Suzuki Sidekick Vitara Grand Vitara XL7 Workshop Repair Service Manual 1984-2014 PDF - MSZKGV8414OPMS.zip
A full factory-style service and repair guide, complete with electrical wiring diagrams, covering the 1984-2014 Suzuki Sidekick, Vitara, Grand Vitara, and XL7 — containing every technical detail needed to service, troubleshoot, fix, and rebuild these vehicles the way professional technicians do.
Inside the Suzuki Sidekick/Vitara/Grand Vitara/XL7 workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Suzuki
YEAR: 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
MODEL: Escudo/Sidekick/Sidekick Sport/Vitara/Grand Vitara/XL-7/XL7/Tracker (GEO)/Samurai (JA420, JA627, JB416, JB419, JB420, JB424, JB627, JB632, JC636, SE416, SJ413, SQ416, SQ420, SQ625, SQ420, SV620)
LANGUAGE: English/French/German/Spanish
TABLE OF CONTENTS
Precautions...7
Precautions...8
Precautions...8
Definition of Caution, Notice, and Important...8
Approved Equipment for Collision Repair Caution...8
Assistant Driving Caution...8
Cleaning Solvent Caution...8
Eye Protection Caution...9
Foam Sound Deadeners Caution...9
Gasoline/Gasoline Vapors Caution...9
Glass and Sheet Metal Handling Caution...9
Moving Parts and Hot Surfaces Caution...9
Protective Goggles and Glove Caution...9
Road Test Caution...9
Work Stall Test Caution...9
Belt Dressing Notice...10
Brake Fluid Effects on Paint and Electrical Components Notice...10
Clean, Dry, Low Pressure Gas Source Notice...10
Clearcoat/Ultraviolet Screeners Notice...10
Component Fastener Tightening Notice...10
Fastener Notice...10
Machined Surface Damage Notice...10
OBDII Symbol Description Notice...11
Pipe Wrench Positioning Notice...11
Test Probe Notice...11
General Information...13
General Information...14
General Description...14
Abbreviations and Meanings...14
Registered and Non-Registered Trademarks...19
Arrows and Symbols...20
RPO Code List...20
US English/Metric Conversion...21
Decimal and Metric Equivalents...22
Fasteners...23
Thread Inserts...26
Lifting and Jacking the Vehicle...27
Vehicle, Engine and Transmission, Transfer Case, Axle ID, and VIN Location, Derivative and Usage...28
Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label...29
Vibration Theory and Terminology...31
Service Programming System (SPS)...39
DTC Symptom Description - Vehicle Diagnostic Information...40
Service Materials (Lubricants, Oil, Grease, Sealant, Adhesive, Cleaner, etc)...42
Component Location...45
Engine Identification...45
Transmission Identification Information...46
Diagnostic Information and Procedures...46
Diagnostic Procedure Instructions - Vehicle Diagnostic Information...46
Strategy Based Diagnosis - Vehicle Diagnostic Information...49
Strategy Based Diagnosis...50
Vehicle-to-Vehicle Diagnostic Comparison...51
Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Information...52
Diagnostic Starting Point - Vehicle Diagnostic Information...68
Diagnostic Starting Point - Vibration Diagnosis and Correction...68
Diagnostic System Check - Vehicle Diagnostic Information...69
Diagnostic Repair Verification - Vehicle Diagnostic Information...71
Symptoms - Vehicle Diagnostic Information...71
Symptoms - Vibration Diagnosis and Correction...72
Squeaks and Rattles...73
Vibration Analysis - Road Testing...74
Vibration Diagnostic Aids...77
Vibration Diagnostic Aids - Vibration Intermittent or Not Duplicated...77
Vibration Diagnostic Aids - Vibration Duplicated, Component Not Identified...79
Vibration Diagnostic Aids - Vibration Duplicated, Difficult to Isolate/Balance Component...79
Vibration Diagnostic Aids - Vibration Duplicated, Appears to be Potential Operating Characteristic...79
Vibration in Service-Stall Test (Non-Torque Sensitive)...80
Vibration in Service-Stall Test (Torque Sensitive)...80
Control Module References...81
Special Tools and Equipment...83
Substitute Special Tool Table...83
Electronic Vibration Analyzer (EVA) Description and Operation...92
Vibrate Software Description and Operation...94
Reed Tachometer Description...94
Special Tools - Squeaks and Rattles...94
Special Tools and Equipment - Vibration Diagnosis and Correction...94
Maintenance and Lubrication...96
Scheduled Maintenance...96
Maintenance Items...96
Maintenance Schedule (North American Emissions)...96
Oil Life System Resetting...96
Specifications...96
Approximate Fluid Capacities...96
Fluid and Lubricant Recommendations...96
Engine...97
Engine General Information and Diagnosis...106
General Description...106
OBD System Description - Mode $06 Data Definitions...106
Schematic and Routing Diagram...109
Engine Controls Schematic Icons...109
Engine Controls Schematics...109
Engine Control Module Connector End Views...122
Engine Controls Connector End Views...124
Component Location...135
Engine Controls Component Views...135
Diagnostic Information and Procedures...143
Diagnostic Starting Point - Engine Controls...143
Diagnostic Starting Point - Engine Electrical...143
Scan Tool Output Controls - Engine Controls - 3.6L (LY7)...143
Scan Tool Output Controls - Engine Electrical...146
Scan Tool Data List - Engine Controls - 3.6L (LY7)...146
Scan Tool Data List - Engine Electrical...151
Scan Tool Data Definitions - Engine Controls - 3.6L (LY7)...153
Scan Tool Data Definitions - Engine Electrical...159
Powertrain Diagnostic Trouble Code (DTC) Type Definitions...160
DTC P0008 or P0009...161
DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095...162
DTC P0011, P0014, P0021, or P0024...164
DTC P0016, P0017, P0018, or P0019...166
DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058...168
DTC P0100, P0102, or P0103...171
DTC P0101...173
DTC P0111, P0112 or P0113...175
DTC P0116...177
DTC P0117 or P0118...180
DTC P0119...182
DTC P0121, P0122, P0123, P0221, P0222, or P0223...184
DTC P0125 or P0128...187
DTC P0131 or P0151...189
DTC P0132 or P0152...191
DTC P0133 or P0153...193
DTC P0134 or P0154...195
DTC P0135, P0141, P0155, or P0161...197
DTC P0137, P0138, P0140, P0157, P0158, or P0160...200
DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277...202
DTC P0300-P0306...204
DTC P0324...207
DTC P0326, P0327, P0328, P0331, P0332, or P0333...208
DTC P0335, P0336, or P0338...210
DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393...212
DTC P0420 or P0430...214
DTC P0442...216
DTC P0443, P0458, or P0459...218
DTC P0446...220
DTC P0449, P0498, or P0499...222
DTC P0451...224
DTC P0452 or P0453...225
DTC P0455...227
DTC P0496...230
DTC P0506, P0507, or P050A...232
DTC P0560...233
DTC P0562...234
DTC P0563...235
DTC P0601, P0602, P0603, P0604, P0605, P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610...236
DTC P0627, P0628, or P0629...237
DTC P0638, P2100, P2101, or P2119...239
DTC P0642 or P0643...241
DTC P0650...243
DTC P0652 or P0653...244
DTC P0685, P0686, P0687, P0689, or P0690...245
DTC P0698 or P0699...248
DTC P0700...249
DTC P0864...249
DTC P1011-P1014...250
DTC P1380...251
DTC P1551...252
DTC P167D...254
DTC P2096 or P2098...255
DTC P2097 or P2099...257
DTC P2105...259
DTC P2107...260
DTC P2122, P2123, P2127, P2128, or P2138...261
DTC P2176...263
DTC P2177, P2179, P2187, or P2189...264
DTC P2178, 2180, P2188, or P2190...267
DTC P2227, P2228, or P2229...269
DTC P2231 or P2234...270
DTC P2232 or P2235...271
DTC P2270 or P2272...273
DTC P2271 or P2273...275
DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316...277
DTC P2636...279
Symptoms - Engine Controls...280
Engine Cranks but Does Not Run...282
Inspection/Maintenance (I/M) System Check...284
Inspection/Maintenance (I/M) Complete System Set Procedure...286
Inspection/Maintenance (I/M) System DTC Table...287
Repair Instructions...287
Idle Learn...287
Specifications...288
Temperature Versus Resistance - Engine Coolant Temperature Sensor...288
Temperature Versus Resistance - Intake Air Temperature Sensor...288
Altitude Versus Barometric Pressure...288
Special Tools and Equipment...289
Special Tools - Engine Controls - 3.6L (LY7)...289
Aux. Emission Control Devices...291
Precautions...291
Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice...291
General Description...291
Evaporative Emission Control System Description...291
Crankcase Ventilation System Description...292
Schematic and Routing Diagram...293
Emission Hose Routing Diagram...293
Evaporative Emissions Hose Routing Diagram...294
Repair Instructions...295
Evaporative Emission Canister Purge Solenoid Valve Replacement...295
Evaporative Emission Canister Vent Solenoid Valve Replacement...296
Evaporative Emission Canister Vent Hose Replacement...297
Evaporative Emission Pipe Replacement...298
Evaporative Emission Canister Replacement...302
Evaporative Emission Canister Filter Replacement...304
Evaporative Emission System Cleaning...305
Specifications...306
Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...306
Special Tools and Equipment...306
Special Tools - Engine Controls - 3.6L (LY7)...306
Engine Electrical Devices...307
Precautions...307
Heated Oxygen and Oxygen Sensor Notice...307
Heated Oxygen Sensor Resistance Learn Reset Notice...307
Silicon Contamination of Heated Oxygen Sensors Notice...307
General Description...308
Air Intake System Description...308
Camshaft Actuator System Description...309
Engine Control Module Description...310
Knock Sensor (KS) System Description...313
Throttle Actuator Control (TAC) System Description...313
Repair Instructions...315
Engine Coolant Temperature Sensor Replacement...315
Mass Airflow Sensor/Intake Air Temperature Sensor Replacement...316
Heated Oxygen Sensor Replacement - Bank 1 Sensor 1...317
Heated Oxygen Sensor Replacement - Bank 1 Sensor 2...318
Heated Oxygen Sensor Replacement - Bank 2 Sensor 1...320
Heated Oxygen Sensor Replacement - Bank 2 Sensor 2...322
Heated Oxygen Sensor Wiring Repairs...324
Accelerator Pedal Position Sensor Replacement...324
Crankshaft Position Sensor Replacement...326
Camshaft Position Sensor Replacement - Bank 1 (Right Side) Exhaust...327
Camshaft Position Sensor Replacement - Bank 1 (Right Side) Intake...328
Camshaft Position Sensor Replacement - Bank 2 (Left Side) Exhaust...329
Camshaft Position Sensor Replacement - Bank 2 (Left Side) Intake...330
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Intake...331
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 1 (Right Side) Exhaust...332
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Intake...333
Camshaft Position Actuator Solenoid Valve Solenoid Replacement - Bank 2 (Left Side) Exhaust...334
Knock Sensor Replacement - Bank 1...335
Knock Sensor Replacement - Bank 2...336
Engine Control Module Replacement...337
Engine Control Module Programming and Setup...339
Specifications...340
Fastener Tightening Specifications - Engine Controls - 3.6L (LY7)...340
Special Tools and Equipment...340
Special Tools - Engine Controls - 3.6L (LY7)...340
Engine Mechanical...341
Precautions...341
Torque Reaction Against Timing Drive Chain Notice...341
General Description...341
Drive Belt System Description...341
Engine Component Description...341
Cleanliness and Care...343
Separating Parts...343
Replacing Engine Gaskets...344
Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer...344
Schematic and Routing Diagram...346
Camshaft Timing Drive Chain Alignment Diagram (Third Design)...346
Camshaft Timing Drive Chain Alignment Diagram (Fourth Design)...349
Component Location...352
Disassembled Views...352
Diagnostic Information and Procedures...366
Diagnostic Starting Point - Engine Mechanical...366
Symptoms - Engine Mechanical...366
Base Engine Misfire without Internal Engine Noises...367
Base Engine Misfire with Abnormal Internal Lower Engine Noises...368
Base Engine Misfire with Abnormal Valve Train Noise...369
Base Engine Misfire with Coolant Consumption...369
Base Engine Misfire with Excessive Oil Consumption...369
Engine Noise on Start-Up, but Only Lasting a Few Seconds...369
Upper Engine Noise, Regardless of Engine Speed...370
Lower Engine Noise, Regardless of Engine Speed...370
Engine Noise Under Load...371
Engine Will Not Crank - Crankshaft Will Not Rotate...372
Coolant in Combustion Chamber...373
Coolant in Engine Oil...373
Engine Compression Test...374
Cylinder Leakage Test...374
Crankcase Ventilation System Inspection/ Diagnosis...375
Drive Belt Chirping, Squeal, and Whine Diagnosis...375
Drive Belt Rumbling and Vibration Diagnosis...378
Drive Belt Falls Off and Excessive Wear Diagnosis...380
Drive Belt Tensioner Diagnosis...381
Vibration Analysis - Engine...382
Vibration Analysis - Engine/Accessory Isolation...384
Vibration Analysis - Engine Balance...390
Engine Order Classification...395
Repair Instructions...398
Air Cleaner Outlet Duct Replacement...398