2004 SUZUKI GRAND VITARA check engine

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-31
Brake pedal Released Depressed
Voltage 0 VBattery
voltage
DIAGNOSTIC FLOW TABLE A-1 (NO TCC LOCK-UP OCCURS)
SYSTEM DESCRIPTION
PCM turns TCC solenoid OFF under any of the following conditions.

Brake pedal switch: ON

4WD LOW switch: ON

Cruise control module: TCC OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor, its
circuit or engine cooling
system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-8 (G16 / J20 engines) or C51-1-2 (H25
engine) terminal of PCM coupler and ground.

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Brake pedal released.

Drive vehicle with TCC ON condition
referring to ªTCC lock-up diagramº in
this section.
Is it battery voltage?Faulty TCC solenoid
valve, its circuit or
transmission.Go to Step 4.
4Is vehicle equipped with H25 engine?Go to Step 5.Go to Step 6.
5Brake switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-31 terminal of PCM coupler
terminal and ground.
Is the result as specified?Go to Step 6.Faulty brake pedal switch
or its circuit.
If OK, substitute a known-
good PCM and recheck.

YH4
GRAND
VITARA
7B1-32 AUTOMATIC TRANSMISSION (4 A / T)
Transfer gear
positionª4Lº or ªNº ª4Hº or ª2Hº
Voltage 0 VBattery
voltage
STEPACTIONYESNO
6ª4WD LOWº switch signal inspection:
(1) With ignition switch ON, check voltage
between C51-1-26 (G16 / J20 engines) or
C51-1-5 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 7.Faulty ª4WD LOWº
switch or its circuit.
If OK, substitute a known-
good PCM and recheck.
7Is vehicle equipped with cruise control
system?Go to Step 8.Substitute a known-good
PCM and recheck.
8Cruise control signal inspection:
(1) With ignition switch ON, check voltage
between E61-35 (G16 / J20 engines) or
E61-3 (H25 engine) terminal of PCM
coupler and ground.
Is it battery voltage?Substitute a known-good
PCM and recheck.Faulty cruise control
module or its circuit.
If OK, substitute a known-
good PCM and recheck.

YH4
GRAND
VITARA
AUTOMATIC TRANSMISSION (4 A / T) 7B1-33
O / D cut
switchOFF ON
VoltageBattery
voltage0 V
DIAGNOSTIC FLOW TABLE A-2 (NO GEAR SHIFT TO O / D)
SYSTEM DESCRIPTION
PCM does not shift to O / D gear under any of the following conditions.

O / D cut switch: ON

4WD LOW switch: ON

Cruise control module: O / D OFF command signal is output (if equipped).

ECT: ECT < 30C (86F)
TROUBLESHOOTING
WARNING:

When performing a road test, select a place where there is no traffic or possibility of a traffic accident
and very careful during testing to avoid occurrence of an accident.

Road test should be carried out with 2 person, a driver and tester, on a level road.
STEPACTIONYESNO
1Was ªAUTOMATIC TRANSMISSION
DIAGNOSTIC FLOW TABLEº performed?Go to Step 2.Go to ªAUTOMATIC
TRANSMISSION
DIAGNOSTIC FLOW
TABLEº.
2ECT check:
(1) Warm up engine to normal operating
temperature.
(2) Check ECT using scan tool.
Is ECT more than 30C (86F)?Go to Step 3.Faulty ECT sensor,
its circuit or engine
cooling system.
If OK, substitute a known-
good PCM and recheck.
3Perform running test under the following
conditions and check voltage between
C51-1-2 (G16 / J20 engines) or C51-1-6 (H25
engine) terminal of PCM coupler and ground,
C51-1-1 terminal of PCM coupler and ground.

O / D cut switch OFF (ªO / D OFFº lamp OFF).

Normal mode in ªDº range.

Transfer ª2Hº position.

Cruise control is not operated (if equipped).

Drive vehicle with 4th gear condition
referring to ªGear shift diagramº in this
section.
Is each voltage about 0 V?Faulty shift solenoid
valve, its circuit or
transmission.ªGº wire or ªG / Rº wire
shorted to power circuit.
If OK, go to Step 4.
4O / D cut switch signal inspection:
(1) With ignition switch ON, check voltage
between E61-33 (G16 / J20 engines) or
E61-14 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 5.Faulty O / D cut switch or
its circuit.
If OK, substitute a known-
good PCM and recheck.

YH4
GRAND
VITARA
7B1-34 AUTOMATIC TRANSMISSION (4 A / T)
Transfer gear
positionª4Lº or ªNº ª4Hº or ª2Hº
Voltage 0 VBattery
voltage
STEPACTIONYESNO
54WD LOW switch signal inspection:
(1) With ignition switch ON, check voltage
between C51-1-26 (G16 / J20 engines) or
C51-1-5 (H25 engine) terminal of PCM
coupler and ground.
Is the result as specified?Go to Step 6.Faulty 4WD LOW switch
or its circuit.
If OK, substitute a known-
good PCM and recheck.
6Is vehicle equipped with cruise control
system?Go to Step 7.Substitute a known-good
PCM and recheck.
7Cruise control signal inspection:
(1) With ignition switch ON, check voltage
between E61-35 (G16 / J20 engines) or
E61-3 (H25 engine) terminal of PCM
coupler and ground.
Is it battery voltage?Substitute a known-good
PCM and recheck.Faulty cruise control
module or its circuit.
If OK, substitute a known-
good PCM and recheck.

YH4
GRAND
VITARA
G16 / J20 Engines
H25 Engine
1. PCM
2. J / B
3. O / D cut switch
4. P / N change switch
5. J / C
1. PCM
2. Fuse
3. O / D cut switch
4. P / N change switch
5. J / C
6. J / C
AUTOMATIC TRANSMISSION (4 A / T) 7B1-35
DIAGNOSTIC FLOW TABLE B-1 ªO / D OFFº LIGHT CIRCUIT CHECK
(ªO / D OFFº LIGHT DOESN'T LIGHT AT IGNITION SWITCH ON BUT
ENGINE STARTS UP)
WIRING DIAGRAM
TROUBLESHOOTING
STEPACTIONYESNO
1ªO / D OFFº light circuit check:
(1) With ignition switch OFF, disconnect
couplers from PCM.
(2) Using service wire, connect E61-20
(G16 / J20 engines) or E61-7 (H25 engine)
terminal of disconnected PCM coupler and
ground.
Does ªO / D OFFº light turn ON at ignition
switch ON?Poor E61-20 (G16 / J20
engines) or E61-7 (H25
engine) terminal
connection.
If OK, substitute a known-
good PCM and recheck.Bulb burned out or faulty
ªW / Bº, ªB / Wº wire.

YH4
GRAND
VITARA
7B1-36 AUTOMATIC TRANSMISSION (4 A / T)
Switch ON
positionSwitch OFF
positionSwitch ON
position
Switch OFF
position
DIAGNOSTIC FLOW TABLE B-2 ªO / D OFFº LIGHT CIRCUIT CHECK
(ªO / D OFFº LIGHT COMES ON STEADILY)
WIRING DIAGRAM ± Refer to Table B-1 in this section.
TROUBLESHOOTING
STEPACTIONYESNO
1Check O / D cut Switch Position.
Is O / D cut switch turned OFF (Is switch button at OFF
position)?Go to Step 2.Turn O / D cut switch
OFF.
2Check Lamp Circuit for Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Turn ignition switch ON.
Does ªO / D OFFº lamp come ON steadily?ªW / Bº circuit shorted
to ground.Go to Step 3.
3Check O / D cut Switch Circuit.
1) Check resistance between terminal E61-33
(G16 / J20 engines) or E61-14 (H25 engine) of
disconnected PCM connector and body ground with
O / D cut switch OFF.
Is continuity indicated?Go to Step 4.Check PCM ground
circuit for open.
If ground circuit is
OK, substitute a
known-good PCM
and recheck.
4Check O / D cut Switch for Operation.
1) Remove console box.
2) Disconnect O / D cut switch connector.
3) Check continuity between switch terminals under
each condition below.
Switch OFF position: No continuity
Switch ON position: Continuity
Is check result satisfactory?ªY / Rº circuit shorted
to ground.Replace O / D cut
switch.
Fig. for Step 1. Fig. for Step 4.

YH4
GRAND
VITARA
G16 / J20 Engines
H25 Engine
1. PCM
2. J / B
3. O / D cut switch
4. P / N change switch
5. J / C
1. PCM
2. Fuse
3. O / D cut switch
4. P / N change switch
5. J / C
6. J / C
AUTOMATIC TRANSMISSION (4 A / T) 7B1-37
DIAGNOSTIC FLOW TABLE B-3 ªPOWERº LIGHT CIRCUIT CHECK
(ªPOWERº LIGHT DOESN'T LIGHT AT IGNITION SWITCH ON BUT
ENGINE STARTS UP)
WIRING DIAGRAM
TROUBLESHOOTING
STEPACTIONYESNO
1ªPOWERº light circuit check:
(1) With ignition switch OFF, disconnect
couplers from PCM.
(2) Using service wire, connect E61-21 (G16 /
J20 engines) or E61-10 (H25 engine)
terminal of disconnected PCM coupler and
ground.
Does ªPOWERº light turn ON at ignition switch
ON?Poor E61-21 (G16 / J20
engines) or E61-10 (H25
engine) terminal
connection.
If OK, substitute a known-
good PCM and recheck.Bulb burned out or faulty
ªGr / Blº, ªB / Wº wire.

YH4
GRAND
VITARA
7B1-38 AUTOMATIC TRANSMISSION (4 A / T)
ª5º
ª4º
DIAGNOSTIC FLOW TABLE B-4 ªPOWERº LIGHT CIRCUIT CHECK
(ªPOWERº LIGHT COMES ON STEADILY)
WIRING DIAGRAM ± Refer to Table B-3 in this section.
TROUBLESHOOTING
STEPACTIONYESNO
1Check Power / Normal Change Switch Position.
Is switch button at Normal position?Go to Step 2.Set Power / Normal
change switch at
Normal position.
2Check Lamp Circuit for Short.
1) Turn ignition switch OFF and disconnect PCM
connectors.
2) Turn ignition switch ON.
Does ªPOWERº lamp come ON steadily?ªGr / Blº circuit
shorted to ground.Go to Step 3.
3Check Power / Normal Change Switch Circuit.
1) Check resistance between terminal E61-31
(G16/J20 engines) or E61-9 (H25 engine) of
disconnected PCM connector and body ground with
P / N change switch OFF.
Is continuity indicated?Go to Step 4.Check PCM ground
circuit for open.
If ground circuit is
OK, substitute a
known-good PCM
and recheck.
4Check Power / Normal Change Switch for Operation.
1) Remove Power / Normal change switch.
2) Check continuity between switch terminals ª4º and
ª5º under each condition below.
Normal position: No continuity
Power position: Continuity.
Is check result satisfactory?ªOr / Blº circuit
shorted to ground.Replace Power /
Normal change
switch.
Fig. for Step 1. Fig. for Step 4.