Table of Contents
Advertisement
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the words
WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by
these signal words.
WARNING:
Indicates a potential hazard that could result in death or injury.
CAUTION:
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
WARNING:
This service manual is intended for authorized SUZUKI dealers and qualified service mechanics only.
Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to
properly perform the services described in this manual. Improper repair may result in injury to the
mechanic and may render the vehicle unsafe for the driver and passengers.
WARNING:
For vehicles equipped with a Supplemental Restraint (Air Bag) System :
• Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer.
Refer to "Air Bag System Components and Wiring Location View" under "General Description" in
air bag system section in order to confirm whether you are performing service on or near the air bag
system components or wiring. Please observe all WARNINGS and "Service Precautions" under
"On-Vehicle Service" in air bag system section before performing service on or around the air bag
system components or wiring. Failure to follow WARNINGS could result in unintentional activation
of the system or could render the system inoperative. Either of these two conditions may result in
severe injury.
• If the air bag system and another vehicle system both need repair, SUZUKI recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
• Do not modify the steering wheel, instrument panel or any other air bag system component (on or
around air bag system components or wiring). Modifications can adversely affect air bag system
performance and lead to injury.
• If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking
process), remove the air bag system components (air bag (inflator) module, sensing and diagnostic
module (SDM), seat belt pretensioner (if equipped) beforehand to avoid component damage or unin-
tended activation.
The circle with a slash in this manual means "Don't do this" or "Don't let this happen".
Important
Advertisement
Chapters
Table of Contents
Related Manuals for Suzuki Engine 2002 GRAND VITARA SQ416
Summarization of Contents
SECTION 6-1 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H25 ENGINE)
General Information on Engine Service and Precautions
Covers engine service precautions, cleanliness, and fuel system safety.
Engine Diagnosis Procedures and DTCs
Details engine diagnosis, diagnostic flow tables, and diagnostic trouble codes (DTCs).
SECTION 6A1 ENGINE MECHANICAL (G16 ENGINE)
G16 Engine General Description and Lubrication
Overview of the G16 engine's design and its lubrication system.
G16 Engine On-Vehicle Service Checks
Covers compression, vacuum, oil pressure checks, valve lash, and air cleaner service.
G16 Engine Overhaul Procedures
Detailed steps for removing and installing the engine assembly and its major components.
SECTION 6A2 ENGINE MECHANICAL (H25 ENGINE)
H25 Engine General Description and Lubrication
Overview of the H25 engine's design, including its DOHC valve mechanism and lubrication system.
H25 Engine On-Vehicle Service Checks
Covers compression, vacuum, and oil pressure checks for the H25 engine.
H25 Engine Piston and Connecting Rod Service
Detailed procedures for removal, disassembly, inspection, and assembly of pistons and related parts.
H25 Engine Overhaul Procedures
Step-by-step instructions for removing and installing the H25 engine assembly.
SECTION 6B ENGINE COOLING
Cooling System General Description and Warnings
Overview of cooling system components and critical safety warnings.
Cooling System Components by Engine Model
Illustrations and lists of cooling system parts for G16, J20, and H25 engines.
Thermostat Specifications and Installation
Details thermostat specifications and installation procedures.
Cooling System Maintenance Procedures
Covers coolant level check, system service, and flush/refill procedures.
Cooling System Diagnosis Table
Table for diagnosing common cooling system issues like overheating.
SECTION 6E1 ENGINE AND EMISSION CONTROL SYSTEM (G16/J20 ENGINES)
Engine and Emission Control System Overview
Introduction to the engine and emission control system's sub-systems.
Air Intake System Components and Operation
Details components like air cleaner, MAF sensor, throttle body, and manifold.
Fuel Delivery System Description and Diagram
Explains the fuel tank, pump, filter, regulator, and injectors.
Electronic Control System Description and Components
Describes sensors, ECM/PCM, and controlled devices in the system.
Engine and Emission Control Diagnosis Table
Table for diagnosing engine and emission control system issues.
Accelerator and Throttle Cable Adjustments
Instructions for adjusting accelerator and A/T throttle cable play.
Idle Speed and IAC Duty Inspection
Procedure to check idle speed and IAC duty using a scan tool.
Fuel Pressure Inspection
Procedure for inspecting fuel pressure, including warnings and specifications.
SECTION 6F1 IGNITION SYSTEM (FOR G16 ENGINE)
G16 Engine Ignition System General Description
Overview of the G16 engine's distributorless ignition system.
G16 Engine Ignition System Wiring Circuit
Diagram illustrating the electrical connections of the ignition system.
G16 Engine Ignition System Components Location
Locates ignition system components like coils, ECM, sensors.
G16 Engine Ignition System Diagnosis
Covers diagnosis table and flow table for ignition system issues.
Ignition Spark Check and Timing
Procedures for checking ignition spark and adjusting ignition timing.
High-Tension Cord Inspection and Replacement
Details inspection of high-tension cords for resistance and damage.
Ignition Coil Assembly Service
Covers removal, inspection, and installation of the ignition coil assembly.
Spark Plug Service
Details removal, inspection, and installation of spark plugs.
CMP Sensor Service
Covers removal, inspection, and installation of the CMP sensor.
Tightening Torque Specifications
Ignition System Tightening Torque Specifications.
Special Tools for Ignition System
Lists special tools required for ignition system service.
SECTION 6F2 IGNITION SYSTEM (FOR J20/H25 ENGINES)
Ignition System General Description (J20/H25)
Overview of the direct ignition system for J20/H25 engines.
Ignition System Wiring Circuit (J20/H25)
Diagram illustrating the system wiring circuit for the ignition system.
Ignition System Components (J20/H25)
Locates ignition system components for J20/H25 engines.
Ignition System Diagnosis
Provides diagnosis table and flow table for ignition system issues.
Ignition Spark Check (J20/H25)
Procedure for checking ignition spark for J20/H25 engines.
Ignition Timing Check and Adjustment
Details how to check and adjust ignition timing.
Ignition Coil Assembly Service (J20/H25)
Covers removal, inspection, and installation of the ignition coil assembly.
Spark Plug Service
Details removal, inspection, and installation of spark plugs.
CMP Sensor Service
Covers removal, installation, and adjustment of the CMP sensor.
Noise Suppressor Inspection
Procedure for inspecting the noise suppressor for conductivity.
Ignition System Tightening Torque Specifications
Specifies tightening torques for ignition system components.
Special Tools for Ignition System
Lists special tools required for ignition system service.
SECTION 6G CRANKING SYSTEM (0.9 kW, 1.2 kW and 1.4 kW Reduction Type)
Cranking Circuit and Starting Motor Description
Explains the components and electrical connections of the cranking circuit.
Starting Motor Components and Assembly
Illustrates and lists the components of the starting motor.
Starting System Diagnosis
Provides possible symptoms, causes, and corrections for starting system troubles.
Starting Motor Unit Repair Overhaul
Details dismounting, disassembly, reassembly, and inspection of the starting motor.
Starting Motor Specifications
Lists specifications for different starting motor types.
Required Service Material for Cranking System
Lists material like lithium grease for the cranking system.
Special Tools for Cranking System
Lists special tools required for servicing the cranking system.
SECTION 6H CHARGING SYSTEM
Battery General Description and Precautions
Explains battery functions, carrier, and precautions for electrolyte and sulfation.
Battery Diagnosis and Visual Inspection
Covers common battery failure causes and visual inspection steps.
Hydrometer Test for Battery State of Charge
Procedure for checking battery state of charge using S.G. and temperature correction.
Generator Diagnosis and Troubleshooting
Covers faulty indicator lamp, undercharged, overcharged batteries, and generator noise.
Undercharged Battery Troubleshooting
Details checks for undercharged battery conditions and troubleshooting steps.
Generator Higher Voltage Troubleshooting
Troubleshooting for higher charging voltage issues.
Generator Lower Voltage Troubleshooting
Troubleshooting for lower charging voltage issues.
Generator Load Check
Procedure for performing a load check on the generator.
Battery Jump Starting and Charging
Instructions for jump starting with auxiliary battery or charging equipment.
Battery Dismounting and Handling
Procedure for removing the battery and safety precautions.
Generator Belt Inspection and Adjustment
Procedure for inspecting and adjusting the cooling fan belt and generator belt.
Generator Unit Repair Overhaul
Details dismounting, disassembly, reassembly, and inspection of the generator.
Charging System Specifications
Provides specifications for battery types and generator ratings.
Charging System Tightening Torque Specifications
Lists tightening torque values for charging system components.
SECTION 6K EXHAUST SYSTEM
Exhaust System General Description
Describes the exhaust system components and emission control function.
Exhaust System Components by Engine Model
Illustrates exhaust system components for G16/J20 and H25 engine models.
Exhaust System Maintenance Checks
Details checks for rubber mountings, leaks, connections, and clearance.
Exhaust Manifold Service
Covers removal and installation procedures for the exhaust manifold.
Muffler Service
Instructions for tightening muffler bolts and nuts.
Need help?
Do you have a question about the Engine 2002 GRAND VITARA SQ416 and is the answer not in the manual?
Questions and answers