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Engine Electrical Devices (j24b) Suzuki Grand Vitara II рестайлинг

Engine Control Systems 54 illustrations ~4138 words

ECM (Engine Control Module) Removal and Installation

CAUTIONAs ECM consists of precision parts, be careful not to expose it to excessive shock.

Note. After replacing ECM, perform following procedure. Registration VIN data to ECM. See VIN (VEHICLE IDENTIFICATION NUMBER) REGISTRATION (EVAP-LEAK-CHECK MODEL) . Registration of ignition key: See PROCEDURE AFTER ECM REPLACEMENT . Electric throttle control system calibration: See ELECTRIC THROTTLE CONTROL SYSTEM CALIBRATION

Scheme 1

Scheme 1: Removal
Scheme 1: Removal

Scheme 2

Scheme 2
Scheme 2
  1. Disconnect negative cable from battery.
  2. Disconnect connectors from ECM as follows. Push lock (1) to release locking of lock lever (2). Turn lock lever in arrow direction until it stops.
  3. Remove ECM (1) and cover from bracket by removing their mounting bolts (2).

Installation

Reverse removal procedure noting the following.

Scheme 3

Scheme 3: Installation
Scheme 3: Installation

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5
  1. Connect connectors to ECM as follows. Make sure that lock lever of ECM connector is in unlock position. Insert ECM connectors to ECM until it stops. Lock ECM connectors securely by setting their lock levers in their locked position.

Scheme 6

Scheme 6: VIN (Vehicle Identification Number) Registration (EVAP-Leak-Check Model)
Scheme 6: VIN (Vehicle Identification Number) Registration (EVAP-Leak-Check Model)
  1. Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel at drive's seat side. Special Tool (A): SUZUKI scan tool (SUZUKI-SDT)
  2. Check VIN shown on left of instrument panel.
  3. Turn ignition switch to ON position.
  4. Select "VIN registration" mode of SUZUKI scan tool.
  5. Confirm whether code of 17 digits displayed on SUZUKI scan tool is corresponding to VIN shown on the left side of instrument panel VIN, register VIN (vehicle identification number) data into ECM referring to «VIN (VEHICLE IDENTIFICATION NUMBER) REGISTRATION (EVAP-LEAK-CHECK MODEL)»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b) .
  6. Push "EXIT" button of SUZUKI scan tool.

Scheme 7

Scheme 7: Registered VIN Data Check (EVAP-Leak-Check Model)
Scheme 7: Registered VIN Data Check (EVAP-Leak-Check Model)
  1. Connect SUZUKI scan tool to data link connector (DLC) (1) located on underside of instrument panel at driver's seat side. Special Tool (A): SUZUKI scan tool (SUZUKI-SDT)
  2. Turn ignition switch to ON position.
  3. Select "VIN registration" under "Utility" menu of SUZUKI scan tool.
  4. Confirm whether 17-digit code displayed is identical with VIN shown on left of instrument panel. If displayed VIN is not identical with instrument panel VIN, register VIN data into ECM referring to «VIN (VEHICLE IDENTIFICATION NUMBER) REGISTRATION (EVAP-LEAK-CHECK MODEL)»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b) .

Throttle Body Assembly On-Vehicle Inspection

WARNINGNever touch throttle valve with finger while ignition switch is in ON position and accelerator pedal is depressed. Otherwise, injury may result by pinching the finger between throttle valve and throttle body.
CAUTIONDo not disassemble throttle body assembly. Do not drop or otherwise give excessive shock to throttle body assembly. Throttle body assembly that has experienced any excessive shock must be replaced. Be careful not to accurate foreign materials (like dust and metallic particle) to throttle body and throttle valve. Otherwise, throttle body assembly will break down by throttle valve accretion. Do not apply excessive force to throttle valve for throttle valve operation check and TP sensor performance check. Otherwise, throttle body assembly will break down by damaging internal resinous gear of throttle valve actuator.

Note. After replacing throttle body assembly, calibrate throttle valve position. See ELECTRIC THROTTLE CONTROL SYSTEM CALIBRATION .

Throttle Valve Visual Check

  1. Turn OFF ignition switch.
  2. Remove air cleaner assembly. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation) .
  3. Check that there isn't any foreign matter caught between throttle valve and throttle body. If there is, take it out after removing throttle body and clean inside of throttle body thoroughly. See «THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__throttle-body-assembly-removal-and-installation) .

Scheme 8

Scheme 8: Throttle Valve Operation Check
Scheme 8: Throttle Valve Operation Check

Scheme 9

Scheme 9
Scheme 9
  1. Turn OFF ignition switch.
  2. Remove air cleaner assembly. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation) .
  3. Check throttle valve operation as follows. If faulty condition is found, replace throttle body. See «THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__throttle-body-assembly-removal-and-installation) . Check that throttle valve (1) moves smoothly from fully closed position and fully open position with finger. Check that throttle valve returns off to default position when you move finger off throttle valve at fully closed position and fully open position. Throttle valve default position "a": 7° from completely closed position (1)

Scheme 10

Scheme 10: Throttle Body System Operation Check
Scheme 10: Throttle Body System Operation Check
  1. Remove air cleaner assembly. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation) .
  2. Turn ignition switch to ON position.
  3. Check throttle body system as follows. If faulty condition is found, go to step 4). Depress accelerator pedal gradually and check that throttle valve moves smoothly until it opens fully. Release accelerator pedal and check that throttle valve moves back to default position. Throttle valve default position "a": 7° from completely closed position (1)
  4. Check the following. If check results are satisfactory, replace throttle body assembly. Wire harness and connections APP sensor: See «APP (ACCELERATOR PEDAL POSITION) SENSOR INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b) . TP sensor: See «TP SENSOR (THROTTLE POSITION SENSOR) PERFORMANCE CHECK»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b) . Throttle motor: See «THROTTLE MOTOR CHECK»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b)

Scheme 11

Scheme 11: Throttle Motor Check
Scheme 11: Throttle Motor Check
  1. Turn OFF ignition switch.
  2. Disconnect connector from throttle body assembly.
  3. Measure resistance between terminals "5" and "6" of throttle body assembly. If faulty condition is found, replace throttle body assembly. See «THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__throttle-body-assembly-removal-and-installation) . Throttle motor resistance 0.3 - 100 ohms at 20 °C, 68 °F

Scheme 12

Scheme 12: TP Sensor (Throttle Position Sensor) Performance Check
Scheme 12: TP Sensor (Throttle Position Sensor) Performance Check

Scheme 13

Scheme 13
Scheme 13
  1. Remove air cleaner assembly. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation) .
  2. Turn OFF ignition switch.
  3. Disconnect connector from throttle body assembly.
  4. Check TP sensor (main and sub) output voltage as follows. If faulty condition is found, replace throttle body. See «THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__throttle-body-assembly-removal-and-installation) . Connect 3 new 1.5 V batteries (1) in series and check that total voltage is 4.5 - 5.0 V. Connect voltmeter (2) and batteries to TP sensor as shown in figure. Check that voltage varies depending on throttle opening angle as shown in figure while throttle valve is opened and closed by finger.

Electric Throttle Control System Calibration

  1. Select calibration procedure from table below. CALIBRATION PROCEDURE Calibration procedure Service item [A] ECM power supply shutoff (i.e. disconnection of battery cable, replacement of battery, "DOME" fuse or "B/U" fuse blown) ECM replacement Clearance of DTC(s) related to electric throttle control system [B] Throttle body assembly replacement APP sensor assembly replacement
  2. Perform selected calibration procedure as follows. Calibration procedure [A]: Keep ignition switch in ON position for 5 seconds or more without running engine. Calibration procedure [B]: Disconnect negative cable from battery. Disconnect ECM connectors for 30 seconds or more to clear calibration data of closed throttle position from ECM. Connect ECM connectors and connect negative cable to battery. Keep ignition switch in ON position for 5 seconds or more without running engine.

APP (Accelerator Pedal Position) Sensor On-Vehicle Inspection

CAUTIONDo not drop or otherwise give excessive shock to accelerator pedal assembly (incorporating APP sensor). Accelerator pedal assembly (incorporating APP sensor) that has experienced any excessive shock must be replaced. Be careful not to expose sensor section of accelerator pedal assembly (incorporating APP sensor) to water and oil. Do not disassemble accelerator pedal assembly (incorporating APP sensor).

Note. After replacing accelerator pedal assembly (incorporating APP sensor), calibrate throttle valve position. See ELECTRIC THROTTLE CONTROL SYSTEM CALIBRATION .

Scheme 14

Scheme 14
Scheme 14
  1. Check that accelerator pedal assembly (incorporating APP sensor) has been mounted to vehicle body properly (no pinched floor carpet, etc.). Reinstall accelerator pedal assembly (incorporating APP sensor) if it is not properly mounted.
  2. Turn OFF ignition switch and connect scan tool to DLC.
  3. Display "Data List" mode.
  4. Check that voltage varies depending on accelerator position as the following graph. If faulty condition is found, check the following. Wire harness and connections APP sensor: See «APP (ACCELERATOR PEDAL POSITION) SENSOR INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b) .

Accelerator Pedal Assembly (Incorporating APP Sensor) Removal and Installation

CAUTIONDo not drop or otherwise give excessive shock to accelerator pedal assembly (incorporating APP sensor). Accelerator pedal assembly (incorporating APP sensor) that has experienced any excessive shock must be replaced. Be careful not to expose sensor section of accelerator pedal assembly (incorporating APP sensor) to water and oil. Do not disassemble accelerator pedal assembly (incorporating APP sensor).

Note. After replacing accelerator pedal assembly (incorporating APP sensor), calibrate throttle valve position.

Removal

  1. Disconnect negative cable from battery.
  2. Remove steering column hole cover. See «INSTRUMENT PANEL REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/entertainment-systems/#instrumentationdriver-infohorn__instrument-panel-removal-and-installation) .
  3. Disconnect connector from accelerator pedal assembly (incorporating APP sensor).
  4. Remove accelerator pedal assembly (incorporating APP sensor) from its bracket.

Reverse removal procedure for installation noting the following.

Scheme 15

Scheme 15: Installation
Scheme 15: Installation
  1. Tighten accelerator pedal assembly nut (1) and accelerator pedal assembly bracket nut (2) to specified torque. Tightening torque Accelerator pedal assembly nut (a): 6.0 N.m (0.61 kg-m, 4.5 lbf-ft) Accelerator pedal assembly bracket nut (b): 6.0 N.m (0.61 kg-m, 4.5 lbf-ft)
  2. Connect connector to APP sensor assembly securely.

Scheme 16

Scheme 16: APP (Accelerator Pedal Position) Sensor Inspection
Scheme 16: APP (Accelerator Pedal Position) Sensor Inspection

Scheme 17

Scheme 17
Scheme 17
  1. Remove Accelerator Pedal assembly.
  2. Check APP sensor output voltage as follows. If faulty condition is found, replace accelerator pedal assembly (incorporated with APP sensor). See «ACCELERATOR PEDAL ASSEMBLY (INCORPORATING APP SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__accelerator-pedal-assembly-incorporating-app-sensor) . Connect 3 new 1.5 V batteries (1) in series and check that total voltage is 4.5 - 5.0 V. Connect voltmeter (2) and batteries to APP sensor as shown in figure. Check that voltage varies depending on accelerator opening angle as the following graph.
  1. Disconnect negative cable from battery.
  2. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-draining) .
  3. Disconnect connector from ECT sensor.
  4. Remove ECT sensor (1).

Reverse removal procedure noting the following.

Scheme 18

Scheme 18: Installation
Scheme 18: Installation
  1. Check O-ring for damage and replace if necessary.
  2. Tighten ECT sensor to specified torque. Tightening torque ECT sensor (a): 12 N.m (1.2 kg-m, 9.0 lbf-ft)
  3. Connect connector to ECT sensor.
  4. Refill cooling system. See «COOLING SYSTEM FLUSHING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-flushing) .
  5. Check for coolant leakage. See «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

ECT (Engine Coolant Temperature) Sensor Inspection

Check that resistance between terminals "1" and "2" varies depending on engine coolant temperature. If faulty condition is found, replace ECT sensor (1).

Scheme 19

Scheme 19: ECT (Engine Coolant Temperature) Sensor Inspection
Scheme 19: ECT (Engine Coolant Temperature) Sensor Inspection

A/F (Air Fuel Ratio) Sensor On-Vehicle Inspection

A/F Sensor

  1. Check that A/F sensor signal is output properly. See «INSPECTION OF ECM AND ITS CIRCUITS»(/suzuki/grand-vitara/ii-2008-2012/remont/testing-diagnostics/#engine-general-information-and-diagnosis-j24b) . If faulty condition is found, check the following. Wire harness and connections Exhaust system leakage If check results are satisfactory, replace A/F sensor. See «A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__af-air-fuel-ratio-sensor-ho2s) .

Scheme 20

Scheme 20: A/F Sensor Heater
Scheme 20: A/F Sensor Heater

Scheme 21

Scheme 21
Scheme 21
  1. Turn OFF ignition switch and disconnect A/F sensor connector.
  2. Check that voltage of A/F sensor connector (vehicle side) between terminals "4" and "3" is battery voltage when ignition switch is in ON position. If faulty condition is found, check power supply circuit, ground circuit and connections.
  3. Using ohmmeter, measure resistance of A/F sensor connector (sensor side) between terminals "3" and "4" at A/F sensor connector. If faulty condition is found, replace A/F sensor. NOTE: Sensor temperature affects resistance value largely. Make sure that sensor heater is at specified temperature. A/F sensor heater resistance 2.16 - 2.64 ohms at 20 °C (68 °F)

HO2S (Heated Oxygen Sensor) On-Vehicle Inspection

HO2S

  1. Check that HO2S signal is output properly. See «INSPECTION OF ECM AND ITS CIRCUITS»(/suzuki/grand-vitara/ii-2008-2012/remont/testing-diagnostics/#engine-general-information-and-diagnosis-j24b) . If faulty condition is found, check the following. Wire harness and connections Exhaust system leakage If check results are satisfactory, replace HO2S.

Scheme 22

Scheme 22: HO2S heater
Scheme 22: HO2S heater

Scheme 23

Scheme 23
Scheme 23
  1. Turn off ignition switch and disconnect HO2S connector.
  2. Check that voltage of HO2S connector (vehicle side) between terminals "4" and "3" is battery voltage when ignition switch is in ON position. If faulty condition is found, check power supply circuit, ground circuit and connections.
  3. Using ohmmeter, measure resistance of HO2S connector (sensor side) of sensor heater between terminals "3" and "4" at sensor connector. If faulty condition is found, replace HO2S. See «A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__af-air-fuel-ratio-sensor-ho2s) . NOTE: Sensor temperature affects resistance value largely. Make sure that sensor heater is at specified temperature. HO2S heater resistance 5.0 - 6.4 ohms at 20 °C (68 °F)

A/F (Air Fuel Ratio) Sensor, HO2S (Heated Oxygen Sensor) Removal and Installation

WARNINGTo avoid danger of being burned, do not touch exhaust system when system is hot. A/F sensor and HO2S removal should be performed when system is cool.
  1. Disconnect negative cable from battery.
  2. Disconnect connector of A/F sensor and/or HO2S.
  3. Remove exhaust manifold cover.
  4. Remove A/F sensor (1) and/or HO2S (2).

Reverse removal procedure noting the following.

Scheme 24

Scheme 24: Installation
Scheme 24: Installation
  1. Tighten A/F sensor (1) to specified torque. Tightening torque A/F sensor (a): 45 N.m (4.6 kg-m, 33.5 lbf-ft)
  2. Tighten HO2S (2) to specified torque. Tightening torque HO2S (b): 45 N.m (4.6 kg-m, 33.5 lbf-ft)
  3. After installation, check exhaust leakage from sensor with engine running.

Scheme 25

Scheme 25: CMP (Camshaft Position) Sensor On-Vehicle Inspection
Scheme 25: CMP (Camshaft Position) Sensor On-Vehicle Inspection
  1. Disconnect connector of CMP sensor.
  2. Turn ignition switch to ON position and check that voltage of CMP sensor connector (vehicle side) between terminals "1" and "2" is battery voltage. If faulty condition is found, check power supply circuit, ground circuit and connections.
  3. Check that CMP sensor signal is output properly. See «INSPECTION OF ECM AND ITS CIRCUITS»(/suzuki/grand-vitara/ii-2008-2012/remont/testing-diagnostics/#engine-general-information-and-diagnosis-j24b) . If faulty condition is found, check the following. Wire harness and connections CMP sensor: See «CMP (CAMSHAFT POSITION) SENSOR INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__cmp-camshaft-position-sensor-inspection) .

CMP (Camshaft Position) Sensor Removal and Installation

  1. Disconnect negative cable from battery.
  2. Disconnect connector from CMP sensor.
  3. Remove CMP sensor from cylinder head.

Scheme 26

Scheme 26: Installation
Scheme 26: Installation
  1. Reverse removal procedure noting the following. Apply engine oil to O-ring of CMP sensor (1). Tighten CMP sensor bolt to specified torque. Tightening torque CMP sensor bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)

CMP (Camshaft Position) Sensor Inspection

Scheme 27

Scheme 27: CMP (Camshaft Position) Sensor Inspection
Scheme 27: CMP (Camshaft Position) Sensor Inspection

Scheme 28

Scheme 28
Scheme 28
  1. Remove CMP sensor. See «CMP (CAMSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__cmp-camshaft-position-sensor-removal-and) .
  2. Check the following. Check that O-ring (1) is free from damage. Check that end face of sensor and signal rotor tooth are free from any metal particles and damage.
  3. Check CMP sensor as follows. If faulty condition is found, replace CMP sensor. Connect battery (1) and ohmmeter (3) to CMP sensor as shown in figure. Check that CMP sensor resistance varies as specified below by passing magnetic substance (iron) (2). If faulty condition is found, replace CMP sensor. NOTE: Be sure to keep approximately 1 mm (0.03 in) gap "a" between magnetic substance (iron) and end face of CMP sensor. CMP sensor resistance Resistance varies between less than 220 ohms (ON) and infinity (OFF)

Scheme 29

Scheme 29: CKP (Crankshaft Position) Sensor On-Vehicle Inspection
Scheme 29: CKP (Crankshaft Position) Sensor On-Vehicle Inspection
  1. Disconnect connector of CKP sensor.
  2. Turn ignition switch to ON position and check that voltage of CKP sensor connector (vehicle side) between terminals "1" and "2" is battery voltage. If faulty condition is found, check power supply circuit, ground circuit and connections.
  3. Check that CKP sensor signal is output properly. See «INSPECTION OF ECM AND ITS CIRCUITS»(/suzuki/grand-vitara/ii-2008-2012/remont/testing-diagnostics/#engine-general-information-and-diagnosis-j24b) . If faulty condition is found, check the following. Wire harness and connections CKP sensor: See «CKP (CRANKSHAFT POSITION) SENSOR INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__ckp-crankshaft-position-sensor-inspection) .

CKP (Crankshaft Position) Sensor Removal and Installation

  1. Disconnect negative cable from battery.
  2. Remove generator. See «GENERATOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
  3. Disconnect connector from CKP sensor.
  4. Remove CKP sensor (1) from cylinder block (2).

Reverse removal procedure noting the following.

Scheme 30

Scheme 30: Installation
Scheme 30: Installation
  1. Apply engine oil to O-ring of sensor. CAUTION: Use new CKP sensor bolt.
  2. Tighten CKP sensor bolt to specified torque. Tightening torque CKP sensor bolt: 11 N.m (1.1 kg-m, 8.5 lbf-ft)
  3. Connect connector and fix wire harness with clamp securely.

CKP (Crankshaft Position) Sensor Inspection

Scheme 31

Scheme 31: CKP (Crankshaft Position) Sensor Inspection
Scheme 31: CKP (Crankshaft Position) Sensor Inspection

Scheme 32

Scheme 32
Scheme 32
  1. Remove CKP sensor. See «CKP (CRANKSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__ckp-crankshaft-position-sensor-removal-and) .
  2. Check the following. Check that O-ring (1) is free from damage. Check that end face of sensor and signal plate tooth are free from any metal particles and damage.
  3. Check CKP sensor as follows. If faulty condition is found, replace CKP sensor. Connect battery (1) and ohmmeter (3) to CKP sensor as shown in figure. Check that CKP sensor resistance varies as specified below by passing magnetic substance (iron) (2). If faulty condition is found, replace CKP sensor. NOTE: Be sure to keep approximately 1 mm (0.03 in) gap "a" between magnetic substance (iron) and end face of CKP sensor. CKP sensor resistance Resistance varies between less than 220 ohms (ON) and infinity (OFF)
  1. Disconnect negative cable from battery.
  2. Remove intake manifold. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__intake-manifold-removal-and-installation) .
  3. Disconnect knock sensor connector.
  4. Remove knock sensor (1) from cylinder block.

Reverse removal procedure noting the following.

Scheme 33

Scheme 33: Installation
Scheme 33: Installation
  1. Install knock sensor (1) as shown in figure.
  2. Tighten knock sensor bolt (2) to specified torque. Tightening torque Knock sensor bolt (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft)

Knock Sensor Inspection

Scheme 34

Scheme 34: Knock Sensor Inspection
Scheme 34: Knock Sensor Inspection

Scheme 35

Scheme 35
Scheme 35
  1. Disconnect connector (2) from knock sensor.
  2. Connect oscilloscope (1) as shown in figure.
  3. Check that knock sensor signal (1) shows the following waveform when cylinder block is given a shock by plastic hammer. If faulty condition is found, replace knock sensor.

Scheme 36

Scheme 36: Main, Fuel Pump, Starting Motor Control and Throttle Motor Control Relays
Scheme 36: Main, Fuel Pump, Starting Motor Control and Throttle Motor Control Relays
  1. Disconnect negative cable from battery.
  2. Remove main relay (1), fuel pump relay (2), starting motor control relay (3) and/or throttle motor control relay (4) from fuse box No. 2.
  3. Check that there is no continuity between terminals "C" and "D". If there is continuity, replace relay.
  4. Connect battery positive (+) terminal to terminal "B" of relay. Connect battery negative (-) terminal to terminal "A" of relay. Check for continuity between terminals "C" and "D". If there is no continuity, replace relay.

Scheme 37

Scheme 37: HO2S Heater Relay (Integration Type Relay)
Scheme 37: HO2S Heater Relay (Integration Type Relay)
  1. Disconnect negative cable at battery.
  2. Remove integration relay No. 2 (1) from fuse box No. 2 (2).
  3. Check that there is no continuity between terminals "[A]-1" and "[B]-8" of relay.
  4. Connect battery positive (+) terminal to "[B]-7" terminal of relay. Connect battery negative (-) terminal to "[B]-6" terminal of relay. Check for continuity between terminal "[A]-1" and "[B]-8". If there is no continuity when relay is connected to the battery, replace integration relay No. 2.

MAF (Mass Air Flow) and IAT (Intake Air Temperature) Sensor On-Vehicle Inspection

Note. Before performed this inspection, be sure to read the PRECAUTIONS FOR ECM CIRCUIT INSPECTION .

Scheme 38

Scheme 38: MAF (Mass Air Flow) and IAT (Intake Air Temperature) Sensor On-Vehicle Inspection
Scheme 38: MAF (Mass Air Flow) and IAT (Intake Air Temperature) Sensor On-Vehicle Inspection
  1. Disconnect MAF and IAT sensor connector.
  2. Check that voltage of MAF and IAT sensor connector (vehicle side) between terminals "3" and "4" is battery voltage when ignition switch is in ON position. If faulty condition is found, check power supply circuit, ground circuit and connections.
  3. Check that MAF sensor signal and IAT sensor signal are output properly. See «INSPECTION OF ECM AND ITS CIRCUITS»(/suzuki/grand-vitara/ii-2008-2012/remont/testing-diagnostics/#engine-general-information-and-diagnosis-j24b) . If faulty condition is found, check the following. Wire harness and connections MAF and IAT sensor. See «MAF (MASS AIR FLOW) AND IAT (INTAKE AIR TEMPERATURE) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__maf-mass-air-flow-and-iat) .

MAF (Mass Air Flow) and IAT (Intake Air Temperature) Sensor Removal and Installation

CAUTIONWhen servicing MAF and IAT sensor, be sure to observe the following items. Do not disassemble MAF and IAT sensor. Do not expose MAF and IAT sensor to any shock. If it has been dropped, it should be replaced. Do not clean MAF and IAT sensor. Do not blow compressed air using air gun or the like. Do not put finger or any other object into MAF and IAT sensor.

Scheme 39

Scheme 39: Removal
Scheme 39: Removal
  1. Disconnect negative cable from battery.
  2. Disconnect MAF and IAT sensor connector.
  3. Remove MAF and IAT sensor (1) from air cleaner case (2).

Reverse removal procedure noting the following.

Scheme 40

Scheme 40: Installation
Scheme 40: Installation
  1. Tighten MAF and IAT sensor screws (1) to specified torque. Tightening torque MAF and IAT sensor screw (a): 1.2 N.m (0.12 kg-m, 0.9 lbf-ft)

MAF (Mass Air Flow) and IAT (Intake Air Temperature) Sensor Inspection

CAUTIONWhen servicing MAF and IAT sensor, be sure to observe the following items. Do not disassemble MAF and IAT sensor. Do not expose MAF and IAT sensor to any shock. If it has been dropped, it should be replaced. Do not clean MAF and IAT sensor. Do not blow compressed air using air gun or the like. Do not put finger or any other object into MAF and IAT sensor. Do not heat MAF and IAT sensor more than 100 °C (212 °F). Otherwise, it will be damaged.

Scheme 41

Scheme 41: IAT sensor inspection
Scheme 41: IAT sensor inspection

Scheme 42

Scheme 42
Scheme 42
  1. Remove MAF and IAT sensor. See «MAF (MASS AIR FLOW) AND IAT (INTAKE AIR TEMPERATURE) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__maf-mass-air-flow-and-iat) .
  2. Check sensor O-ring (1) for damage and deterioration. Replace as necessary.
  3. Measure resistance between sensor terminals "1" and "2" while blowing hot air to temperature sensing part (2) of MAF and IAT sensor (3) using hot air drier (4). If faulty condition is found, replace MAF and IAT sensor. Intake air temperature sensor resistance -20 °C (-4 °F): 13.6 - 18.4 kohms 20 °C (68 °F): 2.21 - 2.69 kohms 60 °C (140 °F): 0.439 - 0.667 kohms

Scheme 43

Scheme 43: MAF sensor inspection
Scheme 43: MAF sensor inspection

Scheme 44

Scheme 44
Scheme 44
  1. Remove MAF and IAT sensor. See «MAF (MASS AIR FLOW) AND IAT (INTAKE AIR TEMPERATURE) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__maf-mass-air-flow-and-iat) .
  2. Connect battery (2) and voltmeter (3) to MAF and IAT sensor (1) as shown in figure.
  3. Check that voltage varies depending on amount of blowing air as the following graph. If faulty condition is found, replace MAF and IAT sensor.

IMRC (Intake Manifold Runner Control) Valve Removal and Installation

IMRC (Intake Manifold Runner Control) Valve Inspection

IMRC Valve Motor Check

CAUTIONDo not connect battery to IMRC valve actuator more than 10 seconds continuously.

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46
  1. Remove IMRC valve. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__intake-manifold-removal-and-installation) .
  2. Using ohmmeter, measure resistance between terminals "4" and "5" of IMRC valve actuator connector. If faulty condition is found, replace IMRC valve (2). IMRC valve motor resistance 8 - 10 ohms at 20 °C (68 °F)
  3. Connect battery (1) to terminals "4" and "5" of IMRC valve actuator connector as shown in figure. Check if IMRC valve is at fully open position.
  4. Connect battery (1) to terminals "4" and "5" of IMRC valve actuator connector as shown in figure. Check if IMRC valve is at fully closed position. If faulty condition is found, replace IMRC valve (2).

Scheme 47

Scheme 47: IMRC Valve Position Sensor Output Voltage Check
Scheme 47: IMRC Valve Position Sensor Output Voltage Check
  1. Remove IMRC valve. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__intake-manifold-removal-and-installation) .
  2. Check IMRC valve position sensor output voltage as follows. If faulty condition is found, replace IMRC valve. Set IMRC valve to fully open position. Connect 3 new 1.5 V batteries (1) in series and check that total voltage is 4.5 - 5.0 V. Connect voltmeter (2) and batteries (1) to IMRC valve position sensor as shown in figure. Measure IMRC valve position sensor output voltage. If faulty condition is found, replace IMRC valve. IMRC valve position sensor output voltage Fully open: 3.253 - 3.947 V Set IMRC valve to fully closed position. Connect voltmeter (2) and batteries (1) to IMRC valve position sensor as shown in figure. Measure IMRC valve position sensor output voltage. If faulty condition is found, replace IMRC valve. IMRC valve position sensor output voltage Fully closed: 0.534 - 0.762 V

IMT (Intake Manifold Tuning) Vacuum Solenoid Valve On-Vehicle Inspection

WARNINGDo not apply vacuum using mouth; otherwise harmful fuel vapor can be breathed in.
CAUTIONDo not apply vacuum more than -86 kPa (-0.86 kgf/cm 2 , -12.47 psi, -0.86 bar); otherwise IMT vacuum solenoid valve could be damaged.

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49
  1. Prepare to operate IMT vacuum solenoid valve as follows. Connect special tool (ECM check harness) between ECM and ECM connector. See «INSPECTION OF ECM AND ITS CIRCUITS»(/suzuki/grand-vitara/ii-2008-2012/remont/testing-diagnostics/#engine-general-information-and-diagnosis-j24b) . Special Tool : 09933-06320 CAUTION: ECM and its circuits should be checked by measuring voltage and pulse signal using special tool. It is strictly prohibited to connect voltmeter or ohmmeter to ECM. NOTE: Operate IMT vacuum solenoid valve using service wire as follows. IMT vacuum solenoid valve OFF: Disconnect "C37-42" terminal from vehicle body ground [a] IMT vacuum solenoid valve ON: Connect "C37-42" terminal to vehicle body ground [b]
  2. Disconnect vacuum hose No. 1 (1) from vacuum tank and vacuum hose No. 2 from IMT vacuum solenoid valve (2).
  3. Install special tool to vacuum hose No. 1 (1). Special Tool (A): 09917-47011
  4. Check that IMT vacuum solenoid valve (2) operates as follows. If faulty condition is found, check the following. Wire harness and connections IMT vacuum solenoid valve Vacuum hoses Operate the special tool and check that vacuum of -60 kPa (-0.6 kgf/cm 2 , -8.7 psi, -0.6 bar) can be applied when IMT vacuum solenoid valve is turned OFF [A]. Operate the special tool and check that no vacuum can be applied when IMT vacuum solenoid valve is turned ON [B].

IMT Vacuum Solenoid Valve Inspection

WARNINGDo not apply vacuum using mouth; otherwise harmful fuel vapor can be breathed in.
CAUTIONDo not apply vacuum more than -86 kPa (-0.86 kgf/cm 2 , -12.47 psi, -0.86 bar); otherwise IMT vacuum solenoid valve could be damaged.

Scheme 50

Scheme 50
Scheme 50

Scheme 51

Scheme 51
Scheme 51
  1. With ignition switch turned OFF, disconnect connector and vacuum hoses from IMT vacuum solenoid valve.
  2. Remove IMT vacuum solenoid valve.
  3. Check resistance between two terminals of IMT vacuum solenoid valve connector. If faulty condition is found, replace IMT vacuum solenoid valve. IMT vacuum solenoid valve resistance 27 - 33 ohms at 20 °C (68 °F)
  4. Check IMT vacuum solenoid valve operation as follows. If faulty condition is found, replace IMT vacuum solenoid valve. Install special tool and vacuum hose (2) to IMT vacuum solenoid valve (1). Special Tool (A): 09917-47011 Operate the special tool and check that vacuum of -60 kPa (-0.6 kgf/cm 2 , -8.7 psi, -0.6 bar) can be applied to IMT vacuum solenoid valve when 12 V battery is not connected to IMT vacuum solenoid valve terminals. Operate the special tool and check that no vacuum can be applied to IMT vacuum solenoid valve when 12 V battery is connected to IMT vacuum solenoid valve terminals.

Scheme 52

Scheme 52: OCV (Oil Control Valve) Inspection
Scheme 52: OCV (Oil Control Valve) Inspection
  1. Remove oil control valve from timing chain cover, and check oil control valve for clog or damage.
  2. Check resistance between terminals of oil control valve connector (1). If check result is not satisfactory, clean or replace OCV. Oil control valve resistance 6.7 - 7.7 ohms (at 20 °C (68 °F)
  3. Connect battery to OCV connector (1) as shown in figure, check operating sound at the same time operate spool valve.

Tightening Torque Specifications

CAUTIONFor fastener with * (asterisk) below, be sure to tighten it according to specified procedure in "Repair Instructions".
Fastening partTightening torque
N.mKgf-mLbf-ft
Accelerator pedal assembly nut6.00.614.5
Accelerator pedal assembly bracket nut6.00.614.5
ECT sensor121.29.0
A/F sensor454.633.5
HO2S454.633.5
CMP sensor bolt111.18.5
CKP sensor bolt111.18.5
Knock sensor bolt252.518.5
MAF and IAT sensor screw1.20.120.9

TORQUE SPECIFICATION

Reference

For the tightening torque of fastener not specified in this information, refer to FASTENER INFORMATION .

Special Tool

SPECIAL TOOL SPECIFICATION 09917-47011 Vacuum pump gauge 09933-06320 ECM check harness (120P) SUZUKI scan tool (SUZUKI-SDT) - This kit includes following items. Tech 2, PCMCIA card, DLC cable, SAE 16/19 adapter, Cigarette cable, DLC loop back adapter, Battery power cable, RS232 cable, RS232 adapter, RS232 loop back connector, Storage case

Scheme 53

Scheme 53: Special Tool
Scheme 53: Special Tool

Scheme 54

Scheme 54
Scheme 54

See also:
• PROCEDURE AFTER ECM REPLACEMENT
• AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION
• THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION
• INSTRUMENT PANEL REMOVAL AND INSTALLATION
• COOLING SYSTEM DRAINING
• COOLING SYSTEM FLUSHING
• ENGINE COOLING SYSTEM INSPECTION
• INSPECTION OF ECM AND ITS CIRCUITS
• GENERATOR REMOVAL AND INSTALLATION
• INTAKE MANIFOLD REMOVAL AND INSTALLATION
• FASTENER INFORMATION
• VIN (VEHICLE IDENTIFICATION NUMBER) REGISTRATION (EVAP-LEAK-CHECK MODEL)
• ELECTRIC THROTTLE CONTROL SYSTEM CALIBRATION
• APP (ACCELERATOR PEDAL POSITION) SENSOR ON-VEHICLE INSPECTION
• ACCELERATOR PEDAL ASSEMBLY (INCORPORATING APP SENSOR) REMOVAL AND INSTALLATION
• ECT (ENGINE COOLANT TEMPERATURE) SENSOR INSPECTION
• A/F (AIR FUEL RATIO) SENSOR, HO2S (HEATED OXYGEN SENSOR) REMOVAL AND INSTALLATION
• A/F (AIR FUEL RATIO) SENSOR ON-VEHICLE INSPECTION
• HO2S (HEATED OXYGEN SENSOR) ON-VEHICLE INSPECTION
• CMP (CAMSHAFT POSITION) SENSOR INSPECTION
• CMP (CAMSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION
• CKP (CRANKSHAFT POSITION) SENSOR INSPECTION
• CKP (CRANKSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION
• KNOCK SENSOR INSPECTION
• MAF (MASS AIR FLOW) AND IAT (INTAKE AIR TEMPERATURE) SENSOR REMOVAL AND INSTALLATION
• IMRC (INTAKE MANIFOLD RUNNER CONTROL) VALVE REMOVAL AND INSTALLATION

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