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GRAND VITARA XL-7 2001
Suzuki GRAND VITARA XL-7 2001 User Manual
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0A-6 GENERAL INFORMATION
Identificatio
n Information
Vehicle Identifica
tion Number
The vehic
le bod
y number i
s on th
e left si
de of in
strumen
t panel
and punch
ed on
the ch
assis i
nside t
he tire
housi
ng on the
right
front
side.
10
12
Table of Contents
General Information
6
Default Chapter
6
Table of Contents
6
Precautions
7
Precaution for Vehicles Equipped with a Supplemental Restraint (Air Bag) System
7
Diagnosis
7
Servicing and Handling
8
Identification Information
11
Vehicle Identification Number
11
Engine Identification Number
12
Transmission Identification Number
12
Warning, Caution and Information Labels
13
Maintenance and Lubrication
14
Maintenance Schedule
15
Maintenance Schedule under Normal Driving Conditions
15
Brakes
16
Maintenance Recommended under Severe Driving Conditions
17
Maintenance Service
18
Engine and Emission Control
18
Drive Belt Inspection and Replacement
18
Engine Oil and Filter Replacement
19
Heater and Ventilation 1A
24
Section 1B Air Conditioning (Optional)
26
General Description
28
Refrigerant Type
28
Refrigerant Flow of Air Conditioning System 1B-3
28
Air Conditioning (Optional) 1B
28
Major Components and Location
29
Diagnosis
31
General
31
Main A/C System (Front A/C System)
31
Rear A/C System
33
Quickly Checking of Refrigerant Charge (if Equipped with Sight Glass)
34
Performance Diagnosis
35
Performance Diagnosis Table
37
Detail Diagnosis Table
38
Wiring Circuit
39
Inspection of A/C Controller and Its Circuits
40
Voltage Check
40
Refrigerant Recovery, Evacuation and Charging
44
Operation Procedure for Charging A/C with Refrigerant
44
Recovery
45
Evacuating
46
Evacuating Procedure
46
Checking System for Pressure Leaks
47
Charging
47
On-Vehicle Service
50
Precaution
50
Piping
50
Handling Refrigerant HFC-134A
51
Refrigerant Charge
51
Refrigerant Recovery
51
Replenishing Compressor Oil
52
Rear A/C Unit (Rear A/C Evaporator)
53
Rear Expansion Valve
54
Rear A/C Evaporator Temperature Controller
55
Refrigerant Pipes and Hoses
56
Solenoid Valve
57
Rear Blower Motor Assembly
58
Rear A/C Main Switch
59
Rear Blower Motor Relay and Solenoid Valve Relay
59
Rear Blower Motor Resistor
60
Rear Blower Motor Switch
61
Rear A/C No.1 and No.2 Duct
62
Rear A/C No.1 Duct
62
Rear A/C No.2 Duct
62
Compressor Assembly
63
Magnet Clutch
66
Required Service Materials
69
Tightening Torque Specification
69
Special Tools
69
Steering Column
79
Front Suspension
88
Section 3E Rear Suspension
90
Rear Suspension
90
On-Vehicle Service
94
Rear Axle Housing
94
Rear Axle Shaft Inner Oil Seal
94
Required Service Material
95
Tightening Torque Specification
95
Special Tool
96
Wheels and Tires
98
Oil Seal
100
On-Vehicle Service
101
Drive Shaft
101
Propeller Shafts
104
Propeller Shaft
105
Section 5A Brakes Pipe/Hose/Master Cylinder
108
General Description
109
Master Cylinder Assembly
109
On-Vehicle Service
110
Front Brake Hose/Pipe
110
Master Cylinder Reservoir
113
Master Cylinder Assembly
114
Brake Booster
115
Special Tool
117
Tightening Torque Specification
117
Section 5C Parking and Rear Brake
118
General Description
119
Drum Brake Assembly
119
On-Vehicle Service
120
Parking Brake Cable
120
Brake Drum
120
Wheel Cylinder
122
Brake Back Plate
122
Tightening Torque Specification
124
Section 5E2 Antilock Brake System (Abs)
126
General Description
128
Components/Parts Location
128
ABS Hydraulic Unit/Control Module Assembly
129
Fail-Safe Function
129
Self-Diagnosis Function
129
Diagnosis
130
Precautions in Diagnosing Troubles
130
ABS Diagnostic Flow Table
131
ABS Warning Lamp Check
134
EBD Warning Lamp (Brake Warning Lamp) Check
134
Diagnostic Trouble Code (DTC) Check (Using ABS Warning Lamp)
135
Diagnostic Trouble Code (DTC) Check (Using SUZUKI Scan Tool)
136
Diagnostic Trouble Code (DTC) Clearance
136
Diagnostic Trouble Code (DTC) Table
137
System Circuit
139
Switch on
140
Ignition Switch Is on
140
Connected to Ground
143
ON" Steady
144
DTC C1015 (DTC 15) - G Sensor Circuit and 4WD Lamp Circuit
145
Dtc C1021 (Dtc 21), Dtc C1022
147
Sensor Circuit or Sensor Ring
147
Dtc C1025 (Dtc 25), Dtc C1026
147
Dtc C1031 (Dtc 31), Dtc C1032
147
Dtc C1035 (Dtc 35), Dtc C1036
147
DTC C1041 (DTC 41) - Right-Front Inlet Solenoid Circuit
149
DTC C1045 (DTC 45) - Left-Front Inlet Solenoid Circuit
149
DTC C1055 (DTC 55) - Rear Inlet Solenoid Circuit
149
DTC C1042 (DTC 42) - Right-Front Outlet Solenoid Circuit
149
DTC C1046 (DTC 46) - Left-Front Outlet Solenoid Circuit
149
DTC C1056 (DTC 56) - Rear Outlet Solenoid Circuit
149
Circuit
150
DTC C1061 (DTC 61) - ABS Pump Motor Circuit
151
DTC C1063 (DTC 63) - ABS Fail-Safe Relay Circuit
152
DTC C1071 (DTC 71) - ABS Control Module
153
On-Vehicle Service
154
Precautions
154
ABS Hydraulic Unit Operation Check (Using SUZUKI Scan Tool)
154
ABS Hydraulic Unit Operation Check (Not Using Suzuki Scan Tool)
154
ABS Hydraulic Unit/Control Module Assembly
156
Rear Sensor Rotor (Retainer Ring)
158
Tightening Torque Specification
159
Special Tool
159
Section 6-1 Engine General Information and Diagnosis (H27 Engine)
162
General Information
164
Statement of Cleanliness and Care
164
General Information on Engine Service
164
Precaution on Fuel System Service
165
Fuel Pressure Relief Procedure
166
Fuel Leakage Check Procedure
166
Engine Diagnosis
167
General Description
167
On-Board Diagnostic System (Vehicle Without Monitor Connector)
167
On-Board Diagnostic System (Vehicle with Monitor Connector)
170
Precaution in Diagnosing Trouble
171
Engine Diagnostic Flow Table
172
Malfunction Indicator Lamp (MIL) Check
177
Diagnostic Trouble Code (DTC) Check
177
Diagnostic Trouble Code (DTC) Clearance
178
Diagnostic Trouble Code (DTC) Table
179
For A/T System (Refer to Section 7B1 for Diagnosis)
182
For Immobilizer Control System (Refer to Section 8G for Diagnosis)
183
Fail-Safe Table
184
Scan Tool Data
185
Scan Tool Data Definitions
188
Engine Diagnosis Table
192
Inspection of PCM (ECM) and Its Circuits
197
ON" or Dims at Ignition Switch on
204
ON (Vehicle with Monitor Connector)
206
Remains on Even with Grounding
206
Monitor Connector)
206
DTC P0100 (DTC No.33, 34) Mass Air Flow Circuit Malfunction
209
DTC P0110 (DTC No.23, 25) Intake Air Temp. (IAT) Circuit Malfunction
211
DTC P0115 (DTC No.14, 15) Engine Coolant Temp. Circuit Malfunction
213
DTC P0120 (DTC No.21, 22) Throttle Position Circuit Malfunction
215
DTC P0121 Throttle Position Circuit Range/Performance Problem
217
DTC P0130 (DTC No.13) HO2S-1 (Bank 1) Circuit Malfunction or no Activity Detected
219
DTC P0133 HO2S-1 (Bank 1) Circuit Slow Response
221
DTC P0135 HO2S-1 (Bank 1) Heater Circuit Malfunction
222
DTC P0136 HO2S-2 (Bank 1) Circuit Malfunction
224
DTC P0141 HO2S-2 (Bank 1) Heater Circuit Malfunction
226
DTC P0150 (DTC No.26) HO2S-1 (Bank 2) Circuit Malfunction or no Activity Detected
228
DTC P0153 HO2S-1 (Bank 2) Circuit Slow Response
230
DTC P0155 HO2S-1 (Bank 2) Heater Circuit Malfunction
231
DTC P0156 HO2S-2 (Bank 2) Circuit Malfunction
233
DTC P0161 HO2S-2 (Bank 2) Heater Circuit Malfunction
235
DTC P0171/P0172 Fuel System too Lean/Rich (Bank 1)
237
DTC P0174/P0175 Fuel System too Lean/Rich (Bank 2)
239
DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder
241
Misfire/Cylinder 2 Misfire/Cylinder 3 Misfire/Cylinder 4 Misfire Detected/Cylinder 5 Misfire Detected/Cylinder 6 Misfire Detected
241
DTC P0335 Crankshaft Position Sensor Circuit Malfunction
245
DTC P0340 (DTC No.42) Camshaft Position Sensor Circuit Malfunction
247
DTC P0400 Exhaust Gas Recirculation Flow Malfunction
250
DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction
253
DTC P0420 Catalyst System Efficiency below Threshold (Bank 1)
255
DTC P0430 Catalyst System Efficiency below Threshold (Bank 2)
257
DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction
259
Evap Canister Purge System Inspection
261
Vacuum Passage Inspection
261
Evap Canister Purge Valve and Its Circuit Inspection
262
Evap Canister Purge Valve Inspection
262
Vacuum Hose Inspection
262
DTC P0460 Fuel Level Sensor Circuit High Input
264
DTC P0500 (DTC No.24) Vehicle Speed Sensor Malfunction
266
DTC P0505 Idle Air Control System Malfunction
269
DTC P0601 (DTC No.71) Internal Control Module Memory Check Sum Error
271
DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction
272
DTC P1450/P1451 Barometric Pressure Sensor Circuit Malfunction/Performance Problem
274
DTC P1500 Engine Starter Signal Circuit Malfunction
275
DTC P1510 Ecm Back-Up Power Supply Malfunction
276
Inspection
277
Inspection
279
Special Tool
286
Section 6A2 Engine Mechanical (H27 Engine)
288
On-Vehicle Service
289
Throttle Body and Intake Manifold
289
Exhaust Manifold
296
LH (No.1) Bank 2Nd Timing Chain and Chain Tensioner
300
Camshaft and Valve Lash Adjuster
301
Valves and Cylinder Heads
304
Unit Repair Overhaul
313
Engine Assembly
313
Main Bearings, Crankshaft and Cylinder Block
317
Special Tool
323
Engine Cooling
326
Engine Fuel
328
Fuel System
328
Fuel Tank
329
Fuel Lines
332
Section 6E2 Engine and Emission Control System (Sequential Multiport Fuel Injection for H27 Engine)
334
Default Chapter
336
System Flow
336
System Diagram
337
Air Intake System
339
Fuel Delivery System
340
Electronic Control System
341
Diagnosis
345
Engine and Emission Control Input/Output Table
345
On-Vehicle Service
346
General
346
Accelerator Cable Adjustment
347
A/T Throttle Cable Adjustment (A/T Vehicle)
347
Idle Speed/Idle Air Control (IAC) Duty Inspection
348
[Using SUZUKI Scan Tool]
348
[Not Using SUZUKI Scan Tool] (Vehicle with Monitor Connector)
349
Idle Mixture Inspection/Adjustment
350
Air Intake System
351
Throttle Body
351
Idle Air Control Valve (IAC Valve)
354
Fast Idle Air Valve
355
Fuel Delivery System
356
Fuel Pressure Inspection
356
Fuel Pump
357
Fuel Pressure Regulator
358
Fuel Injector
359
Electronic Control System
364
Engine Control Module (Ecm)/Powertrain Control Module (PCM)
364
Mass Air Flow Sensor (MAF Sensor)
365
Intake Air Temperature (IAT) Sensor
367
Throttle Position Sensor (TP Sensor)
368
Engine Coolant Temperature Sensor (ECT Sensor)
369
Heated Oxygen Sensor (Sensor 1)
370
Heated Oxygen Sensor (Sensor 2)
371
Vehicle Speed Sensor (VSS)
372
Manifold Absolute Pressure Sensor
372
Fuel Level Sensor (Sender Gauge)
374
Crankshaft Position Sensor
374
Main Relay
374
Fuel Pump Relay
375
Fuel Cut Operation
376
EGR System (if Equipped)
377
Emission Control System
377
EVAP Canister
378
Vacuum Passage
379
PCV System
380
PCV Hose
381
PCV System
381
Tightening Torque Specification
381
Special Tool
381
Section 6F2 Ignition System (for H27 Engine)
384
General Description
385
Components
385
System Wiring
386
Diagnosis
387
Diagnostic Flow Table
387
Ignition Spark Check
389
Ignition Timing Check and Adjustment
389
On-Vehicle Service
391
Ignition Coil Assembly (Igniter and Ignition Coil)
391
Spark Plug
391
CMP Sensor
393
Noise Suppressor
395
Special Tool
396
Section 6H Charging System
398
Default Chapter
398
Charging System
398
General Description
399
Generator
399
Unit Repair Overhaul
400
Generator Assembly
400
Inspection
400
Specifications
403
Battery
403
Generator
403
Exhaust System
404
Manual Transmission
408
Automatic Transmission (4 A/T)
410
General Description
412
Electronic Shift Control System
413
Automatic Gear Shift Diagram
414
Diagnosis
416
On-Board Diagnostic System (Vehicle Without Monitor Connector)
416
On-Board Diagnostic System (Vehicle with Monitor Connector)
417
Precaution in Diagnosing Trouble
418
Automatic Transmission Diagnostic Flow Table
419
Malfunction Indicator Lamp (MIL) Check
422
O/D OFF" Lamp Check
422
POWER" Lamp Check
422
Diagnostic Trouble Code (DTC) Check
422
Diagnostic Trouble Code Clearance
422
Visual Inspection
423
A/T Basic Check
423
Trouble Diagnosis Table 1
424
Trouble Diagnosis Table 2
424
Trouble Diagnosis Table 3
425
Scan Tool Data
426
Inspection of PCM and Its Circuit
426
Wire Harness and Connectors
426
DTC P0715 (DTC NO.76) - Input/Turbine Speed Sensor Circuit Malfunction
438
DTC P0720 (DTC NO.75) Output Speed Sensor Circuit Malfunction
441
DTC P0743 (DTC NO.65/66) - TCC (Lock-Up) Solenoid Electrical
443
DTC P0753 (DTC NO.61/62) Shift Solenoid-A (#1) Electrical DTC P0758 (DTC NO.63/64) Shift Solenoid-B (#2) Electrical
445
Stall Test
447
Line Pressure Test
448
Road Test
449
Manual Road Test
450
Time Lag Test
450
Engine Brake Test
451
P" Range Test
451
On-Vehicle Service
452
Maintenance Service
452
Fluid Level
452
Fluid Change
453
A/T Throttle Cable
454
Solenoid Valves (Shift Solenoid Valves and TCC Solenoid Valve)
454
Manual Selector Assembly
455
Select Cable
457
Unit Repair
458
Sub-Assembly Repair
458
Overdrive (Case Side)
458
Forward Clutch
459
Front Upper Valve Body
463
Unit Assembly
468
Tightening Torque Specification
469
Special Tool
470
Section 7E Differential (Front)
474
General Description
475
4WD Control System
475
System Circuit
475
Diagnosis
476
Differential Assembly Diagnosis Table
476
4WD Control System Diagnostic Flow Table 7E-3
476
Notes on System Circuit Inspection
476
Flow Table
477
4WD Control System Circuit Inspection
478
Voltage Check
478
4WD Control System Inspection
479
On-Vehicle Service
480
Differential Mountings
480
Rear Mounting for Front Differential Carrier
481
Front Differential Assembly
482
Tightening Torque Specification
484
Special Tool
484
Unit Repair
484
Section 7F Differential (Rear)
486
General Description
487
Diagnosis
487
Diagnosis Table
487
On-Vehicle Service
488
Precaution for Maintenance Service
489
Differential Gear Oil Change
489
Rear Differential Assembly
490
Dismounting
490
Remounting
490
Unit Repair
491
Disassembling Unit
491
Component Inspection
494
Sub-Assembly Adjustment and Reassembly 7F-9
494
Differential Carrier
495
Differential Case
495
Differential Side Bearing
497
Drive Bevel Pinion
498
Assembling Unit
503
Tightening Torque Specification
506
Required Service Material
506
Special Tool
507
Combination Meter
513
Oil Pressure Light
516
Brake Warning Light
516
Section 8D Windows, Mirrors, Security and Locks
518
General Description
519
Rear Wiper and Washer (if Equipped)
519
On-Vehicle Service
520
Windshield Wipers
520
Front Wiper and Washer
520
Rear Window Wiper and Washer (for Vehicle with Cruise Control System)
521
Rear Wiper and Washer Switch
521
Rear Window Wiper and Washer (for Vehicle Without Cruise Control System)
521
Rear Wiper Intermittent Relay
521
Cruise Control System
522
General Description
523
Cautions in Servicing
523
Symbols and Marks
523
Abbreviations
523
Wiring Color Symbols
523
Joint Connector
523
Fuse Box and Relay
523
Power Supply Diagram
523
Cruise Control System
524
Cruise Control System Circuit
524
Components and Functions
525
Cancel Conditions
526
Diagnosis
526
Diagnosis Table
526
Note on System Circuit Inspection
528
Cruise Main Switch Indicator Lamp Circuit Check
529
Cruise" Indicator Lamp Circuit Check
530
Cruise Main Switch, Coast/Set, Resume/Accel and Cancel Switches Circuits Check
531
VSS Circuit Check
532
Stop Lamp Switch (with Pedal Position Switch) Circuits Check
533
Throttle Valve Opening Signal Circuit Check
536
Overdrive and TCC off Command Signal Circuit Check
537
Cruise Control Module Power and Ground Circuits Check
537
Cruise Control Module and Its Circuit Inspection
538
Cruise Cable Play Inspection and Adjustment
540
On-Vehicle Service
540
Cruise Main Switch
540
Coast/Set, Resume/Accel and Cancel Switches
541
Vehicle Speed Sensor (VSS)
541
Transmission Range Switch
541
Clutch Pedal Position (CPP) Switch
542
Stop Lamp Switch (with Pedal Position Switch)
543
Cruise Control Actuator Assembly (with Control Module)
544
Cruise Cable
545
Section 9 Body Service
546
Glass, Windows and Mirror
547
Quarter Window
547
Body Structure
548
Under Body Dimensions
548
Body Dimensions
549
Seat
553
Second Seat
553
Third Seat (if Equipped)
554
Paint and Coatings
555
Sealant Application Area
555
Undercoating/Anti-Corrosion Compound Application Area
562
Exterior and Interior Trim
564
Floor Carpet
564
Front Floor Carpet
564
Rear Floor Carpet (Without Third Seat Vehicle)
565
Head Lining
565
Restraint System
568
Seat Belt
570
Front Seat Belt
572
Section 10B Air Bag System
578
Default Chapter
578
Air Bag System
578
General Description
580
System Components and Wiring Location View and Connectors
581
System Wiring Diagram
582
Diagnosis
583
Diagnostic Trouble Code (DTC)
583
Use of Special Tool
583
Intermittents and Poor Connections
585
Air Bag Diagnostic System Check
586
Air Bag Diagnostic System Check Flow Table
587
DTC Check
588
DTC Clearance
589
DTC Table
591
DTC B1015 - Passenger Air Bag Initiator Circuit Resistance High
600
DTC B1016 - Passenger Air Bag Initiator Circuit Resistance Low
600
DTC B1018 - Passenger Air Bag Initiator Circuit Short to Ground
600
DTC B1019 - Passenger Air Bag Initiator Circuit Short to Power Circuit
600
DTC B1021 - Driver Air Bag Initiator Circuit Resistance High
605
DTC B1022 - Driver Air Bag Initiator Circuit Resistance Low
605
DTC B1024 - Driver Air Bag Initiator Circuit Short to Ground
605
DTC B1025 - Driver Air Bag Initiator Circuit Short to Power Circuit
605
DTC B1031 - Power Source Voltage High
610
DTC B1032 - Power Source Voltage Low
610
DTC B1035 - RH Forward Sensor Circuit Open or Short to Ground
613
DTC B1036 - RH Forward Sensor Circuit Short between Two Wires or Short to Power Circuit
613
DTC B1037 - LH Forward Sensor Circuit Open or Short to Ground
613
DTC B1038 - LH Forward Sensor Circuit Short between Two Wires or Short to Power Circuit
613
DTC B1041 - Driver Pretensioner Initiator Circuit Resistance High
617
DTC B1042 - Driver Pretensioner Initiator Circuit Resistance Low
617
DTC B1043 - Driver Pretensioner Initiator Circuit Short to Ground
617
DTC B1044 - Driver Pretensioner Initiator Circuit Short to Power Circuit
617
DTC B1045 - Passenger Pretensioner Initiator Circuit Resistance High
617
DTC B1046 - Passenger Pretensioner Initiator Circuit Resistance Low
617
DTC B1047 - Passenger Pretensioner Initiator Circuit Short to Ground
617
DTC B1048 - Passenger Pretensioner Initiator Circuit Short to Power Circuit
617
DTC B1051 - Frontal Crash Detected
623
DTC B1061 - "AIR BAG" Warning Lamp Circuit Failure
624
DTC B1013 - System Specifications Different from SDM Specifications
625
DTC B1071 - Internal SDM Fault
625
On-Vehicle Service
626
Service Precautions
626
Service and Diagnosis
626
Disabling Air Bag System
627
Enabling Air Bag System
627
Handling and Storage
628
Repairs and Inspections Required after an Accident
633
Accident with Deployment/Activation - Component Replacement
633
Accident with or Without Deployment/Activation - Component Inspections
634
Sdm
637
Forward Sensor
639
Seat Belt Pretensioner
641
Air Bag (Inflator) Module and Seat Belt Pretensioner Disposal
642
Deployment/Activation Outside Vehicle
643
Deployment/Activation Inside Vehicle
649
Deployed Air Bag (Inflator) Module and Activated Seat Belt Pretensioner Disposal
653
Tightening Torque Specification
654
Special Tool
654
5
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Suzuki GRAND VITARA XL-7 2001 Specifications
General
Brand
Suzuki
Model
GRAND VITARA XL-7 2001
Category
Automobile
Language
English
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