engine check SUZUKI GRAND VITARA 2002 2.G Service Manual Online

YH4
GRAND
VITARA
7E-8 DIFFERENTIAL (FRONT)
1. ECM (PCM); viewed from harness side
Voltage Check [H25 engine model]
TER-
MINALCIRCUITWIRE
COLORNORMAL
VOLTAGECONDITION
C51 110 ± 14 VTransfer shift lever: 2H or NC51-1
-74WD Indicator lampOr / B0 ± 1 V4 seconds after transfer shift lever shifted
to 4H or 4L
C51 1Air pump assembly0 ± 1 VTransfer shift lever: 2H or NC51-1
-15(Pump motor and release
valve)R10 ± 14 V1 seconds after transfer shift lever shifted
to 4H or 4L
C51-14WD switchB/Or10 ± 14 VTransfer shift lever: 2H or N
-114WD switchB/Or0 ± 1 VTransfer shift lever: 4H or 4L
C51-3
-26GroundB/Bl0 ± 1 V±
C51-1Airpumpassembly0 ± 1 VTransfer shift lever: 2H or NC51-1
-18
Air um assembly
(pressure switch)P10 ± 14 V4 seconds after transfer shift lever shifted
to 4H or 4L

YH4
GRAND
VITARA
DIFFERENTIAL (FRONT) 7E-9
Viscosity chart SAE
Temperature
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
NOTE:

When having driven through water, check immediately if wa-
ter has entered (if so, oil is cloudy). Water mixed oil must be
changed at once.

Whenever vehicle is hoisted for any other service work than
oil change, also be sure to check for oil leakage and status
of breather hoses.
Gear Oil Change
NOTE:

Hypoid gear oil must be used for differential.

It is highly recommended to use SAE 80W ± 90 viscosity.
1) Before oil change or inspection, be sure to stop engine and lift
up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found, cor-
rect its cause.
3) Drain old oil and pour proper amount of gear oil as specified be-
low (roughly up to level hole).
4) Apply sealant to thread of drain plug (b) and torque plugs to
specification.
Sealant 99000-31110
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
Specified gear oil: Hypoid gear oil API GL-5
SAE 75W ± 85, 90 or 80W ± 90
For oil viscosity, refer to left chart.
Oil capacity: 1.0 liters (2.1 / 1.8 US / lmp. pt)

YH4
GRAND
VITARA
1. Breather hose
2. Oil filler / level plug
3. Rear drain plug
(Apply sealant)
Viscosity chart SAE
DIFFERENTIAL (REAR) 7F-3
ON-VEHICLE SERVICE
MAINTENANCE SERVICE
NOTE:

When having driven through water, check immediately if wa-
ter has entered (if so, oil is cloudy). Water mixed oil must be
changed at once.

Whenever vehicle is hoisted for any other service work than
oil change, also be sure to check for oil leakage and status
of breather hoses.
CHANGING OIL
NOTE:

Hypoid gear oil must be used for differential.

It is highly recommended to use SAE 80W-90 viscosity.
1) Before oil change or inspection, be sure to stop engine and lift
up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found, cor-
rect its cause.
3) Drain old oil and pour proper amount of gear oil as specified
(roughly up to level hole).
4) Torque drain and level / filler plugs to specification.
ªAº: Sealant 99000-31110
Tightening Torque
(a): 50 N
.m (5.0 kg-m, 36.5 lb-ft)
(b): 28 N
.m (2.8 kg-m, 20.5 lb-ft)
Specified gear oil: Hypoid gear oil API GL-5
SAE 75W-85, 80W-90 or 90
For oil viscosity, refer to the chart
at the left.
Oil capacity : 2.2 liters (4.6 / 3.9 US / Imp. pt.)

YH4
GRAND
VITARA
1. Tachometer
2. Speedometer
3. Fuel level meter
4. Water temperature meter
5. Turn signal pilot light (LH)
6. 4WD indicator (if equipped)
7. ABS warning light (if equipped)
8. Immobilizer warning light (if equipped)
9. CHECK ENGINE light
10. Turn signal pilot light (RH)11. AIR BAG warning light (if equipped)
12. O / D OFF light (A / T vehicle only)
13. Fasten seat belt light (if equipped)
14. High beam light
15. Oil pressure warning light
16. Charge warning light
17. Brake and parking brake warning light
18. POWER indicator light (A / T vehicle only)
19. Shift position indicator (A / T vehicle, if equipped)or
CHECK
ENGINEor
ABS
8C-2 INSTRUMENTATION / DRIVER INFORMATION
GENERAL DESCRIPTION
CAUTIONS IN SERVICING
Refer to Section 8.
SYMBOLS AND MARKS
Refer to Section 8.
WIRING COLOR SYMBOLS
Refer to Section 8.
ABBREVIATIONS
Refer to Section 8.
JOINT CONNECTOR
Refer to Section 8.
FUSE BOX AND RELAY
Refer to Section 8.
POWER SUPPLY DIAGRAM
Refer to Section 8.
COMBINATION METER

YH4
GRAND
VITARA
1. To door switch (driver side) B / Bl
2. To transmission range switch G / Bl
(A / T vehicle only, if equipped) L
3. To transmission range switch G / O
(A / T vehicle only, if equipped) 2
4. To transmission range switch Y / G
(A / T vehicle only, if equipped) D
5. To transmission range switch O / Bl
(A / T vehicle only, if equipped) N
6. To transmission range switch O / G
(A / T vehicle only, if equipped) P
7. To transmission range switch R
(A / T vehicle only, if equipped) R
8. To ground B
9. To PCM (A / T vehicle only) W / B
10. To ECT sensor Y / W
11. To fuel level gauge Bl / W
12. To ground B / Y
13. To combination switch G / Y
NOTE:
Terminal arrangement of coupler viewed from harness side.
Coupler A Coupler B Coupler C
Coupler A Coupler B Coupler C
1. Blank ÐÐ
2. Blank ÐÐ
3. To ignition switch B / W
4. Blank ÐÐ
5. To ABS control module Bl / O
(if equipped)
6. To PCM (A / T vehicle only) Gr / Bl
7. To ABS control module Br
(if equipped)
8. To VSS Bl / Y
9. To combination switch G / R
10. To SDM (if equipped) Y / G or Bl
11. To main fuse W / Bl
12. To fuse box W
13. To combination switch R
14. To ECM (PCM for A / T vehicle) V
(if equipped)
15. To ECM (PCM for A / T vehicle) V / Y
16. To ECM (PCM for A / T vehicle) O / B
(if equipped)1. To ground B
2. To ECM (PCM for A / T vehicle) Br
3. To ignition switch (if equipped) V / R
4. To brake fluid level switch R / B
5. To parking brake switch V
6. To seat belt switch (if equipped) Gr / R
7. To generator W / R
8. To oil pressure switch Y / B
9. To combination switch R / Y
10. To ignition switch (if equipped) Bl / R or CHECK
or ENGINE
or ABSif equipped
if equippedif equipped
INSTRUMENTATION / DRIVER INFORMATION 8C-3

YH4
GRAND
VITARA
8C-4 INSTRUMENTATION / DRIVER INFORMATION
DIAGNOSIS
NOTE:
Fuse name (ª º) in the table below is shown on the fuse box cover (Hard Top Model) or the junction box
(Canvas Top Model).
SPEEDOMETER AND VSS
TroublePossible CauseCorrection
Speedometer shows no
operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

VSS faulty

Printed plate in combination meter
faulty

Speedometer faulty

Wiring or grounding faultyReplace fuse to check for short
Replace VSS
Replace printed plate
Replace speedometer
Repair
FUEL METER / FUEL GAUGE UNIT
TroublePossible CauseCorrection
Fuel meter shows no
operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

Fuel gauge unit faulty

Printed plate in combination meter
faulty

Fuel meter faulty

Wiring or grounding faultyReplace fuse to check for short
Replace fuel gauge unit
Replace printed plate
Replace fuel meter
Repair
ENGINE COOLANT TEMP. (ECT) METER AND SENSOR
TroublePossible CauseCorrection
Engine coolant temp.
meter shows no operation
ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

ECT meter faulty

Printed plate in combination meter
faulty

ECT sensor faulty

Wiring or grounding faultyReplace fuse to check for short
Replace ECT meter
Replace printed plate
Replace ECT sensor
Repair
OIL PRESSURE LIGHT
TroublePossible CauseCorrection
Oil pressure warning light
does not light up
Bulb in combination meter blown

ªIG / METERº fuse blown (Hard Top
Model)
ªIGº fuse blown (Canvas Top Model)

Printed plate in combination meter
faulty

Oil pressure switch faulty

Wiring or grounding faultyReplace bulb
Replace fuse to check for short
Replace printed plate
Replace oil pressure switch
Repair

YH4
GRAND
VITARA
8C-10 INSTRUMENTATION / DRIVER INFORMATION
G16
J20
H25
1. ECT sensor
1
ENGINE COOLANT TEMP. (ECT) METER AND
SENSOR
ENGINE COOLANT TEMPERATURE (ECT) METER
INSPECTION
1) Disconnect Y/W lead wire going to ECT sensor.
2) Turn ignition switch ON, and check that ECT meter indicates
COOL.
3) Turn ignition switch OFF.
4) Ground Y/W lead wire through a 3.4 W test bulb (1) as illustrated.
5) Turn ignition switch ON, and check that bulb light up and pointer
(2) moves to hot side.
6) If ECT meter shows no operation, repair or replace defective
parts.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
REMOVAL AND INSTALLATION
Refer to ECT SENSOR in ON-VEHICLE SERVICE in Section 6E1
(for G16 and J20) or Section 6E2 (for H25) of this manual for details.

YH4
GRAND
VITARA
G16
J20
H25
1. Oil pressure switch
INSTRUMENTATION / DRIVER INFORMATION 8C-11
INSPECTION
1) Warm up ECT sensor (1) observing resistance between sensor
terminal (2) and sensor unit (1). Resistance should be de-
creased with increase of its temperature.
2) Check resistance between sensor terminal (2) and sensor unit
(1) shown below. If check result is not as specified, replace sen-
sor.
Temperature
Resistance
50
C (122
F)136 ± 216

OIL PRESSURE LIGHT
OIL PRESSURE SWITCH
REMOVAL AND INSTALLATION
Refer to OIL PRESSURE CHECK in Section 6A1 (for G16), Section
6A2 (for H25), and Section 6A4 (for J20) of this manual for details.
INSPECTION
1) Disconnect oil pressure switch (1) lead wire.
2) Check for continuity between oil pressure switch terminal (2)
and cylinder block (3) as shown.
During Engine Running
No continuity
At Engine StopContinuity
If check result is not as specified, replace oil pressure switch (1).

YH4
GRAND
VITARA
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 with monitor coupler> 8G- 9. . . . . . . . . . . . . . . .
Diagnostic Flow Table equipped with monitor coupler> 8G-10. . . . . . .
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

YH4
GRAND
VITARA
1. Coil antenna
2. Ignition key
3. Immobilizer control module
4. Data link connector (DLC)
5. Immobilizer diagnostic coupler Ignition key
Transponder
code
Immobilizer
Control
ModuleECM/
PCM
8G-2 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
GENERAL DESCRIPTION
The immobilizer control system designed to prevent vehicle burglar consists of following components.

Engine control module (ECM) / Powertrain control module (PCM)

Immobilizer control module

Ignition key (with built-in transponder)

Coil antenna
Operation of this system is as follows.
(1) Each ignition key has its own code (Transponder code) stored in memory. When the ignition switch is turned
ON, Immobilizer Control Module tries to read the Transponder code through the coil antenna installed to the
steering lock assembly.
(2) Immobilizer Control Module compares the Transponder code read in (1) and that registered in Immobilizer Con-
trol Module and checks if they match.
(3) When it is confirmed that two Transponder codes match each other as described above, Immobilizer Control
Module and ECM / PCM check if ECM/Immobilizer Control Module codes registered in them respectively match.
(4) Only when it is confirmed that ECM/Immobilizer Control Module codes match, the engine starts running. If
Transponder codes in Step (2) or ECM/Immobilizer Control Module codes in Step (3) do not match, ECM / PCM
will stop operation of the injector and ignition of spark plug.