Руководство по ремонту suzuki vitara 1997

Table of Contents

3

Abbreviations

4

Front Suspension

5

Free Wheel Device

6

Manual Free Wheel Performance

6

Automatic Free Wheel Performance

6

Free Wheel Types Description

7

Installation of «A» Type Manual Free Wheel

9

Installation of «B» Type Manual Free Wheel

11

Installation of «A» Type Automatic Free Wheel

13

Free Wheel Performance Checking

14

Installation of «B» Type Automatic Free Wheel

15

Replacement of «A» Type Manual Free Wheel

17

Replacement of «B» Type Manual Free Wheel

18

Replacement of «A» Type Automatic Free Wheel

19

Replacement of «B» Type Automatic Free Wheel

20

Front Suspension — Specified Torques

21

Front Suspension — Tools Needed

21

Electronic Fuel Injection System (Sequential Multiport Fuel Injection)

23

Electronic Fuel Injection System — General Description

25

Electronic Fuel Injection System Diagram

26

Electronic Control System

28

Engine Control Module (ECM)

32

On-Board Diagnostic System (Self-Diagnosis Function)

32

Fail-Safe Function

33

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

Diagnosis

37

Diagnosis Flow Chart

38

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 Check

44

A-3 Malfunction Indicator Lamp («Check Engine» Light) Circuit Check

45

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) Circuit

51

Code No. 33 MAF Sensor (Mass Air Flow Sensor) Circuit

52

Code No. 34 MAF Sensor (Mass Air Flow Sensor) Circuit

53

Code No. 42 CMP Sensor (Camshaft Position Sensor) Circuit

54

Code No. 44 CTP Switch Circuit

55

Code No. 45 CTP Switch Circuit

56

Code no 51 EGR Valve (Stepper Motor or Its Circuit Open or Short)

57

B-1 Fuel Pump Circuit Check

58

B-1 Fuel Injector Circuit Check

59

B-3 Fuel Pressure Check

61

B-4 Idle Air Control System Check

63

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 Check

67

Inspection of ECM and Its Circuits

68

M/T Vehicle

69

A/T Vehicle

71

Terminal Arrangement of ECM Coupler (Viewed from Harness Side)

74

On Vehicle Service

77

Electronic Control System Service

77

Mass Air Flow Sensor (MAF Sensor) Inspection

77

Automatic Transmission

79

Electronic Shift Control System Chart

80

Powertrain (Engine) Control Module (PCM/ECM)

80

Throttle Positon Sensor

81

Vehicle Speed Sensor

81

Transmission Range Switch

81

Brake Switch

82

Engine Coolant Temperature Sensor (ECT Sensor) Usage

82

O/D Cut Switch

82

Transfer 4L Switch

82

Mode Selector Switch

83

Fail Safe Function

83

Change Mechanism

83

Automatic Gear Shift Diagram

84

Power Mode

84

Gear Shift Diagram

84

TCC Lock-Up Diagram

84

Normal Mode

85

Transmission Unit Diagnosis

86

Manual Road Test

86

Electronic Shift Control System

87

Precaution in Identifying Diag. Trouble Code

87

Electronic Shift Control System — Diagnostic Flow Chart

88

Diagnostic Trouble Code Table (A/T Related Code)

89

Fail-Safe Table

89

Diagnostic Flow Chart a

90

Diagnostic Flow Chart B

91

Diagnostic Flow Chart C

92

Diagnostic Flow Chart D

94

Group 2 — Supplementary Service Manual

95

Heater and Ventilation

99

Heater and Ventilation — Diagram and General Description

100

Heater Control Operation

101

Mode Control Switch

101

Control Lever a

101

Control Lever B, C

101

A. Forced Ventilation

102

B. Outside Air-Introduced Heating

102

C. Inside Air-Circulated Heating

102

D. Head-Cooled/Feet-Warmed Heating

103

Trouble Diagnosis (Heater and Ventilation)

103

Heater and Ventilation — Wiring Circuit

104

Heater and Ventilation — On-Vehicle Service

105

Mode Control Switch Removal

105

Mode Control Switch Inspection

105

Mode Control Switch Installation

105

Mode Actuator Removal

106

Mode Actuator Inspection

106

Mode Actuator Installation

107

Heater Control Lever Assembly Removal

107

Inspection of Heater Blower Motor Switch

108

Heater Control Lever Assembly Installation

108

Control Cables Removal

109

Brakes

111

PSPV (Load Sensing Proportioning Valve) Assembly

112

Constitution

113

LSPV Operation

113

When LSPV Not at Work

114

When LSPV at Work

114

When Fail-Safe at Work

115

On-Vehicle Service LSPV (Load Sensing Proportioning Valve( R & I)

116

Remove and Install LSPV

116

After-Installation Inspection & Adjustment

117

Fluid Pressure Test

118

Body Electrical System

121

Combination Switch

122

Windshield Wipers (Front Wiper)

123

Wiper/Washer Switch Inspection

123

Intermittent Wiper Relay Circuit

123

Rear Window Wiper and Washer

124

Wiper and Washer Switches Inspection

125

Rear Wiper Intermittent Relay on Circuit

125

WASH Circuit

125

INT Circuit

126

Rear Fog Light Wiring Circuit Diagram

127

Rear Fog Light Wiring Inspection

128

Body Electric System Wiring Diagram

131

Suzuki Vitara 1.9 T. Diesel

135

Section 0A

147

Precautions for Vehicles Equipped with a Supplemental Restraint (Air Bag) System

149

Air Bag System Diagnosis

149

Air Bag System Servicing and Handling

150

General Servicing Precautions

152

Precautions for Catalytic Converter

154

Precautions for Electrical Circuit Service

155

Electrical Circuit Inspection Procedure

157

Open Circuit Check

157

Continuity Check

158

Voltage Check

158

Short Circuit Check (Wire Harness to Ground)

159

Intermittent and Poor Connection

160

Precautions for Installing Mobile Communication Equipment

161

Identification Information

162

Vehicle Identification Number

162

Engine Identification Number

162

Transmission Identification Number

162

Vehicle Lifting Points

163

Abbreviations List

165

Fasteners Information

167

Metric Fasteners

167

Fastener Strength Identification

167

Standard Tightening Torque

168

Maintenance and Lubrication

169

Maintenance Schedule

170

Maintenance Recommended under Severe Driving Conditions

172

Maintenance Service — Engine

173

Water Pump and Generator Drive Belt Inspection

173

Water Pump and Generator Drive Belt Replacement

173

Power Steering Pump And/Or A/C Compressor Drive Belts Inspection

174

Power Steering Pump And/Or A/C Compressor Drive Belts Replacement

174

Camshaft Timing Belt Replacement

175

Valve Lash Inspection (G16 Engine Only)

175

Engine Oil and Filter Change

175

Exhaust System Inspection

178

Ignition System

179

Spark Plugs Replacement

179

Distributor Cap and Rotor Inspection

179

Fuel System

180

Air Cleaner Filter Inspection

180

Air Cleaner Filter Replacement

180

Fuel Lines and Connections Inspection

180

Emission Control System

181

PCV (Positive Crankcase Ventilation) Valve Inspection

181

Evaporative Emission Control System Inspection

181

Fuel Filter Replacement

181

Chassis and Body

182

Clutch Pedal Inspection

182

Brake Discs, Pads, Brake Drums and Shoes Inspection

182

Brake Fluid Change

182

Parking Brake Lever and Cable Inspection

183

Tire Inspection and Rotation

183

Wheel Discs Inspection

184

Free Wheeling Hub Inspection

184

Wheel Bearing Inspection

184

Inspection of Front Wheel Bearing Grease

184

Suspension Inspection

185

Propeller Shafts and Drive Shaft Inspection

186

Transmission Oil Inspection and Change (for Manual Transmission)

187

Transfer and Differential Oil Inspection and Change

187

Steering System Inspection

188

Power Steering (P/S) System Inspection

189

All Hinges, Latches and Locks Inspection

189

Doors Inspection

189

Engine Hood Inspection

189

Final Inspection

190

Seats Inspection

190

Clutch (for Manual Transmission) Inspection

190

Brake Inspection

190

Recommended Fluids and Lubricants

191

Steering Check

191

Engine Check

191

Body, Wheels and Power Transmitting System Check

191

Engine General Information and Diagnosis

193

Engine General Information — Statement of Cleanliness and Care

195

General Information on Engine Service

195

Precautions on Fuel System Service

196

Fuel Pressure Relief Procedure

197

Fuel Leakage Check Procedure

197

Engine Diagnosis

198

On-Board Diagnostic System

198

Warm-Up Cycle

199

Driving Cycle

199

2 Driving Cycles Detection Logic

199

Freeze Frame Data

199

Data Link Connector (DLC)

200

Precaution in Diagnosing Trouble

201

Engine Diagnostic Flow Table

202

Malfunction Indicator Lamp (MIL) Check

205

Diagnostic Trouble Code (DTC) Check

205

Diagnostic Trouble Code (DTC) Clearance

205

Diagnostic Trouble Code (DTC) Table

206

Fail-Safe Table (Engine Diagnosis)

209

Scan Tool Data

210

Scan Tool Data Definitions

212

Visual Inspection (Engine)

214

Engine Basic Check

215

Engine Diagnosis Table

216

Inspection of ECM and Its Circuits — Voltage Checks

221

Resistance Check

225

Table A-1 Malfunction Indicator Lamp Circuit Check — Lamp Does Not Come «On» or Dims at Ignition Switch on (but Engine at Stop) — Wiring Diagram

226

Circuit Description

226

Table A-2 Malfunction Indicator Lamp Circuit Check — Lamp Remains «On» after Engine Starts

227

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 up

228

Table A-3 ECM Power and Ground Circuit Inspection Table

229

DTC P0100 Mass Air Flow Circuit Malfunction — Wiring Diagram

230

DTC Detecting Condition and Trouble Area

230

DTC Confirmation Procedure

231

Troubleshooting (Engine Diagnosis)

231

DTC P0110 Intake Air Temp (IAT) Circuit Malfunction — Wiring Diagram

232

DTC Detecting Condition and Trouble Area Table

232

DTC Confirmation Procedure Steps

232

DTC P0115 Engine Coolant Temp. Circuit Malfunction — Wiring Diagram

234

DTC P0120 Throttle Position Circuit Malfunction

236

DTC P0121 Throttle Position Circuit Performance Problem

238

DTC P0130 HO2S-1 Circuit Malfunction

240

DTC P0133 HO2S-1 Circuit Slow Response

243

DTC P0134 HO2S-1 no Activity Detected

244

DTC P0135 HO2S-1 Heater Circuit Malfunction

245

Troubleshooting Table (DTC P0135)

246

DTC P0136 HO2S-2 Circuit Malfunction

247

DTC Confirmaton Procedure

248

Troubleshooting (DTC P0136)

248

DTC P0141 HO2S-2 Heater Circuit Malfunction

249

Troubleshooting (DTC P0141)

250

DTC P0171 Fuel System too Lean

251

DTC P0172 Fuel System too Rich

251

Troubleshooting (DTC P0171/P0172)

252

DTC P0300 Random Misfire Detected

253

DTC P0301 — P0304 Cylinder Misfire Detected

253

Troubleshooting (DTC P0300/P0301/P0302/P0303/P0304)

254

DTC P0335 Crankshaft Position Sensor Circuit Malfunction

255

Troubleshooting (DTC P0335)

257

DTC P0340 Camshaft Position Sensor Circuit Malfunction

258

DTC P0400 Exhaust Gas Recirculation Flow Malfunction

260

Troubleshooting (DTC P0400)

262

DTC P0403 Exhaust Gas Recirculation Circuit Malfunction

263

Troubleshooting (DTC P0403)

264

DTC P0420 Catalyst System Efficiency below Threshold

265

DTC P0443 EVAP Control System Purge Control Valve Circuit Malfunction

267

Troubleshooting (DTC P0443)

268

EVAP Canister Purge System Check

269

Vacuum Passage Inspection

269

Vacuum Hose Inspection

269

EVAP Canister Purge Valve and Its Circuit Check

270

EVAP Canister Purge Valve Inspection

270

EVAP Canister Check

271

DTC P0460 Fuel Level Sensor Circuit High Input

272

DTC P0500 Vehicle Speed Sensor Malfunction

274

Troubleshooting (DTC P0500)

275

DTC P0505 Idle Air Control System Malfunction

276

Troubleshooting (DTC P0505)

277

Idle Air Adjusting Screw and Its Passage Check

278

Fast Idle Air Valve

278

IAC Valve and Its Circuit Check

279

DTC P0601 Internal Control Module Memory Check Sum Error System Description

280

DTC P1408 Manifold Differential Pressure Sensor Circuit Malfunction

281

Troubleshooting (DTC P1408)

282

DTC P1450 Barometric Pressure Sensor Circuit Malfunction

283

DTC P1451 Barometric Pressure Sensor Performance Problem

283

DTC P1500 Engine Starter Signal Circuit Malfunction

284

DTC P1510 ECM Back-Up Power Supply Malfunction

285

Table B-1 Fuel Pump Circuit Inspection

286

Table B-2 Fuel Injectors and Circuit Inspection

287

Table B-3 Fuel Pressure Inspection

288

Table B-4 Fast Idle Air Valve System Inspection

290

Table B-5 A/C Signal Circuits Inspection

291

Engine Diagnosis — Special Tools

292

Engine Mechanical (1-Cam 16-Valves)

293

Engine Mechanical — General Description

294

Engine Lubrication

295

Cylinder Block

296

Crankshaft and Main Bearings

296

Pistons, Rings, Piston Pins and Connecting Rods

296

Cylinder Head and Valve Train

296

Engine On-Vehicle Service

297

Compression Check

297

Engine Vacuum Check

299

Oil Pressure Check

300

Valve Lash (Clearance)

302

Air Cleaner Element Removal

304

Air Cleaner Element Inspection

304

Air Cleaner Element Cleaning

304

Air Cleaner Element Installation

304

Air Inlet Pipe Removal

305

Air Inlet Pipe Installation

305

Cylinder Head Cover Removal

306

Cylinder Head Cover Installation

306

Throttle Body and Intake Manifold

308

Throttle Body and Intake Manifold Installation

310

Exhaust Manifold Removal

312

Exhaust Manifold Installation

313

Timing Belt and Belt Tensioner Removal

314

Timing Belt and Belt Tensioner Inspection

315

Timing Belt and Belt Tensioner Installation

316

Oil Pan and Oil Pump Strainer Removal

319

Oil Pan and Oil Pump Strainer Cleaning

320

Oil Pan and Oil Pump Strainer Installation

321

Oil Pump Removal

323

Oil Pump Disassembly

324

Oil Pump Inspection

325

Oil Pump Assembly

326

Oil Pump Installation

326

Rocker Arms, Rocker Arm Shaft and Camshaft Removal

328

Rocker Arms, Rocker Arm Shaft and Camshaft Inspection

331

Adjusting Screw and Rocker Arm Inspection

331

Rocker Arm Shaft Runout Check

331

Rocker Arm-To-Rocker Arm Shaft Clearance

331

Cam Wear Check

332

Camshaft Runout Check

332

Camshaft Journal Wear Check

332

Rocker Arms, Rocker Arm Shaft and Camshaft Installation

333

Valves and Cylinder Head Removal

337

Valves and Cylinder Head Disassembly

340

Valves and Cylinder Head Inspection

341

Valve Guides Check

341

Valves Check

341

Cylinder Head Check

343

Valve Springs Check

345

Valves and Cylinder Head Assembly

346

Valves and Cylinder Head Installation

348

Piston, Piston Rings, Connecting Rods and Cylinders Removal

350

Piston, Piston Rings, Connecting Rods and Cylinders Disassembly

351

Piston, Piston Rings, Connecting Rods and Cylinders Cleaning

351

Piston, Piston Rings, Connecting Rods and Cylinders Inspection

352

Pistons Check

352

Piston Pin Check

353

Piston Rings Check

354

Connecting Rod Check

354

Crank Pin and Connecting Rod Bearings

355

Piston, Piston Rings, Connecting Rods and Cylinders Assembly

356

Piston, Piston Rings, Connecting Rods and Cylinders Installation or Connection

358

Unit Repair Overhaul

360

Engine Assembly Removal

360

Engine Assembly Installation

364

Main Bearings, Crankshaft and Cylinder Block

366

Main Bearings, Crankshaft and Cylinder Block Removal

367

Main Bearings, Crankshaft and Cylinder Block Inspection

368

Main Bearings Inspection

369

Selection of Main Bearings

370

Rear Oil Seal Check

373

Flywheel Check

374

Cylinder Block Check

374

Honing or Reboring Cylinders

374

Main Bearings, Crankshaft and Cylinder Block Installation

375

Engine Mechanical — Special Tools

378

Engine Mechanical — Tightening Torque Specifications

380

Engine Fuel

381

Fuel System Description

381

Fuel System — On-Vehicle Service

382

Fuel Filter Removal

383

Fuel Filter Installation

384

Fuel Lines Inspection

384

Fuel Filler Cap

385

Fuel Tank

385

Fuel Tank Inspection

386

Fuel Tank Purging Procedure

387

Fuel Tank Installation

388

Engine and Emission Control System (Sequential Multiport Fuel Injection)

391

Engine and Emission Control System — General Description

393

Engine and Emission Control System — Diagram

394

Air Intake System

396

Fuel Delivery System

397

Electronic Control System Description

398

Engine & Emission Control Input/Output Table

402

Engine & Emission Control System — On-Vehicle System

403

Acceleration Cable Adjustment

404

Idle Speed/Idle Air Control (IAC) Duty Inspection

405

Throttle Body Removal

406

Throttle Body Cleaning

407

Throttle Body Installation

407

Idle Air Control Valve (IAC Valve) Inspection

408

Idle Air Control Valve (IAC Valve) Removal

408

Idle Air Control Valve (IAC Valve) Installation

408

Fuel Pressure Inspection

409

Fuel Pump — On-Vehicle Inspection

410

Fuel Pump Removal and Inspection

410

Fuel Pump Installation

411

Fuel Pressure Regulator Removal

411

Fuel Pressure Regulator Installation

411

Fuel Pulsation Damper Removal

412

Fuel Pulsation Damper Installation

412

Fuel Injector On-Vehicle Inspection

412

Fuel Injector Removal

413

Fuel Injector Inspection

414

Fuel Injector Installation

416

Engine Control Module (ECM) Removal

417

Engine Control Module (ECM) Installation

417

Mass Air Flow Sensor Inspection

418

Mass Air Flow Sensor (MAF Sensor) Removal

418

Intake Air Temperature (IAT) Sensor Removal

419

Intake Air Temperature (IAT) Sensor Inspection

419

Intake Air Temperature (IAT) Sensor Installation

420

Throttle Position Sensor (TP Sensor) Inspection

421

Throttle Position Sensor (TP Sensor) Adjustment

421

Throttle Position Sensor (TP Sensor) Removal

422

Throttle Position Sensor (TP Sensor) Installation

422

Engine Coolant Temperature Sensor (ECT Sensor) Removal

423

Engine Coolant Temperature Sensor (ECT Sensor) Inspection

423

Engine Coolant Temperature Sensor (ECT Sensor) Installation

424

Heated Oxygen Sensor-1 and -2 (HO2S-1 and HO2S-2) Inspection

424

Heated Oxygen Sensor-1 and -2 (HO2S-1 and HO2S-2) Removal

425

Heated Oxygen Sensor-1 and -2 (HO2S-1 and HO2S-2) Installation

425

Vehicle Speed Sensor (VSS) — On-Vehicle Inspection

425

Camshaft Position Sensor (CMP Sensor) Inspection

426

Camshaft Position Sensor (CMP Sensor) Removal and Installation

426

Crankshaft Position Sensor Inspection

426

Crankshaft Position Sensor Removal and Installation

426

Manifold Differential Pressure Sensor Check

427

Main Relay Inspection

428

Fuel Pump Relay Inspection

428

Fuel Cut Operation Inspection

429

EGR System Inspection Using Suzuki Scan Tool

430

EGR System Removal

430

Evaporative Emission Control System

431

EGR System Inspection

431

PCV System

431

PCV Hose

431

PCV Valve

432

Engine and Emission Control System — Tightening Torque Specifications

433

Engine and Emission Control System — Special Tools

433

Section 6F — Ignition System

435

Ignition System — General Description

436

Ignition System Diagnosis Table

437

Diagnostic Flowtable (When Engine Cranks but Does Not Start)

437

Ignition Spark Test

438

High-Tension Cords

438

Spark Plugs

439

Noise Suppressor

439

Distributor Power Supply

440

Distributor Cap and Rotor

440

Ignition Coil Circuit

440

Igniter Circuit

440

Ignition Timing — Inspection and Adjustment

441

Distributor Unit View

442

Distributor Unit Removal

442

Distributor Unit Installation

443

Ignition System — Special Tools

444

Exhaust System

445

Exhaust System Diagram

446

Exhaust System Maintenance

447

Exhaust System On-Vehicle Service

447

Exhaust Manifold

447

Muffler

447

Immobilizer Control System

449

Immobilizer Control System — General Description

450

Ignition Key

451

Coil Antenna

451

Immobilizer Control Module

452

Ecm/Pcm

452

On-Board Diagnostic System (Immobilizer Control Module)

452

Immobilizer Control System Diagnosis

454

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 Module

459

Diagnostic Trouble Code Table — ECM/PCM

459

Table a DTC Is Not Output from Diagnostic Output Terminal

460

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 Matched

463

DTC31 Transponder Code Not Registered

463

DTC12 Fault in Immobilizer Control Module

463

DTC13 no Transponder Code Transmitted or Coil Antenna Opened/Shorted

464

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 Registered

466

DTC22 Ignition Switch Circuit Open/Short

467

DTC23 no Ecm/Immobilizer Control Module Code Transmitted from ECM/)CM or DLC Circuit Opened/Shorted

468

DTC83 no Ecm/Immobilizer Control Module Code Transmitted from Immobilizer Control Module or DLC Circuit Opened/Shorted

468

DTC82 (P1622) Fault in ECM/PCM

469

Inspection of ECM/PCM, Immobilizer Control Module and Its Circuit

470

Immobilizer Control System On-Vehicle Service

472

Precautions in Handling Immobilizer Control System

472

Immobilizer Control Module Removal

473

Immobilizer Control Module Installation

473

How to Register Ignition Key

474

Procedure after Immobilizer Control Module Replacement

475

Procedure after ECM/PCM Replacement

476

Immobilizer Control System — Special Tools

476