
- DTC P0222: Throttle Position Sensor (Sub) Circuit Low122
- DTC P0223: Throttle Position Sensor (Sub) Circuit High125
- DTC P0300 / P0301 / P0302 / P0303 / P0304: Random Misfire Detected / Cylinder 1 / Cylinder 2 / Cylinder 3 / Cylinder 4 Misfire Detected128
- DTC P0327 / P0328: Knock Sensor Circuit Low / High130
- DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for J20 Engine)132
- DTC P0335: Crankshaft Position (CKP) Sensor Circuit (for M16 Engine)134
- DTC P0340: Camshaft Position (CMP) Sensor Circuit137
- DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected / Excessive Detected140
- DTC P0403: Exhaust Gas Recirculation Control Circuit143
- DTC P0420: Catalyst System Efficiency below Threshold145
- DTC P0443: Evaporative Emission System Purge Control Valve Circuit147
- DTC P0462: Fuel Level Sensor Circuit Low149
- DTC P0463: Fuel Level Sensor Circuit High151
- DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit153
- DTC P0500: Vehicle Speed Sensor (VSS) Malfunction157
- DTC P0504: Brake Switch "A"/"B" Correlation (for J20 Engine)159
- DTC P0532: A/C Refrigerant Pressure Sensor Circuit Low161
- DTC P0533: A/C Refrigerant Pressure Sensor Circuit High163
- DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control Module Programming Error / Control Module Performance164
- DTC P0616: Starter Relay Circuit Low165
- DTC P0617: Starter Relay Circuit High167
- DTC P0620: Generator Control Circuit168
- DTC P0625 / P0626: Generator Field Terminal Circuit Low / High170
- DTC P0660: Intake Manifold Tuning Valve Control Circuit / Open (for J20 Engine)172
- DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High174
- DTC P1510: ECM Back-Up Power Supply Malfunction176
  - DTC P1603: TCM Trouble Code Detected (for J20 Engine)177
  - DTC P1674: CAN Communication (Bus off Error)178
  - DTC P1676: CAN Communication (Reception Error for TCM (for A/T Model))183
  - DTC P1678: CAN Communication (Reception Error for BCM)187
  - DTC P1685: CAN Communication (Reception Error for ABS Control Module)191
  - DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance194
  - DTC P2102: Throttle Actuator Control Motor Circuit Low196
  - DTC P2103: Throttle Actuator Control Motor Circuit High198
  - DTC P2111: Throttle Actuator Control System - Stuck Open199
  - DTC P2119: Throttle Actuator Control Throttle Body Range / Performance200
  - DTC P2122: Pedal Position Sensor (Main) Circuit Low Input202
  - DTC P2123: Pedal Position Sensor (Main) Circuit High Input205
  - DTC P2127: Pedal Position Sensor (Sub) Circuit Low Input207
  - DTC P2128: Pedal Position Sensor (Sub) Circuit High Input209
  - DTC P2135: Throttle Position Sensor (Main / Sub) Voltage Correlation212
  - DTC P2138: Pedal Position Sensor (Main / Sub) Voltage Correlation215
  - DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction217
  - Inspection of ECM and Its Circuits219
  - ECM Power and Ground Circuit Check241
  - Fuel Injector Circuit Check245
  - Fuel Pump and Its Circuit Check247
  - Fuel Pressure Check250
  - A/C System Circuits Check252
  - Electric Load Signal Circuit Check255
  - Radiator Cooling Fan Low Speed Control System Check257
  - Radiator Cooling Fan High Speed Control System Check260
- Repair Instructions262
  - Idle Speed and IAC Throttle Valve Opening Inspection262
- Special Tools and Equipment263
  - Special Tool263
Aux. Emission Control Devices264
- Diagnostic Information and Procedures264
  - EGR System Inspection264
- Repair Instructions264
- Specifications269
  - Tightening Torque Specifications269
- Special Tools and Equipment269
  - Recommended Service Material269
  - Special Tool269
Engine Electrical Devices270
- Repair Instructions270
- Specifications286
  - Tightening Torque Specifications286
Engine Mechanical287
For M16A Engine with VVT287
- General Description287
  - Engine Construction Description287
  - Camshaft Position Control (VVT Variable Valve Timing) System Description288
- Diagnostic Information and Procedures290
- Repair Instructions294
1 IV Table of Contents330
- Pistons, Piston Rings, Connecting Rods and Cylinders Disassembly and Assembly330
- Cylinders, Pistons and Piston Rings Inspection331
- Piston Pins and Connecting Rods Inspection333
- Crank Pin and Connecting Rod Bearings Inspection334
- Main Bearings, Crankshaft and Cylinder Block Components338
- Main Bearings, Crankshaft and Cylinder Block Removal and Installation339
- Crankshaft Inspection342
- Main Bearings Inspection343
- Sensor Plate Inspection347
- Rear Oil Seal Inspection347
- Flywheel Inspection348
- Cylinder Block Inspection348
- Specifications349
  - Tightening Torque Specifications349
- Special Tools and Equipment350
  - Recommended Service Material350
  - Special Tool350
For J20 Engine352
- General Description352
- Diagnostic Information and Procedures356
- Repair Instructions361
- Specifications415
  - Tightening Torque Specifications415
- Special Tools and Equipment416
  - Recommended Service Material416
  - Special Tool416
Engine Lubrication System419
For M16A Engine with VVT419
- General Description419
  - Engine Lubrication Description419
- Diagnostic Information and Procedures421
  - Oil Pressure Check421
- Repair Instructions422
- Specifications428
  - Tightening Torque Specifications428
- Special Tools and Equipment428
  - Recommended Service Material428
  - Special Tool428
- General Description429
  - Engine Lubrication Description429
For J20 Engine429
- Diagnostic Information and Procedures431
  - Oil Pressure Check431
- Repair Instructions432
- Specifications437
  - Tightening Torque Specifications437
- Special Tools and Equipment438
  - Recommended Service Material438
  - Special Tool438
Engine Cooling System439
- General Description439
  - Cooling System Description439
  - Coolant Description439
- Schematic and Routing Diagram440
  - Coolant Circulation440
- Diagnostic Information and Procedures441
  - Engine Cooling Symptom Diagnosis441
- Repair Instructions442
- Specifications452
  - Tightening Torque Specifications452
- Special Tools and Equipment452
  - Recommended Service Material452
Fuel System453
- Precautions453
  - Precautions on Fuel System Service453
- General Description453
- Schematic and Routing Diagram454
  - Fuel Delivery System Diagram454
- Diagnostic Information and Procedures455
  - Fuel Pressure Inspection455
  - Fuel Cut Operation Inspection456
- Repair Instructions457
- Specifications474
  - Tightening Torque Specifications474
- Special Tools and Equipment475
  - Recommended Service Material475
  - Special Tool475
Ignition System476
- General Description476
  - Ignition System Construction476
- Schematic and Routing Diagram477
  - Ignition System Wiring Circuit Diagram477
- Component Location478
  - Ignition System Components Location478
1 VI Table of Contents479
- Diagnostic Information and Procedures479
- Repair Instructions482
Starting System487
- Precautions487
  - Cranking System Note487
- General Description487
  - Cranking Circuit Introduction487
  - Starting Motor Circuit Description487
- Diagnostic Information and Procedures488
  - Cranking System Symptom Diagnosis488
  - Starting Motor Performance Test489
- Repair Instructions491
- Specifications496
  - Starting Motor Specifications496
  - Tightening Torque Specifications496
- Special Tools and Equipment496
  - Recommended Service Material496
Charging System497
- General Description497
  - Battery Description497
  - Generator Description498
- Diagnostic Information and Procedures499
- Repair Instructions502
Exhaust System513
- General Description513
  - Exhaust System Description513
- Diagnostic Information and Procedures513
  - Exhaust System Check513
- Repair Instructions513
- Specifications518
  - Tightening Torque Specifications518

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Suzuki GRAND VITARA Specifications

General

Brand	Suzuki
Model	GRAND VITARA
Category	Automobile
Language	English

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