Suzuki 2000 Grand Vitara SQ420 Manuals

Manuals and User Guides for Suzuki 2000 Grand Vitara SQ420. We have 1 Suzuki 2000 Grand Vitara SQ420 manual available for free PDF download: Service Manual

Suzuki 2000 Grand Vitara SQ420 Service Manual (729 pages)

Brand: Suzuki | Category: Automobile | Size: 11.4 MB

Table of Contents

6
- General Information
  7
  - Engine Diagnosis
    10
  - Precaution in Diagnosing Trouble
    15
  - Engine Diagnostic Flow Table
    16
  - Customer Problem Inspection Form
    18
    
    Diagnostic Trouble Code (DTC Clearance
    20
    
    Fail-Safe Table
    21
    
    Diagnostic Trouble Code (DTC) Table
    22
    
    Scan Tool Data
    25
  - Visual Inspection
    31
  - Engine Basic Check
    32
    
    Engine Diagnosis Table
    33
    
    Resistance Check
    44
    
    Table A-5 ECM (PCM) Power and Ground Circuit Check
    47
  - DTC P0110 (DTC no
    51
  - Coolant Temp. Sensor Circuit Malfunction
    53
  - DTC P0130 (DTC No.13)
    59
Table of Contents

113
Engine Mechanical (G16 Engine)

243
- General Description
  
  244
- On-Vehicle Service
  
  246
  - Compression Check
    246
  - Engine Vacuum Check
    248
  - Oil Pressure Check
    249
  - Valve Lash (Clearance)
    251
  - Air Cleaner Element
    253
  - Cylinder Head Cover
    254
  - Throttle Body and Intake Manifold
    255
  - Exhaust Manifold
    258
  - Timing Belt and Belt Tensioner
    260
  - Oil Pan and Oil Pump Strainer
    265
  - Oil Pump
    269
  - Rocker Arms, Rocker Arm Shaft and Camshaft
    274
  - Valves and Cylinder Head
    283
  - Piston, Piston Rings, Connecting Rods and Cylinders
    296
- Unit Repair Overhaul
  
  306
  - Engine Assembly
    306
  - Main Bearings, Crankshaft and Cylinder Block
    311
- Special Tools
  
  323
- Required Service Materials
  
  324
(H25 Engine)

325
- General Description
  
  326
- On-Vehicle Service
  
  328
  - Compression Check
    328
  - Engine Vacuum Check
    329
  - Oil Pressure Check
    330
  - Air Cleaner Element
    331
  - Throttle Body and Intake Manifold
    332
  - Exhaust Manifold
    338
  - Cylinder Head Covers
    342
  - Oil Pan and Oil Pump Strainer
    343
  - Timing Chain Cover
    346
  - Oil Pump
    348
  - LH (NO.1) Bank 2Nd Timing Chain and Chain Tensioner
    351
  - 1St Timing Chain and Chain Tensioner
    357
  - Tightening Torque
    363
  - RH (NO.2) Bank 2Nd Timing Chain and Chain Tensioner
    365
  - Oil Pump Chain
    370
  - Camshaft and Valve Lash Adjuster
    374
  - Valve Lash Adjuster Noise Diagnosis
    381
  - Valves and Cylinder Heads
    382
  - Piston, Piston Rings, Connecting Rods and Cylinders
    393
- Unit Repair Overhaul
  
  404
  - Engine Assembly
    404
  - Main Bearings, Crankshaft and Cylinder Block
    408
- Special Tools
  
  418
- Required Service Material
  
  419
Section 6A4 Engine Mechanical (J20 Engine)

420
- General Description
  
  421
- On-Vehicle Service
  
  423
  - Compression Check
    423
  - Engine Vacuum Check
    425
  - Oil Pressure Check
    426
  - Air Cleaner Element
    427
  - Throttle Body and Intake Manifold
    428
  - Exhaust Manifold
    431
  - Cylinder Head Cover
    434
  - Oil Pan and Oil Pump Strainer
    435
  - Oil Pump
    438
  - Timing Chain Cover
    441
  - 2Nd Timing Chain and Chain Tensioner
    445
  - 1St Timing Chain and Chain Tensioner
    451
  - Camshafts and Valve Lash Adjusters
    457
  - Valve Lash Adjuster Noise Diagnosis
    463
  - Valves and Cylinder Head
    464
  - Pistons, Piston Rings, Connecting Rods and Cylinders
    476
  - Engine Mountings
    486
- Unit Repair Overhaul
  
  487
  - Engine Assembly
    487
  - Main Bearings, Crankshaft and Cylinder Block
    491
- Special Tools
  
  504
- Required Service Materials
  
  505
Section 6B Engine Cooling

506
- Engine Cooling
  506
- General Description
  
  507
  - Cooling System Circulation
    507
  - Thermostat
    509
  - Cooling Fan Clutch
    509
  - Coolant
    510
- Maintenance
  
  511
  - Coolant Level Check
    511
  - Cooling System Service
    512
  - Cooling System Flush and Refill
    512
  - Cooling Fan Belt Tension Check and Adjustment
    514
- Diagnosis
  
  511
  - Diagnosis Table
    511
- On-Vehicle Service
  
  516
  - Coolant Draining
    516
  - Cooling Water Pipes or Hoses
    516
  - Thermostat
    518
  - Cooling Fan Belt
    520
  - Cooling Fan and Fan Clutch
    521
  - Radiator
    522
  - Water Pump
    526
  - Engine Coolant Temperature (ECT) Sensor
    529
- Required Service Material
  
  529
- Tightening Torque Specification
  
  529
  - Engine Fuel
    530
  - Fuel System
    530
  - Fuel Lines
    533
  - Fuel Filler Cap
    534
  - Fuel Tank
    534
Section 6E1 Engine and Emission Control System (Sequential Multiport Fuel Injection for G16/J20 Engines)

538
- Air Intake System
  545
- Fuel Delivery System
  546
- Electronic Control System
  547
  - Engine & Emission Control Input/Output Table
    553
- On-Vehicle Service
  
  554
  - General
    555
  - Accelerator Cable Adjustment
    555
  - A/T Throttle Cable Adjustment (4 A/T)
    555
  - Idle Speed/Idle Air Control Duty
    556
  - Inspection
    556
  - Idle Mixture Inspection/Adjustment
    557
  - Air Intake System
    558
    
    Throttle Body
    558
    
    Idle Air Control Valve
    560
  - Fuel Delivery System
    561
    
    Fuel Pressure Inspection
    561
    
    Fuel Pump
    562
    
    Fuel Pressure Regulator
    563
    
    Fuel Injector
    565
  - Electronic Control System
    568
    
    MAF Sensor
    569
    
    IAT Sensor
    571
    
    TP Sensor
    572
    
    ECT Sensor
    573
    
    Engine Coolant Temperature Sensor
    573
  - Vehicle Speed Sensor
    576
  - Camshaft Position Sensor
    576
  - Crankshaft Position Sensor
    577
  - Fuel Level Sensor
    579
  - Main Relay
    580
  - Fuel Pump Relay
    581
    
    Fuel Cut Operation (Inspection) 6E1-45
    582
  - Emission Control System
    583
    
    EGR System
    583
    
    Evaporative Emission Control System
    585
    
    PCV System
    587
- Tightening Torque Specifications
  
  588
Section 6E2 Engine and Emission Control System (Sequential Multiport Fuel Injection for H25 Engine)

589
- Special Tools
  
  590
- General Description
  
  591
  - Air Intake System
    594
  - Fuel Delivery System
    595
  - Electronic Control System
    596
  - Engine & Emission Control Input/Output Table
    600
- On-Vehicle Service
  
  601
  - General
    602
  - Accelerator Cable Adjustment
    602
  - A/T Throttle Cable Adjustment
    602
  - Idle Speed/Idle Air Control Duty Inspection
    603
  - Air Intake System
    606
    
    Throttle Body
    606
    
    Idle Air Control Valve
    609
  - Fuel Delivery System
    611
    
    Fuel Pressure Inspection
    611
    
    Fuel Pump
    612
    
    Fuel Pressure Regulator
    613
    
    Fuel Injector
    614
  - Electronic Control System
    619
    
    Ecm (Pcm)
    620
    
    IAT Sensor
    622
    
    TP Sensor
    624
    
    ECT Sensor
    625
  - Fuel Pump Relay
    631
  - Fuel Cut Operation
    631
  - Emission Control System
    632
  - EGR System (if Equipped)
    632
  - Evaporative Emission Control System
    634
  - PCV System
    634
- Tightening Torque Specifications
  
  636
Section 6F1 Ignition System (for G16 Engine)

637
- General Description
  
  638
  - System Wiring
    638
  - Components
    639
- Diagnosis
  
  639
  - Diagnostic Flow Table
    640
  - Ignition Spark Check
    641
  - Ignition Timing Check
    642
- On-Vehicle Service
  
  644
  - High-Tension Cord
    644
  - Ignition Coil Assembly (Igniter and Ignition Coil)
    645
  - Spark Plug
    646
  - Ignition Timing Adjusting Resistor (if Equipped)
    646
  - CMP Sensor
    647
  - Noise Suppressor
    647
- Special Tools
  
  648
- Tightening Torque Specification
  
  648
Section 6F2 Ignition System (for J20/H25 Engines)

649
- General Description
  
  650
  - System Wiring
    650
  - Components
    651
- Diagnosis
  
  652
  - Diagnostic Flow Table
    652
  - Ignition Spark Check
    654
  - Ignition Timing Check and Adjustment
    654
- On-Vehicle Service
  
  657
  - Ignition Coil Assembly (Igniter and Ignition Coil)
    657
  - Spark Plug
    657
  - CMP Sensor
    659
  - Noise Suppressor
    660
- Tightening Torque Specifications
  
  662
Section 6G Cranking System (0.9 Kw, 1.2 Kw and 1.4 Kw Reduction Type)

663
- Special Tools
  
  663
- General Description
  
  664
  - Cranking Circuit
    664
  - Starting Motor Circuit
    664
  - Starting Motor
    665
- Diagnosis
  
  666
- Unit Repair Overhaul
  
  668
  - Dismounting and Remounting
    668
  - Disassembly
    668
  - Reassembly
    672
  - Inspection
    674
  - Performance Test
    678
    
    Hold-In Test
    678
    
    No-Load Performance Test
    678
    
    Plunger and Pinion Return Test
    678
    
    Pull-In Test
    678
- Specifications
  
  679
- Required Service Material
  
  680
- Special Tool
  
  680
Section 6G1 Cranking System (0.9 Kw No-Reduction Type)

681
- General Description
  
  682
  - Cranking Circuit
    682
  - Starting Motor
    682
- Diagnosis
  
  684
- Unit Repair Overhaul
  
  686
  - Dismounting
    686
  - Remounting
    686
  - Disassembly
    687
  - Reassembly
    688
  - Inspection
    688
  - Performance Test
    692
    
    Check Pinion Return
    692
    
    Hold-In Test
    692
    
    No-Load Performance Test
    692
    
    Pull-In Test
    692
- Required Service Material
  
  693
- Special Tool
  
  693
- Specifications
  
  693
Section 6H Charging System

694
- Charging System
  694
- General Description
  
  695
  - Battery
    695
  - Generator
    697
- Diagnosis
  
  699
  - Battery
    699
  - Generator
    701
- On-Vehicle Service
  
  704
  - Battery
    704
    
    Jump Starting in Case of Emergency
    704
    
    Dismounting
    705
    
    Handling
    705
    
    Remounting
    705
  - Generator
    706
    
    Generator Belt
    706
- Unit Repair Overhaul
  
  707
  - Generator
    707
    
    Dismounting
    707
    
    Remounting
    708
    
    Disassembly
    709
    
    Inspection
    715
    
    Replace Brush
    719
    
    Reassembly
    720
- Specifications
  
  724
  - Battery
    724
  - Generator
    724
- Tightening Torque Specifications
  
  724
  - Exhaust System
    725

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Suzuki 2000 Grand Vitara SQ420 Manuals

Suzuki 2000 Grand Vitara SQ420 Service Manual (729 pages)

Table of Contents

Table of Contents

Table of Contents

Engine Diagnosis

Special Tools

Engine Mechanical (G16 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Materials

(H25 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Material

Section 6A4 Engine Mechanical (J20 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tools

Required Service Materials

Section 6B Engine Cooling

General Description

Maintenance

Diagnosis

On-Vehicle Service

Required Service Material

Tightening Torque Specification

Section 6E1 Engine and Emission Control System (Sequential Multiport Fuel Injection for G16/J20 Engines)

On-Vehicle Service

Tightening Torque Specifications

Section 6E2 Engine and Emission Control System (Sequential Multiport Fuel Injection for H25 Engine)

Special Tools

General Description

On-Vehicle Service

Tightening Torque Specifications

Section 6F1 Ignition System (for G16 Engine)

General Description

Diagnosis

On-Vehicle Service

Special Tools

Tightening Torque Specification

Section 6F2 Ignition System (for J20/H25 Engines)

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Section 6G Cranking System (0.9 Kw, 1.2 Kw and 1.4 Kw Reduction Type)

Special Tools

General Description

Diagnosis

Unit Repair Overhaul

Specifications

Required Service Material

Special Tool

Section 6G1 Cranking System (0.9 Kw No-Reduction Type)

General Description

Diagnosis

Unit Repair Overhaul

Required Service Material

Special Tool

Specifications

Section 6H Charging System

General Description

Diagnosis

On-Vehicle Service

Unit Repair Overhaul

Specifications

Tightening Torque Specifications

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