Suzuki sq-416-420-625 Manuals

Manuals and User Guides for Suzuki sq-416-420-625. We have 1 Suzuki sq-416-420-625 manual available for free PDF download: Service Manual

Suzuki sq-416-420-625 Service Manual (801 pages)

Brand: Suzuki | Category: Automobile | Size: 12.74 MB

Section 0A General Information

4
Maintenance and Lubrication

28
- Maintenance Schedule
  
  29
- 0B-2 Maintenance and Lubrication
  
  29
  - Maintenance Schedule under Normal Driving Conditions
    29
  - Maintenance Recommended under Severe Driving Conditions
    31
- Maintenance Service
  
  32
  - Engine
    32
  - Ignition System
    39
  - Fuel System
    39
  - Emission Control System
    41
  - Chassis and Body
    42
  - Final Inspection
    51
- Recommended Fluids and Lubricants
  
  52
Heater and Ventilation

53
- General Description
  
  54
  - Body Ventilation
    55
- Diagnosis
  
  55
  - Diagnosis Table
    55
  - Wiring Circuit
    56
- On-Vehicle Service
  
  57
  - Blower Unit
    57
  - Blower Motor
    59
  - Blower Motor Relay
    60
  - Blower Motor Resistor
    61
  - Heater Mode Control Switch
    62
  - Heater Mode Control Actuator
    64
  - Heater Control Lever Assembly
    66
  - Heater Control Cables
    67
  - Heater Unit
    68
  - Rear Duct
    71
Section 1B Air Conditioning (Optional)

72
- General Description
  
  74
- Diagnosis
  
  77
  - General
    77
  - Diagnosis of Abnormal Noise
    79
  - Quickly Checking of Refrigerant Charge
    81
  - (If Equipped with Sight Glass)
    81
  - Compression System Diagnosis
    82
  - Performance Diagnosis
    83
  - Wiring Circuit
    87
  - Inspection of A/C Controller and Its Circuits
    89
  - Drive Belt
    93
- Refrigerant Recovery, Evacuation and Charging
  
  94
  - Operation Procedure for Charging A/C with Refrigerant
    94
  - Recovery
    95
  - Evacuating
    96
  - Charging
    97
  - Removing Manifold Gauge Set
    100
  - Leak-Testing Refrigerant System
    100
  - Liquid Leak Detectors
    100
- On-Vehicle Service
  
  101
  - Precaution
    101
  - A/C Condenser Assembly
    104
  - Condenser Cooling Fan Assembly
    106
  - Condenser Dryer (Receiver/Dryer)
    107
  - Air Filter Element
    108
  - Cooling Unit (Evaporator)
    110
  - Expansion Valve
    113
  - A/C Evaporator Thermistor (Evaporator Temperature Sensor)
    114
  - Refrigerant Pipes and Hoses
    115
  - A/C Switch
    116
  - A/C Controller
    117
  - Dual Pressure Switch
    118
    
    A/C Compressor Relay and A/Ccondenser Cooling Fan Relay
    119
    
    Compressor Assembly
    120
    
    Magnet Clutch Assembly
    124
    
    Magnet Clutch Assembly
    127
    
    Lip Type Seal (for Seiko Seiki)
    130
- Required Service Material
  
  132
- Special Tools
  
  132
  - Wheels and Tires
    133
Section 3B1 Power Steering (P/S) System

145
- General Description
  
  146
  - Power Steering System
    146
  - Steering Gear Box
    147
  - Power Steering (P/S) Pump
    148
- Diagnosis
  
  149
  - General Diagnosis Table
    149
  - Power Steering Fluid
    151
    
    Power Steering Fluid Level Check
    151
  - Steering Wheel
    151
    
    Steering Force Check
    151
    
    Steering Wheel Play Check
    151
  - Power Steering Pump Drive Belt
    152
    
    Belt Tension Adjustment
    152
    
    Belt Tension Check
    152
  - Fluid
    153
    
    Fluid Leakage Check
    153
  - Idle up System
    153
    
    Idle up System Check
    153
  - Hydraulic Pressure in P/S Circuit
    154
    
    Hydraulic Pressure Check
    154
  - Boot
    155
    
    Steering Rack Boot Check
    155
    
    Tie-Rod End Boot Check
    156
  - Air Bleeding Procedure
    156
- On-Vehicle Service
  
  157
- Special Tool
  
  170
- Required Service Material
  
  170
- Tightening Torque Specification
  
  170
Section 3C Steering Wheel and Column (Not Equipped with Air Bag)

171
- Diagnosis
  
  172
  - Inspection and Repair Required after Accident
    172
- General Description
  
  172
- On-Vehicle Service
  
  173
  - Steering Wheel
    173
  - Combination Switch
    174
  - Steering Column Assembly
    175
  - Steering Lock Assembly (Ignition Switch)
    180
  - Steering Lower Shaft Assembly
    181
  - Checking Steering Column for Accident Damage
    183
  - Adjustable Steering Column Release Lever
    184
- Tightening Torque Specifications
  
  184
- Special Tool
  
  184
Section 3C1 Air Bag Steering Wheel and Column

185
- General Description
  
  186
- On-Vehicle Service
  
  187
  - Service Precautions
    187
    
    Diagnosis and Servicing
    187
    
    Disabling Air Bag System
    187
    
    Disposal
    187
    
    Enabling Air Bag System
    187
    
    Handling and Storage
    187
  - Driver Air Bag (Inflator) Module
    188
  - Steering Wheel
    190
  - Centering Contact Coil
    190
  - Contact Coil and Combination Switch Assembly
    191
  - Steering Column
    193
  - Steering Lock Assembly (Ignition Switch)
    198
  - Steering Lower Shaft Assembly
    199
  - Checking Steering Column for Accident Damage
    201
  - Adjustable Steering Column Release Lever
    202
- Diagnosis
  
  187
  - Inspection and Repair Required after Accident
    187
- Special Tool
  
  202
- Tightening Torque Specifications
  
  202
Sectiond Front Suspension

203
- Front Suspension
  203
- General Description
  
  204
- Diagnosis
  
  205
  - Diagnosis Table
    205
  - Stabilizer Bar and Bushing Check
    205
  - Strut Damper And/Or Coil Spring Check
    205
  - Suspension Arm/Knuckle Check
    205
  - Suspension Control Arm Joint Check
    206
  - Suspension Control Arm Bushing Check
    206
  - Wheel Disc, Nut & Bearing Check
    206
- On-Vehicle Service
  
  207
  - Stabilizer Bar/Bushings
    207
  - Strut Damper
    208
  - Coil Spring
    210
  - Bump Stopper/Spring Rubber Seat
    213
  - Wheel Hub (Included Wheel Bearing)
    214
  - Knuckle/Wheel Spindle
    219
  - Suspension Control Arm/Bushings
    223
- Tightening Torque Specifications
  
  225
- Required Service Materials
  
  226
- Special Tools
  
  227
Section 3E Rear Suspension

228
- Rear Suspension
  228
- General Description
  
  229
- Diagnosis
  
  230
  - Diagnosis Table
    230
  - Shock Absorber Check
    230
  - Axle Housing and Coil Spring Check
    230
  - Bearing Retainer & Axle Shaft Inner Oil Seal Check
    231
  - Wheel Disc, Nut & Bearing Check
    231
- On-Vehicle Service
  
  232
  - Shock Absorber
    232
  - Coil Spring
    233
  - Lower Rod
    235
  - Upper Rod
    236
  - Lateral Rod
    237
  - Rear Axle Shaft and Wheel Bearing
    237
  - Rear Axle Shaft Inner Oil Seal
    242
  - Rear Axle Housing
    243
- Required Service Materials
  
  250
- Tightening Torque Specifications
  
  250
- Special Tools
  
  251
Section 3F Wheels and Tires

252
- Replacement Tires
  252
- Wheels and Tires
  252
- Tires
  253
- Diagnosis
  
  254
  - Balancing Wheels
    254
  - Diagnosis Table
    254
- Maintenance and Minor Adjustments
  
  255
  - Wheel and Tire
    255
- On-Vehicle Service
  
  257
  - Wheel
    257
  - Tire
    258
- Tightening Torque Specifications
  
  259
Section 4A2 Front Drive Shaft/Shaft Bearing, Oil Seal

260
- General Description
  
  260
  - Oil Seal
    260
- General Description
  
  261
  - Diagnosis
    261
    
    Diagnosis Table
    261
    
    Drive Shaft Boot and Joint Check
    261
  - On-Vehicle Service
    262
    
    Drive Shaft
    262
    
    Shaft Bearing/Oil Seal
    268
  - Tightening Torque Specifications
    270
  - Required Service Materials
    270
  - Special Tools
    270
    
    Propeller Shafts
    271
    
    Propeller Shaft
    273
Section 5 Brakes

277
- General Description
  
  278
- Diagnosis
  
  279
  - Road Testing Brakes
    279
  - Brake Fluid Leaks
    279
  - Substandard or Contaminated Brake Fluid
    279
  - Diagnosis Table
    280
- Check and Adjustment
  
  283
  - Bleeding Brakes
    283
  - Brake Pedal Free Height Check
    285
  - Brake Light Switch Adjustment
    285
  - Excessive Pedal Travel Check
    285
  - Brake Pedal Play Check
    286
  - Brake Fluid Level Check
    286
  - Brake Hose and Pipe Check
    286
  - Master Cylinder Check
    286
  - Brake Disc Check
    287
  - Brake Pad Check
    287
  - Brake Shoe Check
    287
  - Parking Brake Check and Adjustment
    288
  - Flushing Brake Hydraulic System
    289
  - Fluid Pressure Test
    289
  - Booster Operation Check
    291
- Required Service Material
  
  293
- Tightening Torque Specifications
  
  293
- Special Tools
  
  294
Section 5A Brakes Pipe/Hose/Master Cylinder

295
- General Description
  
  296
  - Master Cylinder Assembly
    296
  - Booster Assembly
    296
  - LSPV (Load Sensing Proportioning Valve) Assembly
    297
- Diagnosis
  
  298
- Check and Adjustment
  
  298
- On-Vehicle Service
  
  298
  - Front Brake Hose/Pipe
    298
  - Rear Brake Hose/Pipe
    301
  - Master Cylinder Reservoir
    302
  - Master Cylinder Assembly
    304
  - Brake Booster
    308
  - LSPV (Load Sensing Proportioning Valve) Assembly
    311
- Required Service Material
  
  313
- Tightening Torque Specifications
  
  313
- Special Tools
  
  313
Section 5B Front Brake

314
- Front Brake
  314
- General Description
  315
- Note
  315
- Check and Adjustment
  316
- Diagnosis
  316
- On-Vehicle Service
  316
  - Front Disc Brake Pad
    316
  - Front Disc Brake Caliper
    319
  - Front Brake Disc
    323
- Required Service Material
  324
- Tightening Torque Specifications
  324
Section 5C Parking and Rear Brake

325
- General Description
  
  326
  - Drum Brake Assembly
    326
- On-Vehicle Service
  
  327
  - Parking Brake Lever
    327
  - Parking Brake Cable
    329
  - Brake Drum
    331
  - Brake Shoe
    333
  - Wheel Cylinder
    336
  - Brake Back Plate
    338
- Diagnosis
  
  327
- Check and Adjustment
  
  327
- Tightening Torque Specifications
  
  341
- Special Tools
  
  341
- Required Service Materials
  
  341
Section 5E1 Antilock Brake System (Abs) (Optional)

342
- General Description
  
  343
  - Brake Hose/Pipe Routing
    344
  - System Schematic
    345
  - ABS Hydraulic Unit/Control Module Assembly
    345
- Diagnosis
  
  348
  - Precaution in Diagnosing Troubles
    348
  - ABS Diagnostic Flow Table
    349
  - ABS" Warning Lamp Check
    352
  - Diagnostic Trouble Code (DTC) Check (Using "ABS" Warning Lamp)
    352
  - EBD Warning Lamp (Brake Warning Lamp) Check
    352
  - Diagnostic Trouble Code (DTC) Clearance
    354
  - DTC Check (Using SUZUKI Scan Tool)
    354
  - Diagnostic Trouble Code (DTC) Table
    355
  - System Circuit
    356
  - DTC 15 - G Sensor Circuit
    362
  - Power Source Circuit
    368
  - DTC 61 - ABS Pump Motor Circuit
    369
  - DTC 63 - ABS Fail-Safe Relay Circuit
    370
  - DTC 71 - ABS Control Module
    371
  - ABS Hydraulic Unit Operation Check
    372
  - Precaution
    372
  - ABS Hydraulic Unit/Control Module Assembly
    373
  - Hydraulic Unit Inspection
    373
    
    Removal
    373
    
    Installation
    374
    
    Front Wheel Speed Sensor
    375
    
    Output Voltage Inspection
    375
    
    Removal
    376
    
    Sensor Inspection
    376
    
    Sensor Rotor Inspection
    376
    
    Front Sensor Rotor
    377
    
    Installation
    377
    
    Removal
    377
    
    Output Voltage Inspection
    378
    
    Rear Wheel Speed Sensor
    378
    
    Removal
    378
    
    Installation
    379
    
    Sensor Inspection
    379
    
    Sensor Rotor Inspection
    379
    
    Installation
    380
    
    Rear Sensor Rotor
    380
    
    Removal
    380
    
    G Sensor
    381
    
    Inspection
    381
    
    Installation
    381
    
    Removal
    381
    
    Transfer 4WD Switch
    382
- Tightening Torque Specifications
  
  382
- Special Tools
  
  383
Section 7A Manual Transmission (Type 1)

384
- Diagnosis
  
  385
- General Description
  
  385
- On-Vehicle Service
  
  386
  - Gear Oil
    386
  - Shift Control Levers
    387
  - Switches
    389
  - Engine Rear Mounting
    391
  - Dismounting of Trans. Unit
    392
  - Remounting of Trans. Unit
    395
  - Extension Case (2WD MODEL)
    396
  - Extension Case Oil Seal (2WD MODEL)
    396
- Special Tool
  
  397
- Tightening Torque Specifications
  
  397
- Unit Repair
  
  397
- Required Service Materials
  
  397
Section 7A1 Manual Transmission (Type 2)

398
- Diagnosis
  
  399
- General Description
  
  399
- On-Vehicle Service
  
  400
  - Gear Oil
    400
  - Shift Control Levers
    401
  - Switches
    401
  - Engine Rear Mounting
    401
  - Dismounting/Remounting of Trans. Unit
    401
- Unit Repair
  
  401
- Required Service Materials
  
  402
- Tightening Torque Specifications
  
  402
Section 7B1 Automatic Transmission (4 A/T)

403
- Automatic Transmission
  403
- General Description
  
  405
  - Clutch/Brake Functions
    407
  - Table of Component Operation
    408
  - Electronic Shift Control System
    409
- Automatic Transmission Diagnosis
  
  419
  - Precaution in Diagnosing Trouble
    422
  - Automatic Transmission Diagnostic Flow Table
    423
    
    Customer Problem Inspection Form
    425
    
    Diagnostic Trouble Code (DTC) Check
    426
    
    Diagnostic Trouble Code (DTC) Clearance
    426
    
    Diagnostic Trouble Code (DTC) Table
    426
    
    Malfunction Indicator Lamp (MIL) Check
    426
    
    O/D OFF" Lamp Check
    426
    
    POWER" Lamp Check
    426
    
    Fail-Safe Table
    427
    
    Visual Inspection
    428
    
    A/T Basic Check
    429
    
    Trouble Diagnosis Table 3
    429
  - Inspection of PCM and Its Circuit
    432
  - Wire Harness and Connectors
    432
  - Diagnostic Flow Table A-1
    433
  - Diagnostic Flow Table A-2
    435
  - Check
    443
  - DTC P0751 Shift Solenoid Valve-A (#1)
    451
    
    DTC P1875 4WD Low Switch Circuit Malfunction
    454
    
    Line Pressure Test
    456
    
    Stall Test
    457
    
    Road Test
    458
    
    Manual Road Test
    459
    
    Time Lag Test
    459
    
    Engine Brake Test
    460
    
    P" Range Test
    460
  - Maintenance Service
    461
    
    Fluid Level
    461
    
    Fluid Change
    462
    
    Oil Cooler Hoses
    463
- On-Vehicle Service
  
  461
  - A/T Throttle Cable
    463
  - Manual Selector Assembly
    464
  - Select Cable
    465
    
    A/T Output Speed Sensor
    466
    
    O/D Cut Switch
    466
    
    Solenoid Valves
    466
    
    Transmission Range Switch
    466
    
    Power/Normal Change Switch
    468
    
    Throttle Position Sensor
    468
    
    Oil Cooler Pipes
    469
    
    Brake Interlock System
    470
    
    Shift Lock Solenoid Control
    470
    
    Shift Lock (Solenoid) Manual Release
    471
    
    System Inspection
    471
    
    Key Interlock Cable
    473
    
    Dismounting of Transmission (with Transfer if Equipped)
    476
    
    Remounting
    479
- Unit Repair
  
  480
- Tightening Torque Specifications
  
  480
- Required Service Materials
  
  481
- Special Tools
  
  481
Section 7C1 Clutch

482
- General Description
  
  483
- Diagnosis
  
  484
- On-Vehicle Service
  
  485
  - Clutch Pedal Height
    485
  - Clutch Pedal Free Travel
    485
  - Clutch Fluid Pipe and Hose
    485
  - Clutch Master Cylinder
    486
  - Fluid Inspection
    487
  - Disassembly and Assembly Clutch Master Cylinder
    488
  - Clutch Operating Cylinder
    489
- Unit Repair
  
  491
  - Clutch Cover, Clutch Disc and Flywheel
    491
- Tightening Torque Specifications
  
  495
- Required Service Materials
  
  495
- Special Tools
  
  495
  - Transfer Assembly
    500
  - Power Supply
    505
  - Removal and Installation
    515
  - Body Electrical System
    526
Section 8B Lighting System

532
- Lighting System
  532
- General Description
  
  533
  - Abbreviations
    533
  - Cautions in Servicing
    533
  - Fuse Box and Relay
    533
  - Headlights
    533
  - Joint Connector
    533
  - Power Supply Diagram
    533
  - Symbols and Marks
    533
  - Wiring Color Symbols
    533
  - Headlight with Leveling System (if Equipped)
    534
- Diagnosis
  
  535
  - Headlights
    535
  - Headlights with Leveling System (if Equipped)
    535
  - Turn Signal and Hazard Warning Lights
    535
  - Back-Up Lights
    536
  - Brake Lights
    536
  - Rear Fog Light (if Equipped)
    536
  - Interior Lights
    536
- On-Vehicle Service
  
  537
  - Headlights
    537
  - Bulb Replacement
    538
  - Headlights with Leveling System (if Equipped)
    539
  - Turn Signal and Hazard Warning Lights
    540
  - Rear Fog Light (if Equipped)
    542
Section 8C Instrumentation/Driver Information

543
- General Description
  544
  - Abbreviations
    544
  - Cautions in Servicing
    544
  - Combination Meter
    544
  - Fuse Box and Relay
    544
  - Joint Connector
    544
  - Power Supply Diagram
    544
  - Symbols and Marks
    544
  - Wiring Color Symbols
    544
  - Diagnosis
    546
  - Engine Coolant Temp. (ECT) Meter and Sensor
    546
  - Fuel Meter/Fuel Gauge Unit
    546
  - Oil Pressure Light
    546
  - Speedometer and VSS
    546
  - Engine Coolant Temp. (ECT) Meter and Sensor
    552
  - Brake and Parking Brake Warning
    554
    
    Door Switch
    555
Section 8D Windows, Mirrors, Security and Locks

556
- General Description
  
  557
  - Cautions in Servicing
    557
  - Symbols and Marks
    557
  - Wiring Color Symbols
    557
  - Abbreviations
    557
  - Joint Connector
    557
  - Fuse Box and Relay
    557
  - Power Supply Diagram
    557
  - Windshield Wiper and Washer
    557
    
    Front Wiper and Washer
    557
  - Power Door Lock and Keyless Entry (if Equipped) System
    559
- Diagnosis 8D
  
  560
- On-Vehicle Service
  
  564
Section 8G Immobilizer Control System (if Equipped)

589
Section 9 Body Service

619
- Glass, Windows and Mirrors 9- 2.
  
  620
  - Front Door Glass
    620
  - Front Door Window Regulator
    623
  - Windshield
    624
  - Rear Door Glass
    630
  - Rear Door Window Regulator
    632
  - Quarter Window
    633
  - Back Door Glass
    634
- Body Structure
  
  635
  - Front Door Assembly
    635
  - Rear Door Assembly
    636
  - Back Door/Rear Gate Assembly
    637
  - Hood
    639
  - Front Fender
    640
  - Front Bumper
    641
  - Rear Bumper
    642
  - Under Body Dimensions
    643
  - Body Dimensions
    644
- Instrumentation and Driver Information
  
  651
  - Instrument Panel
    651
- Seat
  
  652
  - Front Seat
    652
  - Rear Seat
    653
- Paint and Coatings
  
  654
  - Anti-Corrosion Treatment
    654
  - Metal Replacement Parts Finishing
    655
  - Plastic Parts Finishing
    676
- Security and Locks
  
  677
  - Front Door Lock Assembly
    677
  - Rear Door Lock Assembly
    679
  - Back Door/Rear Gate Lock Assembly
    680
  - Key Coding
    681
- Sunroof/Convertible Top
  
  682
  - Sliding Roof (if Equipped)
    682
  - Canvas Top and Topbow Frames
    689
- Exterior and Interior Trim
  
  690
  - Floor Carpet
    690
  - Head Lining
    691
  - Roof Trim (2 Door Model)
    693
  - Side Moldings (if Equipped)
    695
  - Splash Guard (if Equipped)
    696
  - Roof Rail (if Equipped)
    697
  - Roof Molding
    697
  - Luggage under Box
    698
    
    Restraint System
    699
    
    Seat Belt
    701
    
    Front Seat Belt
    703
Section 10B Air Bag System

707

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Suzuki sq-416-420-625 Manuals

Suzuki sq-416-420-625 Service Manual (801 pages)

Table of Contents

Section 0A General Information

How to Use this Manual

Precautions

Identification Information

Warning, Caution and Information Labels

Vehicle Lifting Points

Abbreviations May be Used in this Manual

Metric Information

Maintenance and Lubrication

Maintenance Schedule

0B-2 Maintenance and Lubrication

Maintenance Service

Recommended Fluids and Lubricants

Heater and Ventilation

General Description

Diagnosis

On-Vehicle Service

Section 1B Air Conditioning (Optional)

General Description

Diagnosis

Refrigerant Recovery, Evacuation and Charging

On-Vehicle Service

Required Service Material

Special Tools

Section 3B1 Power Steering (P/S) System

General Description

Diagnosis

On-Vehicle Service

Special Tool

Required Service Material

Tightening Torque Specification

Section 3C Steering Wheel and Column (Not Equipped with Air Bag)

Diagnosis

General Description

On-Vehicle Service

Tightening Torque Specifications

Special Tool

Section 3C1 Air Bag Steering Wheel and Column

General Description

On-Vehicle Service

Diagnosis

Special Tool

Tightening Torque Specifications

Sectiond Front Suspension

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specifications

Required Service Materials

Special Tools

Section 3E Rear Suspension

General Description

Diagnosis

On-Vehicle Service

Required Service Materials

Tightening Torque Specifications

Special Tools

Section 3F Wheels and Tires

Diagnosis

Maintenance and Minor Adjustments

On-Vehicle Service

Tightening Torque Specifications

Section 4A2 Front Drive Shaft/Shaft Bearing, Oil Seal

General Description

General Description

Section 5 Brakes

General Description

Diagnosis

Check and Adjustment

Required Service Material

Tightening Torque Specifications

Special Tools

Section 5A Brakes Pipe/Hose/Master Cylinder

General Description

Diagnosis

Check and Adjustment

On-Vehicle Service