Suzuki Grand Vitara JB416 / JB420. Manual - part 49

1A-145 Engine General Information and Diagnosis: 

DTC P0463: Fuel Level Sensor Circuit High

S5JB0A1104095

Wiring Diagram 
Refer to “DTC P0462: Fuel Level Sensor Circuit Low”.

DTC Detecting Condition and Trouble Area

DTC Confirmation Procedure

1) With ignition switch turned OFF, connect scan tool.
2) Turn ON ignition switch and clear DTC using scan tool.
3) Start engine and run it for 30 sec. or more.
4) Check DTC and pending DTC.

DTC Troubleshooting

NOTE
Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to 
“Precautions For DTC Troubleshooting”.

 

DTC detecting condition

Trouble area

Fuel level sensor voltage is higher than specified value for 3 
seconds continuously.
(1 driving cycle detection logic but MIL does not light up)

• ECM power and/or ground circuit malfunction
• ECM malfunction
• Fuel level sensor and/or its circuit malfunction

Step

Action

Yes

No

1

Was “Engine and Emission Control System Check” 
performed?

Go to Step 2.

Go to “Engine and 
Emission Control 
System Check”.

2

Does fuel level meter in combination meter indicate “E” 
(empty)?

Replenish fuel tank with 
fuel and go to Step 3.

Go to Step 3.

3

Do you have SUZUKI scan tool?

Go to Step 4.

Go to Step 5.

4

Fuel level sensor output signal check with SUZUKI scan 
tool
1) Connect SUZUKI scan tool to DLC with ignition switch 

turned OFF.

2) Turn ON ignition switch and check fuel level displayed 

on SUZUKI scan tool.

Is it 3% or less?

Go to Step 6.

Intermittent trouble. 
Check for intermittent 
referring to “Intermittent 
and Poor Connection 
Inspection in Section 
00”.

5

Fuel level sensor output signal check
1) Turn OFF ignition switch.
2) Remove ECM from its bracket with ECM connectors 

connected.

3) Turn ON ignition switch and measure voltage between 

“E23-24” terminal of ECM connector and vehicle body 
ground.

Is voltage about 3.5 V or more?

Go to Step 6.

Intermittent trouble. 
Check for intermittent 
referring to “Intermittent 
and Poor Connection 
Inspection in Section 
00”.

6

Fuel level sensor circuit resistance check
1) Disconnect connectors from ECM with ignition switch 

turned OFF.

2) Check for proper connection to “E23-24” terminal of 

ECM connector.

3) If OK, measure resistance between “E23-24” terminal of 

ECM connector and vehicle body ground.

Is resistance below 280 

Ω

?

Go to Step 7.

Go to Step 8.

Engine General Information and Diagnosis:  1A-146

7

Short circuit check for fuel level sensor output signal 
circuit
1) Turn ON ignition switch and measure voltage between 

“E23-24” terminal of ECM connector and vehicle body 
ground.

Is voltage 0 V?

Go to Step 8.

“YEL/RED” wire shorted 
to other circuit.

8

Open circuit check for fuel level sensor output signal 
circuit
1) Disconnect fuel pump connector referring to “Fuel Tank 

Removal and Installation in Section 1G”.

2) Check for proper connection to “YEL/RED” and “YEL/

GRN” wire terminals of fuel pump connector.

3) Connect connectors to ECM.
4) Turn ON ignition switch, measure voltage between “YEL/

RED” wire terminal of disconnected fuel pump connector 
and vehicle body ground.

Is voltage 10 – 14 V?

Go to Step 10.

Go to Step 9.

9

Open circuit check for fuel level sensor output signal 
circuit
1) Measure voltage between “E23-24” terminal of ECM 

connector and engine ground.

Is voltage 10 – 14 V?

“YEL/RED” wire is open 
circuit.

Substitute a known-
good ECM and recheck.

10 Fuel level sensor ground circuit check

1) Disconnect connector from sub fuel lever sensor with 

ignition switch turned OFF.

2) Measure resistance between “BLK/YEL” wire terminal of 

fuel pump connector and vehicle body ground.

Is resistance below 5 

Ω

?

Go to Step 11.

“BLK/YEL” wire in open 
or high resistance 
circuit.

11 High resistance circuit check for fuel level sensor circuit

1) Disconnect connectors from ECM.
2) Measure resistance between “YEL/RED” wire terminal of 

fuel pump connector and “E23-24” wire terminal of ECM 
connector.

Is resistance below 5 

Ω

?

Go to Step 12.

“YEL/RED” wire is high 
resistance circuit.

12 Fuel level sensor check

1) Check fuel level sensor (main and sub) referring to “Fuel 

Level Sensor Inspection in Section 9C”.

Is it in good condition?

“YEL/GRN” wire 
between main fuel lever 
sensor and sub fuel 
lever sensor is open or 
high resistance. If wire 
is OK, substitute a 
known-good ECM and 
recheck.

Faulty fuel level sensor.

Step

Action

Yes

No

1A-147 Engine General Information and Diagnosis: 

DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit

S5JB0A1104048

Wiring Diagram

DTC Detecting Condition and Trouble Area

DTC Confirmation Procedure

1) Turn OFF ignition switch.
2) Clear DTC with ignition switch turned ON.
3) Run engine at idle speed.
4) Check DTC.

E23

C37

3

4

18

19

5

6

7

10

11

17

20

47

46

49

50

51

21

22

52

16

25

9

24

14
29

55

57

54 53

59

60

58

2

26

27

28

15
30

56

48

32

31

34

35

36

37

40

42

39 38

44

45

43

41

33

1

12

13

23

8

3

4

18

19

5

6

7

10

11

17

20

47

46

49

50

51

21

22

52

16

25

9

24

14
29

55

57

54 53

59

60

58

2

26

27

28

15
30

56

48

32

31

34

35

36

37

40

42

39 38

44

45

43

41

33

1

12

13

23

8

5V

RED/BLK

E23-46  

E23-47  

BLU/RED

BLU/YEL

BLU/BLK

E23-48  

PPL/YEL

GRY/GRN

C37-24  

C37-57  

1

2

10

3

4

8

5

9

BLK

RED

YEL/GRN

C37-15  

C37-29  
C37-48  

BLK/ORN

C37-58  

C37-30  BLK/ORN

BLK/YEL
BLK/YEL
BLK/YEL

RED/YEL

BLK

BLU

BLU

YEL/GRN

BLU/WHT

YEL/GRN

6

7

I5JB0A110056-01

1. Fuse box No.2

5. Radiator cooling fan relay No. 3

9. ECT sensor

2. Ignition switch

6. Radiator cooling fan motor No.1

10

.

“IG2 SIG” fuse

3. Radiator cooling fan relay No. 1

7. Radiator cooling fan motor No.2

4. Radiator cooling fan relay No. 2

8. ECM

DTC detecting condition

Trouble area

Monitor signal of radiator cooling fan relay is different from 
command signal.
(1 driving cycle detection logic)

• Radiator cooling fan relay circuit malfunction
• Radiator cooling fan relay malfunction
• ECM malfunction

Engine General Information and Diagnosis:  1A-148

DTC Troubleshooting

NOTE
Before this trouble shooting is performed, read the precautions for DTC troubleshooting referring to 
“Precautions For DTC Troubleshooting”.

 

Step

Action

Yes

No

1

Was “Engine and Emission Control System Check” 
performed?

Go to Step 2.

Go to “Engine and 
Emission Control 
System Check”.

2

Wire circuit check
1) Disconnect connectors from ECM with ignition switch 

turned OFF.

2) Check for proper connection to ECM at “E23-46”, “E23-

47” and “E23-48” terminals.

3) If OK, turn ON ignition switch.
4) Measure voltage between “E23-46” terminal of ECM 

connector and vehicle body ground.

Is voltage 10 – 14 V?

Go to Step 3.

Go to Step 4.

3

Radiator cooling fan control No.1 check
1) Connect connectors to ECM with ignition switch turned 

OFF.

2) Run engine until ECT is over 97.5 

°C 207.5 °F.

3) Measure voltage between “E23-46” terminal of ECM 

connector and vehicle body ground.

Is voltage below 1.5 V?

Go to Step 8.

Substitute a known-
good ECM and recheck.

4

Wire circuit check
1) Disconnect radiator cooling fan relay No.1 (1) from relay 

box (2) with ignition switch turned OFF.

2) Turn ON ignition switch.
3) Measure voltage between “YEL/GRN” wire terminal of 

radiator cooling fan relay No.1 connector and vehicle 
body ground. 

Is voltage 10 – 14 V?

Go to Step 5.

“YEL/GRN” wire is open 
circuit.

5

Wire circuit check
1) Measure resistance between “RED/BLK” wire terminal of 

radiator cooling fan relay No.1 connector and vehicle 
body ground with ignition switch turned OFF.

Is resistance infinity?

Go to Step 6.

“RED/BLK” wire is 
shorted to ground 
circuit.

1

2

I5JB0A110057-02