Suzuki Grand Vitara JB416 / JB420. Manual - part 80

1C-5 Engine Electrical Devices: 

Accelerator Pedal Position (APP) Sensor 
Assembly On-Vehicle Inspection

S5JB0A1306024

1) Check that accelerator pedal position (APP) sensor 

assembly has been mounted to vehicle body 
properly (no pinched floor carpet, etc).
If mounting is not properly, reinstall accelerator pedal 
position (APP) sensor assembly properly referring to 
“Accelerator Pedal Position (APP) Sensor Assembly 
Removal and Installation”.

2) Connect scan tool to DLC with ignition switch turned 

OFF.

3) Turn ON ignition switch and select “Data List” mode 

on scan tool.

4) Check that accelerator pedal position sensor voltage 

varies as the following graph.
If sensor voltage is out of specified value or does not 
vary linearly as the following graph, check 
accelerator pedal position (APP) sensor assembly 
referring to “Accelerator Pedal Position (APP) 
Sensor Assembly Inspection”.

Accelerator Pedal Position (APP) Sensor 
Assembly Removal and Installation

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CAUTION

!

 

• Do not expose accelerator pedal position 

(APP) sensor assembly to excessive shock 
like a dropping it. If accelerator pedal 
position (APP) sensor assembly has been 
exposed to excessive shock, it should be 
replaced.

• Be careful not to expose sensor section of 

accelerator pedal position (APP) sensor 
assembly to water.

 

NOTE
After replacing accelerator pedal position 
(APP) sensor assembly, perform calibration 
of throttle valve referring to “Electric Throttle 
Body System Calibration”.

 

Removal

1) Disconnect negative cable at battery.
2) Disconnect connector from accelerator pedal 

position (APP) sensor assembly.

3) Remove accelerator pedal position (APP) sensor 

assembly from its bracket.

Installation
Reverse removal procedure for installation noting the 
following.
• Tighten accelerator pedal position (APP) sensor 

assembly upper nut (1) first and then lower nuts (2) to 
specified torque.

Tightening torque
Accelerator pedal position (APP) sensor assembly 
nut (a):  6.0 N·m (0.6 kgf-m, 4.5 lb-ft)

• If APP sensor assembly bracket is removed, tighten 

its mounting nuts to specified torque

Tightening torque
APP sensor assembly bracket nut:  6.0 N·m (0.6 
kgf-m, 4.3 lb-ft)

• Connect connector to accelerator pedal position 

(APP) sensor assembly securely.

[A]: Accelerator pedal position (APP) sensor (main) voltage
[B]: Accelerator pedal position (APP) sensor (sub) voltage

[C]: Sensor output voltage
[D]: Idle position of accelerator pedal

[E]: Full depressed position of accelerator pedal

[F]: Pedal stroke

[C]

[B]

[D]

[F]

[E]

[A]

1.74 - 2.17 V

0.65 - 0.82 V

3.50 - 4.27 V

0.30 - 0.44 V

I5JB0A130018-05

1, (a)

2, (a)

I5JB0A130036-01

Engine Electrical Devices:  1C-6

Accelerator Pedal Position (APP) Sensor 
Assembly Inspection

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Check accelerator pedal position (APP) sensor (main 
and sub) output voltage as following steps.

1) For accelerator pedal position (APP) sensor (main), 

arrange 3 new 1.5 V batteries (1) in series (check 
that total voltage is 4.7 – 5.0 V) and connect its 
positive terminal to “Vin 1” terminal (2) and negative 
terminal to “Ground 1” terminal (3) of sensor. Then 
using voltmeter, connect positive terminal to “Vout 1” 
terminal (4) of sensor and negative terminal to 
battery.

2) For accelerator pedal position (APP) sensor (sub), 

arrange 3 new 1.5 V batteries (1) in series (check 
that total voltage is 4.7 – 5.0 V) and connect its 
positive terminal to “Vin 2” terminal (2) and negative 
terminal to “Ground 2” terminal (3) of sensor. Then 
using voltmeter, connect positive terminal to “Vout 2” 
terminal (4) of sensor and negative terminal to 
battery.

3) Measure output voltage variation while accelerator 

pedal is no depressed and fully depressed as 
following specification.

If sensor voltage is out of specified value or does not 
vary linearly as the following graph, replace accelerator 
pedal position (APP) sensor assembly.

Accelerator pedal position (APP) sensor output 
voltage
Accelerator pedal position (APP) sensor (main) 
output voltage [A]: 0.82 – 3.50 V, varying according 
to depressed extent of accelerator pedal

Accelerator pedal position (APP) sensor (sub) 
output voltage [B]: 0.44 – 1.74 V, varying according 
to depressed extent of accelerator pedal

Engine Coolant Temperature (ECT) Sensor 
Removal and Installation

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Removal

1) Disconnect negative cable at battery.
2) Drain coolant referring to “Cooling System Draining 

in Section 1F”.

WARNING

!

 

To avoid danger of being burned, do not 
remove radiator cap while engine and 
radiator are still hot.
Scalding fluid and steam can be blown out 
under pressure if cap is taken off too soon.

 

3) Disconnect connector from ECT sensor (1).

4) Remove ECT sensor from water outlet cap.

1

2

3

4

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1

2

3

4

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[C]: Sensor output voltage
[D]: Idle position of accelerator pedal

[E]: Fully depressed position of accelerator pedal

[F]: Pedal stroke

[A]: For J20 engine
[B]: For M16 engine

[C]

[B]

[D]

[F]

[E]

[A]

1.74 - 2.17 V

0.65 - 0.82 V

3.50 - 4.27 V

0.30 - 0.44 V

I5JB0A130021-05

[B]

[A]

1

1

I5JB0A130022-03

1C-7 Engine Electrical Devices: 

Installation
Reverse removal procedure noting the following.
• Clean mating surfaces of ECT sensor and water outlet 

cap.

• Check O-ring for damage and replace, if necessary.
• Tighten ECT sensor (1) to specified torque.

Tightening torque
ECT sensor (a):  12.5 N·m (1.25 kgf-m, 9.0 lb-ft)

• Connect connector to ECT sensor securely.
• Refill coolant referring to “Cooling System Flush and 

Refill in Section 1F”.

Engine Coolant Temperature (ECT) Sensor 
Inspection

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Immerse temperature sensing part of ECT sensor in 
water (or ice) and measure resistance between sensor 
terminals while heating water gradually.
If measured resistance doesn’t show such characteristic 
as shown, replace ECT sensor.

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

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Heater

1) Disconnect A/F sensor connector.
2) Using ohmmeter, measure resistance of Sensor 

heater between terminals “V

B

” and “GND” at sensor 

connector. If found faulty, replace A/F sensor.

NOTE
Temperature of sensor affects resistance 
value largely. Make sure that sensor heater is 
at correct temperature.

 

A/F sensor heater resistance
2 – 3 

Ω at 20 °C (68 °F)

Viewed from terminal side

3) Connect A/F sensor connector securely.

Adjusting Resistor

1) Disconnect A/F sensor connector.
2) Using ohmmeter, measure resistance of adjusting 

resistor between terminals “R+” and “R–” at A/F 
sensor connector.
If found faulty, replace A/F sensor.

Adjusting resistor resistance
100 – 58000 

Ω at 20 °C (68 °F)

Viewed from terminal side

3) Connect A/F sensor connector securely.

[A]: For J20 engine
[B]: For M16 engine

[A]: Lower limit

[D]: Resistance

[B]: Normal

[E]: Temperature

[C]: Upper limit

[B]

[A]

1, (a)

1, (a)

I5JB0A130023-02

20

0

68

32

104

140

176

40

60

80

[E]

2.29 - 2.62

0.309 - 0.331

[A]

[B]

[C]

[D]

I5JB0A130037-01

“GND”

“V

B

”

I5JB0A130001-02

“R+”

“R

−

”

I5JB0A130002-02

Engine Electrical Devices:  1C-8

Heated Oxygen Sensor (HO2S-2) Heater On-
Vehicle Inspection

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1) Disconnect sensor connector.
2) Using ohmmeter, measure resistance of sensor 

heater between terminals “V

B

” and “GND” at sensor 

connector.
If found faulty, replace oxygen sensor.

NOTE
Temperature of sensor affects resistance 
value largely. Make sure that sensor heater is 
at correct temperature.

 

HO2S heater resistance
5.0 – 6.4 

Ω at 20 °C (68 °F)

Viewed from terminal side

3) Connect sensor connector securely.

Air Fuel Ratio (A/F) Sensor, Heated Oxygen 
Sensor (HO2S-2) Removal and Installation

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Removal

WARNING

!

 

To avoid danger of being burned, do not 
touch exhaust system when system is hot. A/
F sensor and/or oxygen sensor removal 
should be performed when system is cool.

 

1) Disconnect negative cable at battery.
2) Disconnect connector of A/F sensor and/or heated 

oxygen sensor.

3) Remove A/F sensor (1) and/or heated oxygen 

sensor (2) from exhaust No.1 pipe.

Installation
Reverse removal procedure noting the following.
• Tighten A/F sensor (1) to specified torque.

Tightening torque
A/F sensor  (a):  45 N·m (4.5 kgf-m, 32.5 lb-ft)

• Tighten heated oxygen sensor (2) to specified torque.

Tightening torque
Heated oxygen sensor (b):  45 N·m (4.5 kgf-m, 
32.5 lb-ft)

Camshaft Position (CMP) Sensor Removal and 
Installation

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Removal

1) Disconnect negative cable at battery.
2) Disconnect connector from CMP sensor.
3) Remove camshaft position sensor from cylinder 

head cover (for J20 engine) or cylinder head (for 
M16 engine).

Installation

1) Install camshaft position sensor to cylinder head 

cover (for J20 engine) or cylinder head (for M16 
engine).

Tightening torque
CMP sensor bolt  (a):  11 N·m (1.1 kgf-m, 8.0 lb-ft)

“GND”

“V

B

”

I5JB0A130024-03

[A]: For J20 engine
[B]: For M16 engine

1,(a)

2,(b)

I5JB0A130025-02

(a)

[B]

[A]

(a)

I5JB0A130026-03