service indicator SUZUKI GRAND VITARA 2001 2.G Service Workshop Manual
[x] Cancel search | Manufacturer: SUZUKI, Model Year: 2001, Model line: GRAND VITARA, Model: SUZUKI GRAND VITARA 2001 2.GPages: 801, PDF Size: 12.15 MB
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5B-4 FRONT BRAKE
1. Wheel nut
2. Washer
(or spacer)
ªAº: Apply grease
Brake Disc
Before this inspection, brake pads must be removed.
Check disc surface for scratches in wearing parts. Scratches on
disc surface noticed at the time of specified inspection or replace-
ment are normal and disc is not defective unless they are serious.
But when there are deep scratches or scratches all over disc sur-
face, replace it. When only one side is scratched, polish and correct
that side.
Disc thickness ªaº
Standard: 22 mm (0.866 in.) For SUMITOMO ELECTRIC. . . . .
brake caliper
17 mm (0.670 in.) For TOKICO brake caliper. . . . .
Service limit: 20 mm (0.787 in.) For SUMITOMO ELECTRIC. .
brake caliper
15 mm (0.590 in.) For TOKICO brake caliper. .
Use wheel nuts and suitable plain washers to hold the disc securely
against the hub, then mount a dial indicator as shown and measure
the runout at 25 mm (0.98 in.) from the outer edge of the disc.
Limit on disc deflection: 0.15 mm (0.006 in.)
NOTE:
Check front wheel bearing for looseness before measure-
ment.
Cylinder Slide Guide Pin / Pin Bolt
Check guide pin for smooth movement as shown.
If it is found faulty, correct or replace. Apply rubber grease to guide
pin outer surface. Rubber grease should be the on whose viscosity
is less affected by such low temperature a ±40C (±40F).
Dust Boot
Check boot for breakage, crack and damage. If defective, replace.
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Example: When right-front wheel speed sensor circuit opens (DTC 21)
1. Diagnosis connector
(6 pins connector)
2. Ground terminal3. Diag. switch terminal
4. Service wire
Voltmeter indicator
(or ªABSº warning
lamp)HIGH
(ON)
LOW
(OFF)
Time (sec.)
1. EBD warning lamp
(brake warning lamp)
ANTILOCK BRAKE SYSTEM (ABS) (OPTIONAL) 5E1-11
EBD WARNING LAMP (BRAKE WARNING
LAMP) CHECK
NOTE:
Perform this check on a level place.
1) Turn ignition switch ON with parking brake applied.
2) Check that brake warning lamp is turned ON.
3) Release parking brake with ignition switch ON and check that
EBD warning lamp (brake warning lamp) goes off.
If it doesn't go off, go to ªTABLE-Eº in this section.
ªABSº WARNING LAMP CHECK
1) Turn ON the ignition switch.
2) Check that ªABSº warning lamp lights for about 2 seconds and
then goes OFF.
If anything faulty is found, advance to Diagnostic table ± A, B or
C.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
(USING ªABSº WARNING LAMP)
1) Using service wire, connect diag. switch terminal of diagnosis
connector to ground.
2) Turn ignition switch ON.
3) Read flashing of ªABSº warning lamp which represents DTC as
shown in example below and write it down. When more than 2
DTC's are stored in memory, deflection and flashing for each
DTC is repeated three times starting with the smallest DTC num-
ber in increasing order.
For details of DTC, refer to ªDTC Tableº.
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7B1
AUTOMATIC TRANSMISSION (4 A / T) 7B1-1
GENERAL DESCRIPTION7B1- 3 . . . . . . . . . . . . . .
CLUTCH / BRAKE FUNCTIONS 7B1- 5. . . . . . . . .
TABLE OF COMPONENT OPERATION 7B1- 6. . .
ELECTRONIC SHIFT CONTROL
SYSTEM 7B1- 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSIS7B1-17 . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION IN DIAGNOSING
TROUBLE 7B1-20. . . . . . . . . . . . . . . . . . . . . . . . . .
AUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLE 7B1-21. . . . . . . . . .
Customer Problem Inspection Form 7B1-23. . .
Malfunction Indicator lamp (MIL)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
ªO / D OFFº Lamp Check 7B1-24. . . . . . . . . . . . .
ªPOWERº Lamp Check 7B1-24. . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Check 7B1-24. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC)
Clearance 7B1-24. . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code (DTC) Table7B1-24 . . .
Fail-Safe Table 7B1-25. . . . . . . . . . . . . . . . . . . . .
Visual Inspection 7B1-26. . . . . . . . . . . . . . . . . . .
A / T Basic Check 7B1-27. . . . . . . . . . . . . . . . . . .
Trouble Diagnosis Table 1 7B1-28. . . . . . . . . . .
Trouble Diagnosis Table 2 7B1-28. . . . . . . . . . . Trouble Diagnosis Table 3 7B1-29. . . . . . . . . . .
Scan Tool Data 7B1-30. . . . . . . . . . . . . . . . . . . . .
Inspection of PCM and Its Circuit 7B1-30. . . . .
Wire Harness and Connectors 7B1-30. . . . . . . .
Diagnostic Flow Table A-1 7B1-31. . . . . . . . . . .
Diagnostic Flow Table A-2 7B1-33. . . . . . . . . . .
Table B-1 ªO / D OFFº Light Circuit
Check 7B1-35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-2 ªO / D OFFº Light Circuit
Check 7B1-36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-3 ªPOWERº Light Circuit
Check 7B1-37. . . . . . . . . . . . . . . . . . . . . . . . . . .
Table B-4 ªPOWERº Light Circuit
Check 7B1-38. . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC P0705 Transmission Range
Sensor (Switch) Circuit Malfunction 7B1-39. .
DTC P0715 Input / Turbine Speed
Sensor Circuit Malfunction 7B1-42. . . . . . . . . .
DTC P0720 Output Speed Sensor
Circuit Malfunction 7B1-44. . . . . . . . . . . . . . . . .
DTC P0741 TCC Solenoid Valve
Performance or Stuck Off 7B1-46. . . . . . . . . . .
DTC P0743 TCC Solenoid Electrical 7B1-47. .
DTC P0751 Shift Solenoid Valve-A (#1)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
DTC P0756 Shift Solenoid Valve-B (#2)
Performance or Stuck Off 7B1-49. . . . . . . . . . .
SECTION 7B1
AUTOMATIC TRANSMISSION
(4 A/T)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
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7E-6 DIFFERENTIAL (FRONT)
STEPACTIONYESNO
1Turn ON ignition switch (but engine at stop) and
check malfunction indicator lamp.
Does lamp light up?Go to step 2.A trouble has
occurred at some
place. Repair it
referring to
MALFUNCTION
INDICATOR LAMP
(ªCHECK ENGINEº
LAMP) CHECK in
DIAGNOSIS of
SECTION 6.
2Check 4WD switch circuit.
Turn ignition switch ON and check that voltage
between terminal C51-2-18 and terminal C51-3-17
(ground) for G16 / J20 (terminal C51-1-11 and terminal
C51-3-26 (ground) for H25) is as follows.
When transfer shift lever is in N or 2H: 10 ± 14 V
When transfer shift lever is in 4L or 4H: 0 ± 1 V
Is the check result satisfactory?Go to step 3.Check 4WD switch
(refer to SECTION
7A), ªB / Orº and ªBº
circuits of 4WD
switch.
If OK, substitute a
known-good ECM
(PCM) and recheck.
3Check power supply.
1) Turn ignition switch ON.
2) Check voltage between C51-2-7 and C51-3-17
(ground) for G16 / J20 (C51-1-15 and C51-3-26
(ground) for H25). The check results should be as
follows.
When transfer shift lever is in N or 2H: 0 ± 1 V
When transfer shift lever is in 4L or 4H: 10 ± 14 V
Is the check result satisfactory?Go to step 4.Check ªRº circuit. If
it is OK, substitute a
known-good ECM
(PCM) and recheck.
4Check air pump assembly circuit.
1) Check for proper connection to air pump
assembly at all terminals.
2) Turn ignition switch ON.
3) Check voltage between C51-2-27 and C51-3-17
(ground) for G16 / J20 (C51-1-18 and C51-3-26
(ground) for H25). The check result should be as
follows.
When transfer shift lever is in 2H or N: 0 ± 1 V
When transfer shift lever is in 4L or 4H
(more than 4 seconds after shifted to 4L or 4H):
10 ± 14 V
Is the check result satisfactory?Go to step 5.Check air pump
assembly referring
to ªON-VEHICLE
SERVICEº, and then
ªPº circuit.
If OK, substitute a
known-good ECM
(PCM) and recheck.
5Check 4WD indicator lamp circuit.
1) Turn ignition switch ON.
2) Check voltage between E61-19 and C51-3-17
(ground) for G16 / J20 (C51-1-7 and C51-3-26
(ground) for H25). The check result should be as
follows.
When transfer shift lever is in 2H or N: 10 ± 14 V
When transfer shift lever is in 4L or 4H: 0 ± 1 V
Is the check result satisfactory?4WD control system
is in good condition.Check ªOr / Bº circuit
(including indicator
lamp and
combination meter).
If OK, substitute a
known-good ECM
(PCM) and recheck.
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8G
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-1
GENERAL DESCRIPTION8G- 2 . . . . . . . . . . . . . .
Ignition Key 8G- 3. . . . . . . . . . . . . . . . . . . . . . . . . .
Coil Antenna 8G- 3. . . . . . . . . . . . . . . . . . . . . . . . .
Immobilizer Control Module 8G- 4. . . . . . . . . . . .
ECM/PCM 8G- 4. . . . . . . . . . . . . . . . . . . . . . . . . . .
On-Board Diagnostic System
(Self-Diagnosis Function) 8G- 4. . . . . . . . . . . . .
DIAGNOSIS8G- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions in Diagnosing Troubles 8G- 6. . . . .
Diagnostic Flow Table
Diagnostic Flow Table
Diagnostic Trouble Code Check
(Immobilizer Control Module) 8G-11. . . . . . . .
Diagnostic Trouble Code Check
(ECM / PCM) 8G-11. . . . . . . . . . . . . . . . . . . . . .
Diagnostic Trouble Code Table 8G-13. . . . . . . . .
TABLE A DTC is not Output
from Diagnostic Output Terminal 8G-14. . . . . . .
TABLE B Immobilizer Indicator Lamp
Check (Immobilizer Indicator Lamp
does not Light at Ignition Switch ON) 8G-15. . .
TABLE C Immobilizer Indicator Lamp
Check (Immobilizer Indicator Lamp
Remains on after Engine Starts) 8G-16. . . . . . .
DTC11 Transponder Code Not Matched8G-17 . .
DTC31 Transponder Code Not
Registered 8G-17. . . . . . . . . . . . . . . . . . . . . . . . .
DTC12 Fault in Immobilizer
Control Module 8G-17. . . . . . . . . . . . . . . . . . . . . .
DTC13 No Transponder Code Transmitted
or Coil Antenna Opened/Shorted 8G-18. . . . . . DTC21 ECM/Immobilizer Control Module
Code Not Matched (Immobilizer Control
Module Side) 8G-20. . . . . . . . . . . . . . . . . . . . . . .
DTC81 (P1623) ECM/Immobilizer
Control Module Code Not Matched
(ECM/PCM Side) 8G-20. . . . . . . . . . . . . . . . . . . .
DTC84 (P1620) ECM/Immobilizer Control
Module Code Not Registered 8G-20. . . . . . . . .
DTC22 Ignition Switch Circuit Open/Short8G-21 . .
DTC23 No ECM/Immobilizer Control
Module Code Transmitted from ECM/
PCM or DLC Circuit Opened/Shorted8G-22 . . . .
DTC83 (P1621) No ECM/Immobilizer
Control Module Code Transmitted from
Immobilizer Control Module or DLC
Circuit Opened/Shorted 8G-22. . . . . . . . . . . . . .
DTC82 (P1622) Fault in ECM/PCM 8G-23. . . . .
Inspection of ECM/PCM, Immobilizer
Control Module and Its Circuit 8G-24. . . . . . . . .
Voltage Check 8G-24. . . . . . . . . . . . . . . . . . . . .
Resistance Check 8G-25. . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE8G-26 . . . . . . . . . . . . . . . .
Precautions in Handling Immobilizer
Control System 8G-26. . . . . . . . . . . . . . . . . . . . .
Immobilizer Control Module 8G-27. . . . . . . . . . . .
Coil Antenna 8G-27. . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO REGISTER IGNITION KEY8G-28 . . . . .
PROCEDURE AFTER IMMOBILIZER
CONTROL MODULE REPLACEMENT8G-29 . .
PROCEDURE AFTER ECM/PCM
REPLACEMENT8G-30 . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS8G-30 . . . . . . . . . . . . . . . . . . . . . .
SECTION 8G
IMMOBILIZER CONTROL SYSTEM
(IF EQUIPPED)
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System
Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº in air bag system section before performing service on or around
the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional
activation of the system or could render the system inoperative. Either of these two conditions may
result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
ªLOCKº position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
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IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-9
Fig. 1 for Step 1 Fig. 2 for Step 1 Fig. 3 for Step 2
1. Monitor coupler
2. Service wire
A: Diagnosis switch terminal
B: Ground terminal
Fig. 4 for Step 3
ªCHECK ENGINEº light
0.5
ON
OFF
TIME (sec.)
DIAGNOSTIC FLOW TABLE
STEPACTIONYESNO
11) Make sure that diagnosis switch
terminal in monitor coupler is not
grounded by service wire. See Fig. 1.
2) Check malfunction indicator lamp
while ignition switch is ON (but without
starting engine). See Fig. 2.
Dose malfunction indicator lamp flash?Go to Step 3.If malfunction indicator lamp
remains ON, go to Step 2.
If malfunction indicator lamp
remains OFF, go to
ªMALFUNCTION INDICATOR
LAMP CHECKº in Section 6.
21) Using service wire, ground diagnosis
switch terminal in monitor coupler.
See Fig. 3.
Dose malfunction indicator lamp flash?Immobilizer control
system is in good
condition.Go to ªMALFUNCTION
INDICATOR LAMP CHECKº in
Section 6.
3Dose malfunction indicator lamp flash as
Fig. 4?Go to Step 4.Go to ªMALFUNCTION
INDICATOR LAMP CHECKº in
Section 6.
41) Check DTC stored in immobilizer
control module referring to
ªDIAGNOSTIC TROUBLE CODE
CHECK (IMMOBILIZER CONTROL
MODULE)º in this section.
Is there any DTC(s)?Go to flow table for
DTC No.Go to Step 5.
51) Check DTC stored in ECM/PCM
referring to ªDIAGNOSTIC TROUBLE
CODE CHECK (ECM / PCM)º in this
section.
Is there any DTC(s)?Go to flow table for
DTC No.Substitute a known-good ECM/
PCM and recheck.
NOTE:
After replacing with a known-
good ECM/PCM, register
ECM / Immobilizer Control
Module code in ECM/PCM by
performing procedure described
in ªProcedure after ECM/PCM
Replacementº section.
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IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-11
1. Immobilizer diagnostic coupler
EXAMPLE : COIL ANTENNA FAILURE (CODE NO.13)
Voltmeter indicator
NORMAL (No code)
Voltmeter indicatorTIME (sec.)
TIME (sec.) CODE No. 13CODE No. 13CODE No. 13
High
Low
High
Low
1. Monitor coupler
2. Service wire
A: Diagnosis switch
terminal
B: Ground terminal
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
(IMMOBILIZER CONTROL MODULE)
1) Using analog type voltmeter, connect positive probe to diagnos-
tic output terminal and negative probe to ground of immobilizer
diagnostic coupler with ignition switch turned ON.
2) Read deflection of voltmeter indicator which represents DTC as
shown in example below and write it down. For details of DTC,
refer to Immobilizer Control Module side in ªDiagnostic Trouble
Code Tableº.
If voltmeter indicator dose not deflect, go to ªDiagnostic Flow
Table Aº.
NOTE:
If abnormality or malfunction lies in two or more areas, volt-
meter indicates applicable codes three times each.
DIAGNOSTIC TROUBLE CODE (DTC) CHECK (ECM/PCM)
[Not using SUZUKI scan tool] (Vehicle equipped with
monitor coupler)
1) Using service wire, ground diagnostic switch terminal in monitor
coupler.
2) Read DTC from flashing pattern of malfunction indicator lamp as
shown in example below and write it down. For details of DTC,
refer to ECM / PCM side in ªDiagnostic Trouble Code Tableº.
If lamp remains ON, go to ªMalfunction Indicator Lamp Checkº
in Section 6.
NOTE:
If abnormality or malfunction lies in two or more areas, mal-
function indicator lamp indicates applicable codes three
times each.
And flashing of these codes is repeated as long as diagno-
sis terminal is grounded and ignition switch is held at ON
position.
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8G-12 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
EXAMPLE: When serial data link wire is defective (Code No.83)
ON
OFFMalfunction
indicator lamp
Code No.83 Code No.83 Code No.83
Time (sec.)
1. Data link connector (DLC)
3) After completing the check, turn ignition switch OFF and discon-
nect service wire from monitor coupler.
[Using SUZUKI scan tool]
1) Turn ignition switch OFF.
2) After setting cartridge to Suzuki scan tool, connect it to data link
connector (DLC) located on underside of instrument panel at
driver's seat side.
Special Tool
(A): 09931-76011 (Suzuki scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16 / 12 pin DLC adapter)
3) Turn ignition switch ON.
4) Read DTC according to instructions displayed on Suzuki scan
tool and print it or write it down. Refer to Suzuki scan tool opera-
tor's manual for further details.
NOTE:
When reading DTC stored in ECM / PCM using Suzuki scan
tool, select ªECMº from the applications menu and ªSU-
ZUKI modeº from the communication mode menu dis-
played on Suzuki scan tool.
If ECM / PCM detects a trouble in both electric fuel injec-
tion system and immobilizer control system, Suzuki scan
tool indicates trouble codes of both systems using Suzu-
ki mode of ECM application.
If communication between Suzuki scan tool and ECM / PCM is
not possible, check if Suzuki scan tool is communicable by con-
necting it to ECM / PCM in another vehicle. If communication is
possible in this case, Suzuki scan tool is in good condition. Then
check data link connector and serial data line (circuit) in the ve-
hicle with which communication was not possible.
5) After completing the check, turn ignition switch OFF and discon-
nect Suzuki scan tool from data link connector (DLC).
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IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-15
1. Main fuse
2. Main relay
3. ECM/PCM
4. Immobilizer indicator lamp
(Vehicle not equipped with
monitor coupler) For G16 / J20 engine For H25 engine
G16 / J20 Engine
H25 Engine
TABLE B IMMOBILIZER INDICATOR LAMP CHECK
(IMMOBILIZER INDICATOR LAMP DOSE NOT LIGHT AT IGNITION
SWITCH ON)
STEPACTIONYESNO
11) Turn ignition switch ON.
Do other indicator / warning lights in
combination meter come ON?Go to Step 2.ªIGº fuse blown, main fuse blown,
ignition switch malfunction,
ªB / Wº circuit between ªIGº fuse
and combination meter or poor
coupler connection at
combination meter.
21) Turn ignition switch OFF and
disconnect connectors from ECM /
PCM.
2) Check for proper connection to ECM /
PCM at terminal E61-5 for G16 / J20
engine or E61-23 for H25 engine.
3) If OK, then using service wire, ground
terminal E61-5 for G16 / J20 engine or
E61-23 for H25 engine in connector
disconnected.
Does immobilizer indicator lamp turn on
at ignition switch ON?Substitute a known-
good ECM / PCM and
recheck.Bulb burned out or ª(b)º wire
circuit open.
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10B-12 AIR BAG SYSTEM
1. Data link connector (DLC)
2. DLC cable adapter
3. DLC cable
-1. ªAIR BAGº
warning lamp
-2. ªAIR BAGº fuse box
-3. ªAIR BAGº
monitor coupler
3-1. Diagnostic switch
terminal
-4. Air bag harness
(covered yellow tube)
EXAMPLE: When driver air bag initiator circuit resistance high (Code No.21) is set
Malfunction indicator lamp
(ªAIR BAGº warning lamp)
Turn ON
Turn OFF
Time (sec.) Code No. 21 Code No. 21 Code No. 21 1
DIAGNOSTIC TROUBLE CODE (DTC) CHECK
[Using SUZUKI scan tool]
1) Turn ignition switch OFF.
2) After setting cartridge to Tech 1, connect it to data link connector
(DLC) located on underside of instrument panel at driver's seat
side.
Special Tool
(A): 09931-76011 (Tech 1)
(B): Mass storage cartridge
(C): 09931-76030
3) Turn ignition switch ON.
4) Read DTC according to instructions displayed on Tech 1 and
print it or write it down. Refer to Tech 1 operator's manual for fur-
ther details.
5) After completing the check, turn ignition switch OFF and discon-
nect Tech 1 from data link connector (DLC).
[Not using SUZUKI scan tool]
1) Check that malfunction indicator lamp (ªAIR BAGº warning
lamp) comes ON when ignition switch is turned ON.
If it does not come ªONº, proceed to ªTable Bº on p.10B-18.
2) Using service wire, ground diagnosis switch terminal in monitor
coupler.
3) Read DTC from flashing pattern of malfunction indicator lamp
(ªAIR BAGº warning lamp). (Refer to ªDiagnostic Trouble Code
Tableº on p.10B-14 and 10B-15.)
4) After completing the check, turn ignition switch OFF and discon-
nect service wire from ªAIR BAGº monitor coupler.