check engine light SUZUKI GRAND VITARA 2003 2.G Service Workshop Manual

YH4
GRAND
VITARA
L
LH : Left Hand
LSPV : Load Sensing Proportioning
Valve
M
MAF Sensor : Mass Air Flow Sensor
(Air Flow Sensor, AFS, Air
Flow Meter, AFM)
MAP Sensor : Manifold Absolute Pressure
Sensor (Pressure Sensor, PS)
Max : Maximum
MFI : Multiport Fuel Injection
(Multipoint Fuel Injection)
Min : Minimum
MIL : Malfunction Indicator Lamp
(ªCHECK ENGINEº Light)
M / T : Manual Transmission
N
NOx : Nitrogen Oxides
O
OBD : On-Board Diagnostic System
(Self-Diagnosis Function)
O / D : Overdrive
OHC : Over Head Camshaft
P
PNP : Park / Neutral Position
P / S : Power Steering
PSP Switch : Power Steering Pressure
Switch (P / S Pressure Switch)
PCM : Powertrain Control Module
PCV : Positive Crankcase Ventilation
R
RH : Right Hand
S
SAE : Society of Automotive
Engineers
SDM : Sensing and Diagnostic
Module (Air bag controller,
Air bag control module)
SFI : Sequential Multiport Fuel
Injection
SOHC : Single Over Head Camshaft
T
TBI : Throttle Body Fuel Injection
(Single-Point Fuel Injection,
SPI)
TCC : Torque Converter Clutch
TCM : Transmission Control Module
(A / T Controller, A / T Control
Module)
TP Sensor : Throttle Position Sensor
TVV : Thermal Vacuum Valve
(Thermal Vacuum Switching
Valve, TVSV, Bimetal Vacuum
Switching Valve, BVSV)
TWC : Three Way Catalytic
Converter (Three Way
Catalyst)
2WD : 2 Wheel Drive
V
VIN : Vehicle Identification
Number
VSS : Vehicle Speed Sensor
W
WU-OC : Warm Up Oxidation
Catalytic Converter
WU-TWC : Warm Up Three Way
Catalytic Converter
0A-22 GENERAL INFORMATION

YH4
GRAND
VITARA
MAINTENANCE AND LUBRICATION 0B-25
Steering

Check to ensure that steering wheel is free from in-
stability, or abnormally heavy feeling.

Check that the vehicle does not wander or pull to
one side.
Engine

Check that engine responds readily at all speeds.

Check that engine is free from abnormal noise and
abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting sys-
tem are free from abnormal noise and abnormal
vibration or any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter, tem-
perature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that air comes out from defroster
outlet when operating heater or air conditioning.
Set fan switch lever to ªHIº position for this check.
RECOMMENDED FLUIDS AND LUBRICANTS
Engine oilSG, SH or SJ (Refer to engine oil viscosity chart in item 1-4)
Engine coolant (Ethylene glycol
base coolant)ªAntifreeze / Anticorrosion coolantº
Brake fluidDOT 3
Manual transmission oilRefer to Section 7A or 7A1Transfer oilRefer to Section 7A or 7A1.
Differential oil (front & rear)Refer to Section 7E or 7F.
Automatic transmission fluid and
Power steering fluidRefer to Section 3B1 or 7B1.
Door hingesEngine oil or water resistance chassis greaseHood latch assemblyEngine oil or water resistance chassis grease
Key lock cylinderSpray lubricant

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-15
AMBIENT TEMPERATURE WITHIN 30 ± 35C (85 ± 95F)
CONDITION
MANIFOLD
GAUGEMPa
(kg/cm2)
(psi)DETAILCAUSECORRECTION
LoHi
0.23 ± 0.35
(2.3 ± 3.5)
(33 ± 50)1.4 ± 1.75
(14 ± 17.5)
(200 ± 249)
Normal condition.ÐÐÐÐ
Negative
pressure0.5 ± 0.6
(5 ± 6)
(71.2 ± 85.3)

The low pressure side
reads a negative pressure,
and the high pressure side
reads an extremely low
pressure.

Presence of frost around
tubing to and from receiver /
dryer and expansion valve.
Dust particles or water
droplets are either stuck or
frozen inside expansion
valve, preventing the
refrigerant from flowing.
Clean expansion valve.
Replace it if it cannot be
cleaned.

Replace receiver / dryer.

Evacuate the A / C
system and recharge
with fresh refrigerant.
Normal:
0.23 ± 0.35
(2.3 ± 3.5)
(33 ± 50)

Abnormal:
Negative
pressureNormal:
1.4 ± 1.75
(14 ± 17.5)
(200 ± 249)

Abnormal:
0.69 ± 0.98
(7 ± 10)
(100 ± 142)
During A / C operation, the
low pressure side
sometimes indicates
negative pressure, and
sometimes normal
pressure. Also high
pressure side reading
fluctuates between the
abnormal and normal
pressure.
Expansion valve is frozen
due to moisture in the
system, and temporarily
shuts off the refrigeration
cycle.
Replace expansion
valve.

Replace receiver / dryer.

Evacuate A / C system
and recharge with fresh
refrigerant.
0.05 ± 0.15
(0.5 ± 1.5)
(4.2 ± 21.3)
0.69 ± 0.98
(7 ± 10)
(100 ± 142)

Both low and high pressure
sides indicate low readings.

Continuous air bubbles are
visible through sight glass.

Output air is slightly cold.
Insufficient refrigerant in
system. (Refrigerant
leaking)
Using a gas leak
detector, check for leaks
and repair as necessary.

Recharge refrigerant to a
specified amount.
If the pressure reading is
almost 0 when the
manifold gauges are
attached, check for any
leaks, repair them, and
evacuate the system.
0.4 ± 0.6
(4 ± 6)
(56.9 ± 85.3)

Pressure on low pressure
side is high.

Pressure on high pressure
side is low.

Both pressure becoming
equal right after A / C is
turned OFF.
Internal leak in compressor.
Inspect compressor and
repair or replace as
necessary.
035 045

High pressure reading on
both low and high pressure
sides.

Air bubbles are not visible
even when engine rpm is
lowered.
Overcharged A / C system.

Faulty condenser cooling
operation.

Faulty condenser fan
operation.
Adjust refrigerant to
specified amount.

Clean condenser.

Inspect and repair
condenser fan.
0.35 ± 0.45(3.5 ± 4.5)
(50 ± 64)
1.96 ± 2.45
(20 ± 25)
(285 ± 355)

High pressure reading on
both low and high pressure
sides.

Low pressure side tubing is
not cold when touched.

Air bubbles are visible
through sight glass.
Presence of air in A / C
system. (Improperly
evacuated)
Replace receiver / dryer.

Inspect quantity of
compressor oil and
presence of
contaminants in oil.

Evacuate system and
recharge with fresh
refrigerant.
0.45 ± 0.55
(4.5 ± 5.5)
(64 ± 78)

High pressure reading on
both low and high pressure
sides.

Large amount of frost or
dew on the low pressure
side tubing.
Faulty expansion valve.

Refrigerant flow is not
regulated properly.
Replace expansion
valve.

YH4
GRAND
VITARA
5-6 BRAKES
ConditionPossible CauseCorrection
Brake warning light
turns on after
engine start
Parking brake applied.

Insufficient amount of brake fluid.

Brake fluid leaking from brake line.

Brake warning light circuit faulty.

Malfunctioning EBD system, if equipped
with ABS.Release parking brake and check
that brake warning light turns off.
Add brake fluid.
Investigate leaky point, correct it and
add brake fluid.
Repair circuit.
Check system referring to
ªDIAGNOSISº of ABS section.
Brake warning light
turns on when
brake is applied
Brake fluid leaking from brake line.

Insufficient amount of brake fluid.Investigate leaky point, correct it and
add brake fluid.
Add brake fluid.
Brake warning light
fails to turn on
even when parking
brake is applied
Bulb burnt out.

Brake warning light circuit open.Replace bulb.
Repair circuit.
ABS warning light
does not turn on
for 2 sec. after
ignition switch has
turned ON
Bulb burnt out.

ABS warning light circuit open, if equipped
with ABS. (including check relay)Replace bulb.
Check system referring to
ªDIAGNOSISº of ABS section.
ABS warning light
remains on after
ignition switch has
turned on for 2 sec.
Malfunctioning ABS, if equipped with ABS.Check system referring to
ªDIAGNOSISº of ABS section.

YH4
GRAND
VITARA
1. Stop light switch
BRAKES 5-9
BRAKE PEDAL FREE HEIGHT CHECK
Remove foot rest and displace carpet and dash silencer(s) so as to
measure brake pedal free height between pedal face and asphalt
sheet installed on dash panel.
Brake pedal free height ªaº from asphalt sheet:
208 ± 218 mm (8.19 ± 8.58 in.)
If the measurement is not within the specification, check the posi-
tion of booster push rod clevis and / or stop light switch according
to the instruction shown in this section.
The free height varies depending on installation position of booster
push rod clevis and stop light switch.
BRAKE LIGHT SWITCH ADJUSTMENT
Adjustment should be made as follows when installing switch. Pull
up brake pedal toward you and while holding it there, adjust switch
position so that clearance between end of thread and brake pedal
return cushion (shown as ªbº in figure).
Then tighten lock nut to specified torque.
Clearance ªbº: 1.5 ± 2.0 mm (0.06 ± 0.08 in.)
Tightening Torque
(b): 7.5 N
.m (0.75 kg-m, 5.5 lb-ft)
EXCESSIVE PEDAL TRAVEL CHECK
1) Remove foot rest and displace carpet and dash silencer(s).
2) Start engine.
3) Depress brake pedal a few times.
4) With brake pedal depressed with approximately 30 kg (66 lbs)
load, measure pedal to asphalt sheet clearance ªcº.
Clearance ªcº: over 115 mm (4.53 in.)
5) If clearance ªcº is less than specification, the most possible
cause is either rear brake shoes are worn out beyond limit or air
is in lines.
Should clearance ªcº remain less than specification even after
replacement of brake shoes and bleeding of system, other pos-
sible but infrequent cause is malfunction of rear brake shoe ad-
justers or booster push rod length out of adjustment.

YH4
GRAND
VITARA
7B1-24 AUTOMATIC TRANSMISSION (4 A / T)
MALFUNCTION INDICATOR LAMP (MIL) CHECK
Refer to the same item in Section 6 / 6-1 for checking procedure.
ªO / D OFFº LAMP CHECK
1) Check that O / D cut switch button is at OFF position (pushed).
2) Turn ignition switch ON.
3) Check that ªO / D OFFº lamp lights for about 2 ± 4 sec. and then goes OFF.
If anything faulty is found, advance ªDiagnostic flow table B-1 or B-2º O / D OFF ªLAMP CIRCUIT CHECKº.
ªPOWERº LAMP CHECK
1) Check that Power / Normal change switch button is at Normal position.
2) Turn ignition switch ON.
3) Check that ªPowerº Lamp light for 2 ± 4 sec. and then goes OFF.
If anything faulty is found, advance ªDiagnostic flow table B-3 or B-4 ªPOWERº LAMP CIRCUIT CHECK 2.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
Refer to the same item in Section 6 / 6-1 for checking procedure.
DIAGNOSTIC TROUBLE CODE (DTC) CLEARANCE
Refer to the same item in Section 6 / 6-1 for clearance procedure.
DIAGNOSTIC TROUBLE CODE (DTC) TABLE (A / T RELATED CODE)
DTC NO.MIL
Using
scan toolNot using
scan toolDETECTED ITEMDETECTING CONDITION
Vehicle
without
monitor
connectorVehicle
with
monitor
connector
±12±No trouble.±±
P070572Transmission range
sensor circuit
Multiple signals inputted simulta-
neously or no signal inputted while
2 driving
cycles
Not
applicablesensor circuit
malfunction
neously or no signal in utted while
running at 60 km / h or more.
cyclesa licable
P071576Input / Turbine speed
sensor circuit
malfunctionInput shaft revolution speed is lower
than specified value while
vehicle is running with ªDº range and
specified engine speed or higher.2 driving
cyclesNot
applicable
P072075Output speed sensor
circuit malfunctionOutput speed sensor signal not
inputted while VSS signal being
inputted.2 driving
cyclesNot
applicable
*1
P0741
Not
applicableTCC (lock-up) solenoid
performance or stack
offActual TCC operation does not
agree with ON / OFF control from
PCM to TCC.2 driving
cyclesNot
applicable
P074365
66TCC (lock-up)
solenoid electricalMonitor signal OFF is detected
When TCC control solenoid is ON or
monitor signal ON is detected when
it is OFF.1 driving
cycleNot
applicable
*1
P0751
Not
applicableShift solenoid A (#1)
performance or stuck
offGear change control from PCM to
A / T does not agree with actual gear
position of A / T.2 driving
cyclesNot
applicable
P075361
62Shift solenoid A (#1)
electricalMonitor signal OFF is detected
when shift solenoid A (#1) is ON or
monitor signal ON is detected when
it is OFF.1 driving
cycleNot
applicable

YH4
GRAND
VITARA
G16 / J20 Engines
H25 Engine
1. PCM
2. J / B
3. O / D cut switch
4. P / N change switch
5. J / C
1. PCM
2. Fuse
3. O / D cut switch
4. P / N change switch
5. J / C
6. J / C
AUTOMATIC TRANSMISSION (4 A / T) 7B1-35
DIAGNOSTIC FLOW TABLE B-1 ªO / D OFFº LIGHT CIRCUIT CHECK
(ªO / D OFFº LIGHT DOESN'T LIGHT AT IGNITION SWITCH ON BUT
ENGINE STARTS UP)
WIRING DIAGRAM
TROUBLESHOOTING
STEPACTIONYESNO
1ªO / D OFFº light circuit check:
(1) With ignition switch OFF, disconnect
couplers from PCM.
(2) Using service wire, connect E61-20
(G16 / J20 engines) or E61-7 (H25 engine)
terminal of disconnected PCM coupler and
ground.
Does ªO / D OFFº light turn ON at ignition
switch ON?Poor E61-20 (G16 / J20
engines) or E61-7 (H25
engine) terminal
connection.
If OK, substitute a known-
good PCM and recheck.Bulb burned out or faulty
ªW / Bº, ªB / Wº wire.

YH4
GRAND
VITARA
7B1-36 AUTOMATIC TRANSMISSION (4 A / T)
Switch ON
positionSwitch OFF
positionSwitch ON
position
Switch OFF
position
DIAGNOSTIC FLOW TABLE B-2 ªO / D OFFº LIGHT CIRCUIT CHECK
(ªO / D OFFº LIGHT COMES ON STEADILY)
WIRING DIAGRAM ± Refer to Table B-1 in this section.
TROUBLESHOOTING
STEPACTIONYESNO
1Check O / D cut Switch Position.
Is O / D cut switch turned OFF (Is switch button at OFF
position)?Go to Step 2.Turn O / D cut switch
OFF.
2Check Lamp Circuit for Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Turn ignition switch ON.
Does ªO / D OFFº lamp come ON steadily?ªW / Bº circuit shorted
to ground.Go to Step 3.
3Check O / D cut Switch Circuit.
1) Check resistance between terminal E61-33
(G16 / J20 engines) or E61-14 (H25 engine) of
disconnected PCM connector and body ground with
O / D cut switch OFF.
Is continuity indicated?Go to Step 4.Check PCM ground
circuit for open.
If ground circuit is
OK, substitute a
known-good PCM
and recheck.
4Check O / D cut Switch for Operation.
1) Remove console box.
2) Disconnect O / D cut switch connector.
3) Check continuity between switch terminals under
each condition below.
Switch OFF position: No continuity
Switch ON position: Continuity
Is check result satisfactory?ªY / Rº circuit shorted
to ground.Replace O / D cut
switch.
Fig. for Step 1. Fig. for Step 4.

YH4
GRAND
VITARA
G16 / J20 Engines
H25 Engine
1. PCM
2. J / B
3. O / D cut switch
4. P / N change switch
5. J / C
1. PCM
2. Fuse
3. O / D cut switch
4. P / N change switch
5. J / C
6. J / C
AUTOMATIC TRANSMISSION (4 A / T) 7B1-37
DIAGNOSTIC FLOW TABLE B-3 ªPOWERº LIGHT CIRCUIT CHECK
(ªPOWERº LIGHT DOESN'T LIGHT AT IGNITION SWITCH ON BUT
ENGINE STARTS UP)
WIRING DIAGRAM
TROUBLESHOOTING
STEPACTIONYESNO
1ªPOWERº light circuit check:
(1) With ignition switch OFF, disconnect
couplers from PCM.
(2) Using service wire, connect E61-21 (G16 /
J20 engines) or E61-10 (H25 engine)
terminal of disconnected PCM coupler and
ground.
Does ªPOWERº light turn ON at ignition switch
ON?Poor E61-21 (G16 / J20
engines) or E61-10 (H25
engine) terminal
connection.
If OK, substitute a known-
good PCM and recheck.Bulb burned out or faulty
ªGr / Blº, ªB / Wº wire.

YH4
GRAND
VITARA
7B1-38 AUTOMATIC TRANSMISSION (4 A / T)
ª5º
ª4º
DIAGNOSTIC FLOW TABLE B-4 ªPOWERº LIGHT CIRCUIT CHECK
(ªPOWERº LIGHT COMES ON STEADILY)
WIRING DIAGRAM ± Refer to Table B-3 in this section.
TROUBLESHOOTING
STEPACTIONYESNO
1Check Power / Normal Change Switch Position.
Is switch button at Normal position?Go to Step 2.Set Power / Normal
change switch at
Normal position.
2Check Lamp Circuit for Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Turn ignition switch ON.
Does ªPOWERº lamp come ON steadily?ªGr / Blº circuit
shorted to ground.Go to Step 3.
3Check Power / Normal Change Switch Circuit.
1) Check resistance between terminal E61-31
(G16/J20 engines) or E61-9 (H25 engine) of
disconnected PCM connector and body ground with
P / N change switch OFF.
Is continuity indicated?Go to Step 4.Check PCM ground
circuit for open.
If ground circuit is
OK, substitute a
known-good PCM
and recheck.
4Check Power / Normal Change Switch for Operation.
1) Remove Power / Normal change switch.
2) Check continuity between switch terminals ª4º and
ª5º under each condition below.
Normal position: No continuity
Power position: Continuity.
Is check result satisfactory?ªOr / Blº circuit
shorted to ground.Replace Power /
Normal change
switch.
Fig. for Step 1. Fig. for Step 4.