PDF Service Manual Suzuki SQ416 SQ420 SQ625 - 2 MB
This is the complete two-volume service manual for the Suzuki SQ416, SQ420, and SQ625 models, commonly known as the Grand Vitara and Vitara.
It offers extensive details on all aspects of repair, from engine and transmission work to electrical diagnostics and bodywork.
This is the definitive guide for professionals and experienced DIY enthusiasts alike.
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99500-65D10-01E
99500-65D10-01E
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0A-10 GENERAL INFORMATION
PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE
When disconnecting and connecting coupler, make sure to
turn ignition switch OFF, or electronic parts may get dam-
aged.
Be careful not to touch the electrical terminals of parts which
use microcomputers (e.g. electronic control unit like as
ECM, PCM, P/S controller, etc.). The static electricity from
your body can damage these parts.
Never connect any tester (voltmeter, ohmmeter, or whatever)
to electronic control unit when its coupler is disconnected.
Attempt to do it may cause damage to it.
Never connect an ohmmeter to electronic control unit with
its coupler connected to it. Attempt to do it may cause dam-
age to electronic control unit and sensors.
Be sure to use a specified voltmeter/ohmmeter. Otherwise,
accurate measurements may not be obtained or personal in-
jury may result.
When taking measurements at electrical connectors using a
tester probe, be sure to insert the probe from the wire har-
ness side (backside) of the connector.
1. Coupler
2. Probe
When connecting meter probe from terminal side of coupler
because it can’t be connected from harness side, use extra
care not to bend male terminal of coupler of force its female
terminal open for connection.
In case of such coupler as shown connect probe as shown
to avoid opening female terminal.
Never connect probe where male terminal is supposed to fit.
1. Coupler
2. Probe
3. Where male
terminal fits
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MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
0B
MAINTENANCE AND LUBRICATION
WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an autho-
rized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “Gener-
al 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 Precau-
tions” 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.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system may
be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
CONTENTS
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 2
Maintenance Schedule Under Normal Driving Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 2
Maintenance Recommended Under Severe Driving Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 4
MAINTENANCE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 5
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B- 5
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-12
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-12
Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-14
Chassis and Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-15
Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-24
RECOMMENDED FLUIDS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B-25
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0B-16 MAINTENANCE AND LUBRICATION
ITEM 6-3
Brake Hoses and Pipes Inspection
Check brake hoses and pipes for proper hookup, leaks, cracks,
chafing and other damage.
Replace any of these parts as necessary.
CAUTION:
After replacing any brake pipe or hose, be sure to carry out
air purge operation.
ITEM 6-4
Brake Fluid Change
Change brake fluid as follows.
Drain existing fluid from brake system completely, fill system with
specified fluid and carry out air purge operation.
For air purging procedure, refer to Section 5.
ITEM 6-5
Parking Brake Lever and Cable Inspection
“a”: Parking brake lever
stroke: Parking brake lever
5 – 7 notches
(With 20 kg or 44 lbs 1) Check tooth tip of each notch for damage or wear. If any damage
of pull pressure)
or wear is found, replace parking lever.
2) Check parking brake lever for proper operation and stroke, and
“a” adjust it if necessary.
For checking and adjusting procedures, refer to Parking Brake
Inspection and Adjustment in Section 5.
Parking brake cable
Inspect brake cable for damage and smooth movement.
Replace cable if it is in deteriorated condition.
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1A-6 HEATER AND VENTILATION
6) Remove cooling unit (If equipped).
Refer to item COOLING UNIT (EVAPORATOR) REMOVAL in
Section 1B.
7) Disconnect fresh air control cable from blower motor case.
8) Remove blower motor unit (1) by removing its fastening nuts
(2).
9) Disconnect blower motor lead wire (2) at coupler from blower
unit (1).
10) Remove blower motor (3) by removing its mounting screws (4).
INSTALLATION
1) Reverse removal procedure for installation.
2) Connect fresh air control cable, refer to HEATER CONTROL
CABLES INSTALLATION.
3) Enable air bag system, if equipped. Refer to ENABLING AIR
BAG SYSTEM in Section 10B.
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1B-2 AIR CONDITIONING (OPTIONAL)
Condenser Dryer (Receiver/Dryer) . . . . . . 1B-36 A/C Compressor Relay and A/C
Air Filter Element . . . . . . . . . . . . . . . . . . . . . 1B-37 Condenser Cooling Fan Relay . . . . . . . . 1B-48
Cooling Unit (Evaporator) . . . . . . . . . . . . . . 1B-39 Compressor Assembly . . . . . . . . . . . . . . . . 1B-49
Expansion Valve . . . . . . . . . . . . . . . . . . . . . 1B-42 Magnet Clutch Assembly
A/C Evaporator Thermistor (Evaporator (For Denso Compressor) . . . . . . . . . . . 1B-53
Temperature Sensor) . . . . . . . . . . . . . . . . 1B-43 Magnet Clutch Assembly
Refrigerant Pipes and Hoses . . . . . . . . . . . 1B-44 (For Seiko Seiki Compressor) . . . . . . . 1B-56
A/C Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-45 Lip Type Seal (For Seiko Seiki) . . . . . . . 1B-59
A/C Controller . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 REQUIRED SERVICE MATERIAL . . . . . . . . 1B-61
Dual Pressure Switch . . . . . . . . . . . . . . . . . 1B-47 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . 1B-61
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AIR CONDITIONING (OPTIONAL) 1B-17
FOR RH VEHICLE
1. Blower motor main relay 10. Compressor relay 19. Battery
2. Blower motor 11. Compressor 20. Generator
3. Blower motor resistor 12. Condenser cooling fan relay 21. Ignition main fuse 60 A
4. Blower motor switch 13. Condenser cooling fan 22. Heater / A / C main fuse 60 A
5. A / C controller 14. Fuse box 23. Ignition / meter fuse 20 A
6. ECM 15. A / C fuse 25 A 24. Rear defogger fuse 15 A
7. Heater mode control switch 16. Ignition switch 25. Heater fuse 30 A
8. Evaporator temperature sensor 17. Main fuse box 26. Compressor thermal switch
9. Refrigerant pressure switch 18. Battery main fuse 80 A (only IWATA production vehicle)
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1B-32 AIR CONDITIONING (OPTIONAL)
REPLENISHING COMPRESSOR OIL
When replacing air conditioning parts with new ones, it is necessary
to replenish oil by the amount supposedly remaining in each part.
When changing gas only
When it is unavoidable to change gas without replacing any compo-
nent part for engine removal and installation or for some other rea-
son, replenish 20 cc oil. When replenishing gas only, oil replenish-
ment it not necessary.
When replacing compressor
Compressor oil is sealed in each new compressor by the amount
required for air conditioner cycle. Therefore, when using a new
compressor for replacement, drain oil from it by the amount calcu-
lated as follows.
“C” = “A” – “B”
“C”: Amount of oil to be drained
1. New compressor “A”: Amount of oil sealed in a new compressor
2. Removed compressor
3. Excess oil (A – B) “B”: Amount of oil remaining in removed compressor
When replacing other part
Amount of compressor oil
Replaced part
to be replenished
Evaporator 25 cc
Condenser 15 cc
Receiver /dryer 20 cc
Hoses 10 cc each
Pipes 10 cc each
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AIR CONDITIONING (OPTIONAL) 1B-47
DUAL PRESSURE SWITCH
INSPECTION
1) Check dual pressure switch (1) on liquid pipe for continuity at
normal temperature (approx. 25_C (77_F)) when A/C system
has a proper charge of refrigerant and when A/C system (com-
pressor) is under operation. In each of these cases, switch
should show proper continuity.
2) Using a manifold gauge set, check switch for operation at speci-
fied pressure as shown, refer to “PERFORMANCE DIAGNO-
SIS” in this section.
Switch ON : above “C” and below “D”
Switch OFF : below “A” or above “B”
“A”: Approx. 200 kPa (2.0 kg/cm2)
SWITCH
ON
“B”: Approx. 3200 kPa (32 kg/cm2)
C D
(Continuity) “C”: Approx. 230 kPa (2.3 kg/cm2)
“D”: Approx. 2800 kPa (28 kg/cm2)
OFF
(No continuity)
A B Tightening torque:
Pressure
Dual pressure switch: 10 N.m (1.0 kg-m, 7.5 lb-ft)
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STEERING, SUSPENSION, WHEELS AND TIRES 3-1
SECTION 3
STEERING, SUSPENSION, WHEELS AND TIRES
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3
FRONT END ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
POWER STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B1-1
AIR BAG STEERING WHEEL AND COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C1-1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-1
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-1
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-1
CONTENTS
GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . . 3-1 Radial Tire Waddle . . . . . . . . . . . . . . . . . . . 3-6
Diagnosis Table . . . . . . . . . . . . . . . . . . . . . . 3-1 Radial Tire Lead . . . . . . . . . . . . . . . . . . . . . . 3-8
TIRE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 3-6 VIBRATION DIAGNOSIS . . . . . . . . . . . . . . . 3-8
Irregular and/or Premature Wear . . . . . . . 3-6
Wear Indicator . . . . . . . . . . . . . . . . . . . . . . . 3-6
GENERAL DIAGNOSIS
Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered
when diagnosing a complaint. To avoid using the wrong symptom, always road test the vehicle first.
Proceed with the following preliminary inspections and correct any defects which are found.
1) Inspect tires for proper pressure and uneven wear.
2) Raise vehicle on a hoist and inspect front and rear suspension and steering system for loose or damaged parts.
3) Spin front wheel. Inspect for out-of-round tires, out-of-balance tires, bent rims, loose and/or rough wheel bear-
ings.
DIAGNOSIS TABLE
Condition Possible Cause Correction
Vehicle Pulls (Leads) Mismatched or uneven tires. Replace tire.
Tires not adequately inflated. Adjust tire pressure.
Broken or sagging springs. Replace spring.
Radial tire lateral force. Replace tire.
Disturbed front end alignment. Check front end alignment.
Disturbed rear axle alignment. Check rear axle alignment.
Brake dragging in one road wheel. Repair front brake.
Loose, bent or broken front or rear Tighten or replace suspension part.
suspension parts.
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3B1-4 POWER STEERING (P / S) SYSTEM
POWER STEERING (P/S) PUMP
The power steering pump is a vane type and is driven by the V-ribbed belt from the crankshaft.
1. Suction connector
2. O-ring
3. Pressure switch
4. Flow control valve
(Relief valve)
5. Spring
6. Plug
7. Pump cover
8. Cam ring
9. Vane
10. Rotor
11. Snap ring
12. Side plate
13. Pulley (pump shaft)
14. Oil seal
15. Pump body
16. Flow control valve Assembly
Model Vane type
6500 kPa (65 kg / cm2, 924 psi)
. . . . . . . . . . . . . . . . . . . . . . G16 Type engine
Relieved 7000 kPa (70 kg / cm2, 995 psi)
Hydraulic pressure . . . . . . . . . . . . . . . . . . . . . . . J20 Type engine
pressure 7350 kPa (73.5 kg / cm2, 1045 psi)
control . . . . . . . . . . . . . . . . . . . . . . H25 Type engine
Control Flow control valve
device Relief valve
Switch turns on (closes) when the
Power steering pressure is higher than 2500 – 3500 kPa
pressure switch (25 – 35 kg / cm2, 356 – 498 psi).
ECM uses this signal for idle speed control.
0.70 – 0.75
Capacity
(1.48 / 1.23 – 1.58 / 1.32 US / Imp. pt)
DEXRONII, DEXRONIII A / T fluid
Specified fluid
or equivalent
FLOW CONTROL VALVE
As the discharge rate of the P/S pump increases in proportion to the
pump revolution speed, a flow control valve is added to control it so
that the optimum amount of fluid for steering operation is supplied
according to the engine speed (driving condition).
Described below is its operation at different engine speed.
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POWER STEERING (P / S) SYSTEM 3B1-19
POWER STEERING PUMP
[G16 ENGINE MODEL] Tightening Torque
(a): 60 N.m (6.0 kg-m, 43.5 lb-ft)
(b):25 N.m (2.5 kg-m, 18.5 lb-ft)
(c): 55 N.m (5.5 kg-m, 40.0 lb-ft)
(d):11 N.m (1.1 kg-m, 8.0 lb-ft)
(e): 35 N.m (3.5 kg-m, 25.5 lb-ft)
( f ):40 N.m (4.0 kg-m, 29.0 lb-ft)
(g):45 N.m (4.5 kg-m, 33.0 lb-ft)
[H25 ENGINE MODEL]
[J20 ENGINE MODEL]
1. Power steering pump assembly 4. High pressure hose & pipe 7. Oil tank bracket
2. Bracket 5. Suction hose 8. To P / S gear box
3. P / S fluid reservoir 6. Low pressure return hose
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3C-8 STEERING WHEEL AND COLUMN
4) Check steering column lower seal for breakage or deformation.
If found defective, replace.
1. Steering column lower seal
5) Check steering shaft joints and shaft for any damages such as
crack, breakage, malfunction or excessive play.
If anything is found faulty, replace as steering lower shaft assem-
bly or steering column assembly.
6) Check steering shaft for smooth rotation.
If found defective, replace as column assembly.
7) Check steering shaft and column for bend, cracks or deforma-
tion.
If found defective, replace as column assembly.
INSTALLATION
In engine room
CAUTION:
After tightening steering column mounting bolts, steering
shaft joint bolts should be tightened.
After tightening steering column lower bolts, steering col-
umn upper bolts should be tightened.
1) Be sure that front wheels and steering wheel are in straight-
ahead position.
In cabin
2) If equipped with shift (key) interlock cable, install shift (key) inter-
lock cable to ignition switch.
3) Install steering column assembly to dash panel and upper
bracket so that boss of steering column lower seal and all around
it project out of hole in dash panel into engine room. Tighten
steering column lower bolts (4 pieces) first and then upper bolts
(2 pieces) to specified torque.
1. Steering column Tightening Torque
2. Mounting bolt
3. Steering column lower seal (a): 23 N.m (2.3 kg-m, 17.0 lb-ft)
4. Dash panel
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AIR BAG STEERING WHEEL AND COLUMN 3C1-9
3) Connect all connectors that have been removed in removal.
4) Install steering column upper and lower cover, and then tighten
steering column cover screws.
CAUTION:
When installing lower cover and upper cover, be careful
so that contact coil and combination switch lead wire is