Name: Suzuki VITARA
Brand: Suzuki
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Table of Contents3
Abbreviations4
Front Suspension5
Free Wheel Device6
Manual Free Wheel Performance6
Automatic Free Wheel Performance6
Free Wheel Types Description7
Installation of "A" Type Manual Free Wheel9
Installation of "B" Type Manual Free Wheel11
Installation of "A" Type Automatic Free Wheel13
Free Wheel Performance Checking14
Installation of "B" Type Automatic Free Wheel15
Replacement of "A" Type Manual Free Wheel17
Replacement of "B" Type Manual Free Wheel18
Replacement of "A" Type Automatic Free Wheel19
Replacement of "B" Type Automatic Free Wheel20
Front Suspension - Specified Torques21
Front Suspension - Tools Needed21
Electronic Fuel Injection System (Sequential Multiport Fuel Injection)23
Electronic Fuel Injection System - General Description25
Electronic Fuel Injection System Diagram26
Electronic Control System28
Engine Control Module (ECM)32
On-Board Diagnostic System (Self-Diagnosis Function)32
Fail-Safe Function33
Throttle Position Sensor (TP Sensor)34
Engine Coolant Temperature Sensor (ECT Sensor)34
Exhaust Gas Recirculation (EGR) System (for Vehicle with EGR Stepper Motor)35
Exhaust Gas Recirculation (EGR) System (for Vehicle with EGR Valve, Pressure Transducer and Solenoid Vacuum Valve)36
Diagnosis37
Diagnosis Flow Chart38
Diagnostic Trouble Code Table (1 of 2 T/T/ and A/T)39
A-1 ECM Power and Ground Circuit Check (Vehicle with Immobilizer)41
A-1 ECM Power and Ground Circuit Check (Vehicle Without Immobilizer)43
A-2 Malfunction Indicator Lamp ("Check Engine" Light) Circuit Check44
A-3 Malfunction Indicator Lamp ("Check Engine" Light) Circuit Check45
Code No. 13 Heated Oxygen Sensor Circuit (Signal Voltage Doesn't Change)46
Code no 14 ECT Sensor (Engine Coolant Temp. Sensor) Circuit (Low Temperature Indicated, Signal Voltage High)47
Code no 15 ECT Sensor (Engine Coolant Temp. Sensor) Circuit (High Temperature Indicated, Signal Voltage Low)48
Code no 21 TP Sensor (Throttle Position Sensor) Circuit (Signal Voltage High)49
Code no 22 TP Sensor (Throttle Position Sensor) Circuit (Signal Voltage Low)50
Code No. 24 VSS (Vehicle Speed Sensor) Circuit51
Code No. 33 MAF Sensor (Mass Air Flow Sensor) Circuit52
Code No. 34 MAF Sensor (Mass Air Flow Sensor) Circuit53
Code No. 42 CMP Sensor (Camshaft Position Sensor) Circuit54
Code No. 44 CTP Switch Circuit55
Code No. 45 CTP Switch Circuit56
Code no 51 EGR Valve (Stepper Motor or Its Circuit Open or Short)57
B-1 Fuel Pump Circuit Check58
B-1 Fuel Injector Circuit Check59
B-3 Fuel Pressure Check61
B-4 Idle Air Control System Check63
B-5 EGR System Check (Vehicle with EGR Stepper Motor)65
B-5 EGR System Check (Vehicle with EGR Solenoid Vacuum Valve)66
B-6 Evaporative Emission Control System Check67
Inspection of ECM and Its Circuits68
M/T Vehicle69
A/T Vehicle71
Terminal Arrangement of ECM Coupler (Viewed from Harness Side)74
On Vehicle Service77
Electronic Control System Service77
Mass Air Flow Sensor (MAF Sensor) Inspection77
Automatic Transmission79
Electronic Shift Control System Chart80
Powertrain (Engine) Control Module (PCM/ECM)80
Throttle Positon Sensor81
Vehicle Speed Sensor81
Transmission Range Switch81
Brake Switch82
Engine Coolant Temperature Sensor (ECT Sensor) Usage82
O/D Cut Switch82
Transfer 4L Switch82
Mode Selector Switch83
Fail Safe Function83
Change Mechanism83
Automatic Gear Shift Diagram84
Power Mode84
Gear Shift Diagram84
TCC Lock-Up Diagram84
Normal Mode85
Transmission Unit Diagnosis86
Manual Road Test86
Electronic Shift Control System87
Precaution in Identifying Diag. Trouble Code87
Electronic Shift Control System - Diagnostic Flow Chart88
Diagnostic Trouble Code Table (A/T Related Code)89
Fail-Safe Table89
Diagnostic Flow Chart a90
Diagnostic Flow Chart B91
Diagnostic Flow Chart C92
Diagnostic Flow Chart D94
Group 2 - Supplementary Service Manual95
Heater and Ventilation99
Heater and Ventilation - Diagram and General Description100
Heater Control Operation101
Mode Control Switch101
Control Lever a101
Control Lever B, C101
A. Forced Ventilation102
B. Outside Air-Introduced Heating102
C. Inside Air-Circulated Heating102
D. Head-Cooled/Feet-Warmed Heating103
Trouble Diagnosis (Heater and Ventilation)103
Heater and Ventilation - Wiring Circuit104
Heater and Ventilation - On-Vehicle Service105
Mode Control Switch Removal105
Mode Control Switch Inspection105
Mode Control Switch Installation105
Mode Actuator Removal106
Mode Actuator Inspection106
Mode Actuator Installation107
Heater Control Lever Assembly Removal107
Inspection of Heater Blower Motor Switch108
Heater Control Lever Assembly Installation108
Control Cables Removal109
Brakes111
PSPV (Load Sensing Proportioning Valve) Assembly112
Constitution113
LSPV Operation113
When LSPV Not at Work114
When LSPV at Work114
When Fail-Safe at Work115
On-Vehicle Service LSPV (Load Sensing Proportioning Valve( R & I)116
Remove and Install LSPV116
After-Installation Inspection & Adjustment117
Fluid Pressure Test118
Body Electrical System121
Combination Switch122
Windshield Wipers (Front Wiper)123
Wiper/Washer Switch Inspection123
Intermittent Wiper Relay Circuit123
Rear Window Wiper and Washer124
Wiper and Washer Switches Inspection125
Rear Wiper Intermittent Relay on Circuit125
WASH Circuit125
INT Circuit126
Rear Fog Light Wiring Circuit Diagram127
Rear Fog Light Wiring Inspection128
Body Electric System Wiring Diagram131
Suzuki Vitara 1.9 T. Diesel135
Section 0A147
Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System149
Air Bag System Diagnosis149
Air Bag System Servicing and Handling150
General Servicing Precautions152
Precautions for Catalytic Converter154
Precautions for Electrical Circuit Service155
Electrical Circuit Inspection Procedure157
Open Circuit Check157
Continuity Check158
Voltage Check158
Short Circuit Check (Wire Harness to Ground)159
Intermittent and Poor Connection160
Precautions for Installing Mobile Communication Equipment161
Identification Information162
Vehicle Identification Number162
Engine Identification Number162
Transmission Identification Number162
Vehicle Lifting Points163
Abbreviations List165
Fasteners Information167
Metric Fasteners167
Fastener Strength Identification167
Standard Tightening Torque168
Maintenance and Lubrication169
Maintenance Schedule170
Maintenance Recommended under Severe Driving Conditions172
Maintenance Service - Engine173
Water Pump and Generator Drive Belt Inspection173
Water Pump and Generator Drive Belt Replacement173
Power Steering Pump And/Or A/C Compressor Drive Belts Inspection174
Power Steering Pump And/Or A/C Compressor Drive Belts Replacement174
Camshaft Timing Belt Replacement175
Valve Lash Inspection (G16 Engine Only)175
Engine Oil and Filter Change175
Exhaust System Inspection178
Ignition System179
Spark Plugs Replacement179
Distributor Cap and Rotor Inspection179
Fuel System180
Air Cleaner Filter Inspection180
Air Cleaner Filter Replacement180
Fuel Lines and Connections Inspection180
Emission Control System181
PCV (Positive Crankcase Ventilation) Valve Inspection181
Evaporative Emission Control System Inspection181
Fuel Filter Replacement181
Chassis and Body182
Clutch Pedal Inspection182
Brake Discs, Pads, Brake Drums and Shoes Inspection182
Brake Fluid Change182
Parking Brake Lever and Cable Inspection183
Tire Inspection and Rotation183
Wheel Discs Inspection184
Free Wheeling Hub Inspection184
Wheel Bearing Inspection184
Inspection of Front Wheel Bearing Grease184
Suspension Inspection185
Propeller Shafts and Drive Shaft Inspection186
Transmission Oil Inspection and Change (for Manual Transmission)187
Transfer and Differential Oil Inspection and Change187
Steering System Inspection188
Power Steering (P/S) System Inspection189
All Hinges, Latches and Locks Inspection189
Doors Inspection189
Engine Hood Inspection189
Final Inspection190
Seats Inspection190
Clutch (for Manual Transmission) Inspection190
Brake Inspection190
Recommended Fluids and Lubricants191
Steering Check191
Engine Check191
Body, Wheels and Power Transmitting System Check191
Engine General Information and Diagnosis193
Engine General Information - Statement of Cleanliness and Care195
General Information on Engine Service195
Precautions on Fuel System Service196
Fuel Pressure Relief Procedure197
Fuel Leakage Check Procedure197
Engine Diagnosis198
On-Board Diagnostic System198
Warm-Up Cycle199
Driving Cycle199
2 Driving Cycles Detection Logic199
Freeze Frame Data199
Data Link Connector (DLC)200
Precaution in Diagnosing Trouble201
Engine Diagnostic Flow Table202
Malfunction Indicator Lamp (MIL) Check205
Diagnostic Trouble Code (DTC) Check205
Diagnostic Trouble Code (DTC) Clearance205
Diagnostic Trouble Code (DTC) Table206
Fail-Safe Table (Engine Diagnosis)209
Scan Tool Data210
Scan Tool Data Definitions212
Visual Inspection (Engine)214
Engine Basic Check215
Engine Diagnosis Table216
Inspection of ECM and Its Circuits - Voltage Checks221
Resistance Check225
Table A-1 Malfunction Indicator Lamp Circuit Check - Lamp Does Not Come "On" or Dims at Ignition Switch on (but Engine at Stop) - Wiring Diagram226
Circuit Description226
Table A-2 Malfunction Indicator Lamp Circuit Check - Lamp Remains "On" after Engine Starts227
Table A-3 ECM Power and Ground Circuit Check - MIL Doesn't Light at Ignition Switch on and Engine Doesn't Start Though It Is Cranked up228
Table A-3 ECM Power and Ground Circuit Inspection Table229
DTC P0100 Mass Air Flow Circuit Malfunction - Wiring Diagram230
DTC Detecting Condition and Trouble Area230
DTC Confirmation Procedure231
Troubleshooting (Engine Diagnosis)231
DTC P0110 Intake Air Temp (IAT) Circuit Malfunction - Wiring Diagram232
DTC Detecting Condition and Trouble Area Table232
DTC Confirmation Procedure Steps232
DTC P0115 Engine Coolant Temp. Circuit Malfunction - Wiring Diagram234
DTC P0120 Throttle Position Circuit Malfunction236
DTC P0121 Throttle Position Circuit Performance Problem238
DTC P0130 HO2S-1 Circuit Malfunction240
DTC P0133 HO2S-1 Circuit Slow Response243
DTC P0134 HO2S-1 no Activity Detected244
DTC P0135 HO2S-1 Heater Circuit Malfunction245
Troubleshooting Table (DTC P0135)246
DTC P0136 HO2S-2 Circuit Malfunction247
DTC Confirmaton Procedure248
Troubleshooting (DTC P0136)248
DTC P0141 HO2S-2 Heater Circuit Malfunction249
Troubleshooting (DTC P0141)250
DTC P0171 Fuel System too Lean251
DTC P0172 Fuel System too Rich251
Troubleshooting (DTC P0171/P0172)252
DTC P0300 Random Misfire Detected253
DTC P0301 - P0304 Cylinder Misfire Detected253
Troubleshooting (DTC P0300/P0301/P0302/P0303/P0304)254
DTC P0335 Crankshaft Position Sensor Circuit Malfunction255
Troubleshooting (DTC P0335)257
DTC P0340 Camshaft Position Sensor Circuit Malfunction258
DTC P0400 Exhaust Gas Recirculation Flow Malfunction260
Troubleshooting (DTC P0400)262
DTC P0403 Exhaust Gas Recirculation Circuit Malfunction263
Troubleshooting (DTC P0403)264
DTC P0420 Catalyst System Efficiency below Threshold265
DTC P0443 EVAP Control System Purge Control Valve Circuit Malfunction267
Troubleshooting (DTC P0443)268
EVAP Canister Purge System Check269
Vacuum Passage Inspection269
Vacuum Hose Inspection269
EVAP Canister Purge Valve and Its Circuit Check270
EVAP Canister Purge Valve Inspection270
EVAP Canister Check271
DTC P0460 Fuel Level Sensor Circuit High Input272
DTC P0500 Vehicle Speed Sensor Malfunction274
Troubleshooting (DTC P0500)275
DTC P0505 Idle Air Control System Malfunction276
Troubleshooting (DTC P0505)277
Idle Air Adjusting Screw and Its Passage Check278
Fast Idle Air Valve278
IAC Valve and Its Circuit Check279
DTC P0601 Internal Control Module Memory Check Sum Error System Description280
DTC P1408 Manifold Differential Pressure Sensor Circuit Malfunction281
Troubleshooting (DTC P1408)282
DTC P1450 Barometric Pressure Sensor Circuit Malfunction283
DTC P1451 Barometric Pressure Sensor Performance Problem283
DTC P1500 Engine Starter Signal Circuit Malfunction284
DTC P1510 ECM Back-Up Power Supply Malfunction285
Table B-1 Fuel Pump Circuit Inspection286
Table B-2 Fuel Injectors and Circuit Inspection287
Table B-3 Fuel Pressure Inspection288
Table B-4 Fast Idle Air Valve System Inspection290
Table B-5 A/C Signal Circuits Inspection291
Engine Diagnosis - Special Tools292
Engine Mechanical (1-Cam 16-Valves)293
Engine Mechanical - General Description294
Engine Lubrication295
Cylinder Block296
Crankshaft and Main Bearings296
Pistons, Rings, Piston Pins and Connecting Rods296
Cylinder Head and Valve Train296
Engine On-Vehicle Service297
Compression Check297
Engine Vacuum Check299
Oil Pressure Check300
Valve Lash (Clearance)302
Air Cleaner Element Removal304
Air Cleaner Element Inspection304
Air Cleaner Element Cleaning304
Air Cleaner Element Installation304
Air Inlet Pipe Removal305
Air Inlet Pipe Installation305
Cylinder Head Cover Removal306
Cylinder Head Cover Installation306
Throttle Body and Intake Manifold308
Throttle Body and Intake Manifold Installation310
Exhaust Manifold Removal312
Exhaust Manifold Installation313
Timing Belt and Belt Tensioner Removal314
Timing Belt and Belt Tensioner Inspection315
Timing Belt and Belt Tensioner Installation316
Oil Pan and Oil Pump Strainer Removal319
Oil Pan and Oil Pump Strainer Cleaning320
Oil Pan and Oil Pump Strainer Installation321
Oil Pump Removal323
Oil Pump Disassembly324
Oil Pump Inspection325
Oil Pump Assembly326
Oil Pump Installation326
Rocker Arms, Rocker Arm Shaft and Camshaft Removal328
Rocker Arms, Rocker Arm Shaft and Camshaft Inspection331
Adjusting Screw and Rocker Arm Inspection331
Rocker Arm Shaft Runout Check331
Rocker Arm-To-Rocker Arm Shaft Clearance331
Cam Wear Check332
Camshaft Runout Check332
Camshaft Journal Wear Check332
Rocker Arms, Rocker Arm Shaft and Camshaft Installation333
Valves and Cylinder Head Removal337
Valves and Cylinder Head Disassembly340
Valves and Cylinder Head Inspection341
Valve Guides Check341
Valves Check341
Cylinder Head Check343
Valve Springs Check345
Valves and Cylinder Head Assembly346
Valves and Cylinder Head Installation348
Piston, Piston Rings, Connecting Rods and Cylinders Removal350
Piston, Piston Rings, Connecting Rods and Cylinders Disassembly351
Piston, Piston Rings, Connecting Rods and Cylinders Cleaning351
Piston, Piston Rings, Connecting Rods and Cylinders Inspection352
Pistons Check352
Piston Pin Check353
Piston Rings Check354
Connecting Rod Check354
Crank Pin and Connecting Rod Bearings355
Piston, Piston Rings, Connecting Rods and Cylinders Assembly356
Piston, Piston Rings, Connecting Rods and Cylinders Installation or Connection358
Unit Repair Overhaul360
Engine Assembly Removal360
Engine Assembly Installation364
Main Bearings, Crankshaft and Cylinder Block366
Main Bearings, Crankshaft and Cylinder Block Removal367
Main Bearings, Crankshaft and Cylinder Block Inspection368
Main Bearings Inspection369
Selection of Main Bearings370
Rear Oil Seal Check373
Flywheel Check374
Cylinder Block Check374
Honing or Reboring Cylinders374
Main Bearings, Crankshaft and Cylinder Block Installation375
Engine Mechanical - Special Tools378
Engine Mechanical - Tightening Torque Specifications380
Engine Fuel381
Fuel System Description381
Fuel System - On-Vehicle Service382
Fuel Filter Removal383
Fuel Filter Installation384
Fuel Lines Inspection384
Fuel Filler Cap385
Fuel Tank385
Fuel Tank Inspection386
Fuel Tank Purging Procedure387
Fuel Tank Installation388
Engine and Emission Control System (Sequential Multiport Fuel Injection)391
Engine and Emission Control System - General Description393
Engine and Emission Control System - Diagram394
Air Intake System396
Fuel Delivery System397
Electronic Control System Description398
Engine & Emission Control Input/Output Table402
Engine & Emission Control System - On-Vehicle System403
Acceleration Cable Adjustment404
Idle Speed/Idle Air Control (IAC) Duty Inspection405
Throttle Body Removal406
Throttle Body Cleaning407
Throttle Body Installation407
Idle Air Control Valve (IAC Valve) Inspection408
Idle Air Control Valve (IAC Valve) Removal408
Idle Air Control Valve (IAC Valve) Installation408
Fuel Pressure Inspection409
Fuel Pump - On-Vehicle Inspection410
Fuel Pump Removal and Inspection410
Fuel Pump Installation411
Fuel Pressure Regulator Removal411
Fuel Pressure Regulator Installation411
Fuel Pulsation Damper Removal412
Fuel Pulsation Damper Installation412
Fuel Injector On-Vehicle Inspection412
Fuel Injector Removal413
Fuel Injector Inspection414
Fuel Injector Installation416
Engine Control Module (ECM) Removal417
Engine Control Module (ECM) Installation417
Mass Air Flow Sensor Inspection418
Mass Air Flow Sensor (MAF Sensor) Removal418
Intake Air Temperature (IAT) Sensor Removal419
Intake Air Temperature (IAT) Sensor Inspection419
Intake Air Temperature (IAT) Sensor Installation420
Throttle Position Sensor (TP Sensor) Inspection421
Throttle Position Sensor (TP Sensor) Adjustment421
Throttle Position Sensor (TP Sensor) Removal422
Throttle Position Sensor (TP Sensor) Installation422
Engine Coolant Temperature Sensor (ECT Sensor) Removal423
Engine Coolant Temperature Sensor (ECT Sensor) Inspection423
Engine Coolant Temperature Sensor (ECT Sensor) Installation424
Heated Oxygen Sensor-1 and -2 (HO2S-1 and HO2S-2) Inspection424
Heated Oxygen Sensor-1 and -2 (HO2S-1 and HO2S-2) Removal425
Heated Oxygen Sensor-1 and -2 (HO2S-1 and HO2S-2) Installation425
Vehicle Speed Sensor (VSS) - On-Vehicle Inspection425
Camshaft Position Sensor (CMP Sensor) Inspection426
Camshaft Position Sensor (CMP Sensor) Removal and Installation426
Crankshaft Position Sensor Inspection426
Crankshaft Position Sensor Removal and Installation426
Manifold Differential Pressure Sensor Check427
Main Relay Inspection428
Fuel Pump Relay Inspection428
Fuel Cut Operation Inspection429
EGR System Inspection Using Suzuki Scan Tool430
EGR System Removal430
Evaporative Emission Control System431
EGR System Inspection431
PCV System431
PCV Hose431
PCV Valve432
Engine and Emission Control System - Tightening Torque Specifications433
Engine and Emission Control System - Special Tools433
Section 6F - Ignition System435
Ignition System - General Description436
Ignition System Diagnosis Table437
Diagnostic Flowtable (When Engine Cranks but Does Not Start)437
Ignition Spark Test438
High-Tension Cords438
Spark Plugs439
Noise Suppressor439
Distributor Power Supply440
Distributor Cap and Rotor440
Ignition Coil Circuit440
Igniter Circuit440
Ignition Timing - Inspection and Adjustment441
Distributor Unit View442
Distributor Unit Removal442
Distributor Unit Installation443
Ignition System - Special Tools444
Exhaust System445
Exhaust System Diagram446
Exhaust System Maintenance447
Exhaust System On-Vehicle Service447
Exhaust Manifold447
Muffler447
Immobilizer Control System449
Immobilizer Control System - General Description450
Ignition Key451
Coil Antenna451
Immobilizer Control Module452
Ecm/Pcm452
On-Board Diagnostic System (Immobilizer Control Module)452
Immobilizer Control System Diagnosis454
Diagnostic Flow Table (Immobilizer Control System)456
Diagnostic Trouble Code (DTC) Check (Immobilizer Control Module)457
Diagnostic Trouble Code (DTC) Check (ECM/PCM)458
Diagnostic Trouble Code Table - Immobilizer Control Module459
Diagnostic Trouble Code Table - ECM/PCM459
Table a DTC Is Not Output from Diagnostic Output Terminal460
Table B Immobilizer Indicator Lamp Check (Immobilizer Indicator Lamp Does Not Light at Ignition Switch On)461
Table C Immobilizer Indicator Lamp Check (Immobilizer Indicator Lamp Remains on after Engine Starts)462
DTC11 Transponder Code Not Matched463
DTC31 Transponder Code Not Registered463
DTC12 Fault in Immobilizer Control Module463
DTC13 no Transponder Code Transmitted or Coil Antenna Opened/Shorted464
DTC 21 Ecm/Immobilizer Control Module Code Not Matched (Immobilizer Control Module Side)466
DTC81 Ecm/Immobilizer Control Module Code Not Matched (ECM/PCM Side)466
DTC84 - Ecm/Immobilizer Control Module Code Not Registered466
DTC22 Ignition Switch Circuit Open/Short467
DTC23 no Ecm/Immobilizer Control Module Code Transmitted from ECM/)CM or DLC Circuit Opened/Shorted468
DTC83 no Ecm/Immobilizer Control Module Code Transmitted from Immobilizer Control Module or DLC Circuit Opened/Shorted468
DTC82 (P1622) Fault in ECM/PCM469
Inspection of ECM/PCM, Immobilizer Control Module and Its Circuit470
Immobilizer Control System On-Vehicle Service472
Precautions in Handling Immobilizer Control System472
Immobilizer Control Module Removal473
Immobilizer Control Module Installation473
How to Register Ignition Key474
Procedure after Immobilizer Control Module Replacement475
Procedure after ECM/PCM Replacement476
Immobilizer Control System - Special Tools476

Brand	Suzuki
Model	VITARA
Category	Automobile
Language	English

Suzuki VITARA User Manual

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