Suzuki Engine 2002 GRAND VITARA SQ416 Manuals

Manuals and User Guides for Suzuki Engine 2002 GRAND VITARA SQ416. We have 1 Suzuki Engine 2002 GRAND VITARA SQ416 manual available for free PDF download: Service Manual

Suzuki Engine 2002 GRAND VITARA SQ416 Service Manual (834 pages)

Brand: Suzuki | Category: Engine | Size: 20.2 MB

Engine General Information and Diagnosis (G16/J20 Engines)

6
Table of Contents

143
Section 6A1 Engine Mechanical (G16 Engine)

292
- Engine Mechanical (G16 Engine)
  
  292
- General Description
  
  293
  - Engine
    293
  - Engine Lubrication
    294
- On-Vehicle Service
  
  295
  - Compression Check
    295
  - Engine Vacuum Check
    296
  - Oil Pressure Check
    297
  - Valve Lash (Clearance)
    299
  - Air Cleaner Element
    300
  - Cylinder Head Cover
    301
  - Throttle Body and Intake Manifold
    302
  - Exhaust Manifold
    305
  - Timing Belt and Belt Tensioner
    307
  - Oil Pan and Oil Pump Strainer
    312
  - Oil Pump
    316
  - Rocker Arms, Rocker Arm Shaft and Camshaft
    322
  - Valves and Cylinder Head
    332
  - Piston, Piston Rings, Connecting Rods and Cylinders
    344
- Unit Repair Overhaul
  
  354
  - Engine Assembly
    354
  - Main Bearings, Crankshaft and Cylinder Block
    360
- Special Tool
  
  373
- Required Service Material
  
  374
- Tightening Torque Specifications
  
  375
Section 6A2 Engine Mechanical (H25 Engine)

376
- General Description
  
  377
  - Engine
    377
  - Engine Lubrication
    378
- On-Vehicle Service
  
  379
  - Compression Check
    379
  - Engine Vacuum Check
    380
  - Oil Pressure Check
    381
  - Air Cleaner Element
    382
  - Throttle Body and Intake Manifold
    384
  - Exhaust Manifold
    391
  - Cylinder Head Covers
    395
  - Oil Pan and Oil Pump Strainer
    397
  - Timing Chain Cover
    401
  - Oil Pump
    405
  - LH (No.1) Bank 2Nd Timing Chain and Chain Tensioner
    409
  - 1St Timing Chain and Chain Tensioner
    415
  - RH (No.2) Bank 2Nd Timing Chain and Chain Tensioner
    423
  - Oil Pump Chain
    428
  - Camshaft and Valve Lash Adjuster
    432
  - Valve Lash Adjuster Noise Diagnosis
    440
  - Valves and Cylinder Heads
    441
  - Piston, Piston Rings, Connecting Rods and Cylinders
    454
- Unit Repair Overhaul
  
  467
  - Engine Assembly
    467
  - Main Bearings, Crankshaft and Cylinder Block
    472
- Special Tool
  
  485
- Required Service Material
  
  487
Section 6A4 Engine Mechanical (J20 Engine)

490
- Engine Mechanical (J20 Engine)
  
  490
- General Description
  
  491
  - Engine
    491
  - Engine Lubrication
    492
- On-Vehicle Service
  
  493
  - Compression Check
    493
  - Engine Vacuum Check
    495
  - Oil Pressure Check
    496
  - Air Cleaner Element
    497
  - Throttle Body and Intake Manifold
    498
  - Exhaust Manifold
    501
  - Cylinder Head Cover
    504
  - Oil Pan and Oil Pump Strainer
    505
  - Oil Pump
    509
  - Timing Chain Cover
    513
  - 2Nd Timing Chain and Chain Tensioner
    518
  - 1St Timing Chain and Chain Tensioner
    524
  - Camshafts and Valve Lash Adjusters
    530
  - Valves and Cylinder Head
    539
  - Pistons, Piston Rings, Connecting Rods and Cylinders
    552
  - Engine Mountings
    566
- Unit Repair Overhaul
  
  567
  - Engine Assembly
    567
  - Main Bearings, Crankshaft and Cylinder Block
    572
- Special Tool
  
  587
- Required Service Material
  
  589
Section 6B Engine Cooling

592
- General Description
  
  593
  - Cooling System Component
    594
    
    For G16 Engine Model
    594
    
    For J20 Engine Model
    595
    
    For H25 Engine Model
    596
  - Cooling System Circulation
    597
  - Thermostat
    599
  - Cooling Fan Clutch
    600
  - Coolant
    600
- Diagnosis
  
  602
  - Diagnosis Table
    602
- Maintenance
  
  603
  - Coolant Level Check
    603
  - Cooling System Service
    604
  - Cooling System Flush and Refill
    605
  - Cooling Fan Belt Tension Check and Adjustment
    606
- On-Vehicle Service
  
  608
  - Coolant Draining
    608
  - Cooling Water Pipes or Hoses
    608
  - Thermostat
    611
  - Cooling Fan Belt
    613
  - Cooling Fan and Fan Clutch
    614
  - Radiator
    615
  - Water Pump
    617
  - Engine Coolant Temperature (ECT) Sensor
    622
- Tightening Torque Specifications
  
  622
- Required Service Materials
  
  622
Section 6C Engine Fuel

624
- Fuel System
  624
- General Description
  
  625
- Diagnosis
  
  625
  - Diagnosis Table
    625
- On-Vehicle Service
  
  625
  - Precautions
    625
  - Fuel Pump
    626
  - Fuel Filter
    626
  - Fuel Lines
    627
  - Fuel Filler Cap
    628
  - Fuel Tank
    628
- Tightening Torque Specification
  
  631
Section 6E1 Engine and Emission Control System (G16/J20 Engines)

632
- Engine and Emission Control System (G16/J20 Engines)
  
  632
- General Description
  
  634
- On-Vehicle Service
  
  654
  - Engine and Emission Control System Description
    654
  - Accelerator Cable Adjustment
    656
  - A/T Throttle Cable Adjustment
    656
  - Idle Speed/Idle Air Control (IAC) Duty Inspection
    657
  - Idle Mixture Inspection/Adjustment (Vehicle Without Heated Oxygen Sensor)
    658
  - Air Intake System
    659
  - Throttle Body
    659
  - Idle Air Control Valve (IAC Valve)
    661
  - Fuel Delivery System
    662
    
    Fuel Pressure Inspection
    662
    
    Fuel Pump
    664
    
    Fuel Pressure Regulator
    665
    
    Fuel Injector
    666
  - Electronic Control System
    670
    
    Engine Control Module (ECM)/ Powertrain Control Module (PCM)
    670
    
    Mass Air Flow Sensor (MAF Sensor)
    671
    
    Intake Air Temperature (IAT) Sensor
    672
    
    Throttle Position Sensor (TP Sensor)
    674
    
    Engine Coolant Temperature Sensor (ECT Sensor)
    675
    
    Heated Oxygen Sensor-1 and -2 (HO2S-1 and HO2S-2)
    676
    
    Vehicle Speed Sensor (VSS)
    678
  - Camshaft Position Sensor (CMP Sensor)
    678
  - Crankshaft Position Sensor (G16 Engine)
    679
  - Crankshaft Position Sensor (J20 Engine)
    680
  - Manifold Absolute Pressure (MAP) Sensor
    680
  - Fuel Level Sensor (Sender Gauge)
    682
  - Main Relay
    683
  - Fuel Pump Relay
    685
  - A/C Compressor Relay and Condenser Fan Motor Relay (Other than Canvas Top Model)
    686
  - Fuel Cut Operation
    687
  - Emission Control System
    687
  - EGR System
    687
  - Evaporative Emission Control System
    689
  - PCV System
    691
- Diagnosis
  
  654
  - Diagnosis Table
    654
Section 6E2 Engine and Emission Control System (H25 Engine)

694
- General Description
  
  696
- Diagnosis
  
  708
  - Diagnosis Table
    708
- On-Vehicle Service
  
  709
  - Engine and Emission Control System Description
    709
  - Accelerator Cable Adjustment
    710
  - A/T Throttle Cable Adjustment
    711
  - Idle Speed/Idle Air Control (IAC) Duty Inspection
    711
  - Idle Mixture Inspection/Adjustment
    714
  - Sensor)
    714
  - Air Intake System
    715
    
    Throttle Body
    715
    
    Idle Air Control Valve (IAC Valve)
    718
  - Fuel Delivery System
    719
    
    Fuel Pressure Inspection
    719
    
    Fuel Pump
    721
    
    Fuel Pressure Regulator
    722
    
    Fuel Injector
    723
  - Electronic Control System
    727
    
    Engine Control Module (ECM)/ Powertrain Control Module (PCM)
    727
    
    Mass Air Flow Sensor (MAF Sensor)
    728
    
    Intake Air Temperature (IAT) Sensor
    729
    
    Throttle Position Sensor (TP Sensor)
    730
    
    Engine Coolant Temperature Sensor
    732
    
    Heated Oxygen Sensor (Sensor 1)
    733
    
    Heated Oxygen Sensor (Sensor 2)
    734
  - Vehicle Speed Sensor (VSS)
    735
  - Crankshaft Position Sensor
    736
  - Main Relay
    737
  - Fuel Pump Relay
    738
  - A/C Compressor Relay and Condenser Fan Motor Relay
    738
  - Fuel Cut Operation
    739
  - Emission Control System
    739
  - EGR System (if Equipped)
    739
  - Evaporative Emission Control System
    741
  - PCV System
    741
Section 6F1 Ignition System (for G16 Engine)

744
- General Description
  
  745
  - System Wiring
    746
  - Components
    747
- Diagnosis
  
  748
  - Diagnostic Flow Table
    748
- On-Vehicle Service
  
  750
  - Ignition Spark Check
    750
  - Ignition Timing Check
    750
  - High-Tension Cord
    753
  - Ignition Coil Assembly (Igniter and Ignition Coil)
    754
  - Spark Plug
    755
  - Ignition Timing Adjusting Resistor (if Equipped)
    757
  - CMP Sensor
    757
  - Noise Suppressor
    758
- Special Tool
  
  759
- Tightening Torque Specification
  
  759
Section 6F2 Ignition System (for J20/H25 Engines)

760
- General Description
  
  761
  - System Wiring
    762
  - Components
    763
- Diagnosis
  
  764
  - Diagnostic Flow Table
    764
- On-Vehicle Service
  
  766
  - Ignition Spark Check
    766
  - Ignition Timing Check and Adjustment
    766
  - Ignition Coil Assembly (Igniter and Ignition Coil)
    769
  - Spark Plug
    770
  - CMP Sensor
    771
  - Noise Suppressor
    773
- Special Tool
  
  775
- Tightening Torque Specification
  
  775
Section 6G Cranking System (0.9 Kw, 1.2 Kw and 1.4 Kw Reduction Type)

776
- General Description
  
  777
  - Cranking Circuit
    777
  - Starting Motor Circuit
    777
  - Starting Motor
    778
- Diagnosis
  
  779
- Unit Repair Overhaul
  
  781
  - Dismounting and Remounting
    781
  - Disassembly
    781
  - Reassembly
    784
  - Inspection
    786
  - Performance Test
    790
- Specifications
  
  792
  - Kw Type (1.4 Kw Type)
    792
  - 0.9 Kw Type
    792
- Required Service Material
  
  793
- Special Tool
  
  793
Section 6H Charging System

794
- Charging System
  
  794
- General Description
  
  795
  - Battery
    795
    
    Carrier and Hold-Down
    795
    
    Electrolyte Freezing
    795
    
    Sulfation
    795
    
    Built-In Indicator (if Equipped)
    796
    
    Care of Battery
    797
  - Generator
    798
- Diagnosis
  
  800
  - Battery
    800
    
    Common Causes of Failure
    800
    
    Visual Inspection
    800
    
    Hydrometer Test
    801
  - Generator
    802
    
    Undercharged Battery
    803
    
    Overcharged Battery
    805
- On-Vehicle Service
  
  806
  - Battery
    806
    
    Jump Starting in Case of Emergency
    806
    
    Dismounting
    807
    
    Handling
    807
    
    Remounting
    807
  - Generator
    808
    
    Generator Belt
    808
- Unit Repair Overhaul
  
  809
  - Generator
    809
    
    Dismounting
    809
    
    Remounting
    810
    
    Disassembly [60 a Type]
    811
    
    Disassembly [70 a and 80 a Types]
    814
    
    Inspection [60 a Type]
    817
    
    Inspection [70 a and 80 a Types]
    819
    
    Replace Brush
    821
    
    Reassembly [60 a Type]
    822
    
    Reassembly [70 a and 80 a Types]
    823
- Specifications
  
  826
  - Battery
    826
  - Generator
    826
- Tightening Torque Specifications
  
  826
  - General Description
    829
    
    Components
    829
  - Maintenance
    831
  - On-Vehicle Service
    832
    
    Exhaust Manifold
    832
    
    Muffler
    832

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Suzuki Engine 2002 GRAND VITARA SQ416 Manuals

Suzuki Engine 2002 GRAND VITARA SQ416 Service Manual (834 pages)

Table of Contents

Engine General Information and Diagnosis (G16/J20 Engines)

Engine General Information and Diagnosis (G16/J20 Engines)

Exhaust System

Engine Diagnosis

Engine Cooling

Engine Fuel

Table of Contents

Section 6A1 Engine Mechanical (G16 Engine)

Engine Mechanical (G16 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tool

Required Service Material

Tightening Torque Specifications

Section 6A2 Engine Mechanical (H25 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tool

Required Service Material

Section 6A4 Engine Mechanical (J20 Engine)

Engine Mechanical (J20 Engine)

General Description

On-Vehicle Service

Unit Repair Overhaul

Special Tool

Required Service Material

Section 6B Engine Cooling

General Description

Diagnosis

Maintenance

On-Vehicle Service

Tightening Torque Specifications

Required Service Materials

Section 6C Engine Fuel

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specification

Section 6E1 Engine and Emission Control System (G16/J20 Engines)

Engine and Emission Control System (G16/J20 Engines)

General Description

On-Vehicle Service

Diagnosis

Section 6E2 Engine and Emission Control System (H25 Engine)

General Description

Diagnosis

On-Vehicle Service

Section 6F1 Ignition System (for G16 Engine)

General Description

Diagnosis

On-Vehicle Service

Special Tool

Tightening Torque Specification

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

General Description

Diagnosis

On-Vehicle Service

Special Tool

Tightening Torque Specification

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

General Description

Diagnosis

Unit Repair Overhaul

Specifications

Required Service Material

Special Tool

Section 6H Charging System

Charging System

General Description

Diagnosis

On-Vehicle Service

Unit Repair Overhaul

Specifications

Tightening Torque Specifications

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