Suzuki Engine 2002 GRAND VITARA SQ420 Service manual

Table of Contents

• 6. Table of Contents
• 8. ENGINE GENERAL INFORMATION AND DIAGNOSIS...
• 11. EXHAUST SYSTEM
• 12. BRAKES
• 13. Engine Diagnosis
• 17. On-Board Diagnostic System (Vehicle with...
• 18. Precaution in Diagnosing Trouble
• 19. Engine Diagnostic Flow Table
• 22. Customer Problem Inspection Form (Exampl...
• 23. Malfunction Indicator Lamp (MIL) Check
• 25. Diagnostic Trouble Code (DTC) Clearance
• 26. Fail-Safe Table
• 27. Diagnostic Trouble Code (DTC) Table
• 31. Scan Tool Data
• 34. Scan Tool Data Definitions
• 38. Visual Inspection
• 39. Engine Basic Check
• 40. Engine Diagnosis Table
• 47. Inspection of PCM (ECM) and Its Circuits
• 48. Ignition Switch On
• 61. Or Dims at Ignition Switch On (But Engin...
• 62. Circuit Check – MIL Remains "ON After En...
• 63. Connector)
• 64. Switch On and Engine Doesn't Start Thoug...
• 66. DTC P0100 (DTC No.33, 34) Mass Air Flow ...
• 68. DTC P0110 (DTC No.23, 25) Intake Air Tem...
• 70. DTC P0115 (DTC No.14, 15) Engine Coolant...
• 72. DTC P0120 (DTC No.21, 22) Throttle Posit...
• 74. DTC P0121 Throttle Position Range/Perfor...
• 76. DTC P0130 (DTC No.13) HO2S-1 Circuit Mal...
• 79. DTC P0133 HO2S-1 Circuit Slow Response
• 80. DTC P0134 HO2S-1 No Activity Detected
• 81. DTC P0135 HO2S-1 Heater Circuit Malfunct...
• 83. DTC P0136 HO2S-2 Circuit Malfunction
• 85. DTC P0141 HO2S-2 Heater Circuit Malfunct...
• 87. DTC P0171 Fuel System Too Lean DTC P0172...
• 89. DTC P0300 Random Misfire Detected
• 91. DTC P0325 (DTC No.43) Knock Sensor Circu...
• 93. DTC P0335 Crankshaft Position Sensor Cir...
• 96. DTC P0340 (DTC No.42) Camshaft Position ...
• 100. DTC P0400 Exhaust Gas Recirculation Flow...
• 103. DTC P0403 (DTC No.51) Exhaust Gas Recirc...
• 105. DTC P0420 Catalyst System Efficiency Bel...
• 107. DTC P0443 EVAP Control System Purge Cont...
• 108. EVAP canister purge system check
• 109. EVAP canister purge valve inspection
• 110. DTC P0460 Fuel Level Sensor Circuit High...
• 112. DTC P0500 (DTC No.24) Vehicle Speed Sens...
• 114. DTC P0505 Idle Air Control System Malfun...
• 117. DTC P0601 (DTC No.71) Internal Control M...
• 118. DTC P1408 Manifold Absolute Pressure Sen...
• 120. DTC P1450 Barometric Pressure Sensor Cir...
• 121. DTC P1500 Engine Starter Signal Circuit ...
• 122. DTC P1510 ECM Back-Up Power Supply Malfu...
• 123. Inspection
• 125. Inspection
• 133. Equipped)
• 139. Control System Inspection (Other than Ca...
• 142. ENGINE FUEL
• 153. On-Board Diagnostic System (Vehicle with...
• 154. Precaution in Diagnosing Trouble
• 155. Engine Diagnostic Flow Table
• 161. Malfunction Indicator Lamp (MIL) Check
• 163. Diagnostic Trouble Code (DTC) Clearance
• 164. Diagnostic Trouble Code (DTC) Table
• 168. Fail-Safe Table
• 169. Scan Tool Data
• 172. Scan Tool Data Definitions
• 176. Engine Diagnosis Table
• 182. ECM (PCM) Substitution
• 196. MIL does not come on or MIL dimms at ign...
• 198. MIL remains on after engine starts
• 200. MIL does not light at ignition switch ON...
• 202. DTC P0100 Mass Air Flow Sensor Circuit M...
• 204. DTC P0110 Intake Air Temp. Circuit Malfu...
• 206. DTC P0115 Engine Coolant Temp
• 208. DTC P0120 Throttle Position Circuit Malf...
• 210. DTC P0121 Throttle Position Circuit Perf...
• 212. DTC P0130 (Vehicle without Diagnosis Con...
• 215. DTC P0133 HO2S (Bank-1 Sensor-1) Circuit...
• 216. DTC P0134 (Vehicle without Diagnosis Con...
• 218. DTC P0135 HO2S (Bank-1 Sensor-1) Heater ...
• 220. DTC P0136 HO2S (Bank-1 Sensor-2) Circuit...
• 222. DTC P0141 HO2S (Bank-1 Sensor-2) Heater ...
• 224. DTC P0150 (Vehicle without Diagnosis Con...
• 227. DTC P0153 HO2S (Bank-2 Sensor-1) Circuit...
• 228. DTC P0154
• 230. DTC P0155 HO2S (Bank-2 Sensor-1) Heater ...
• 232. DTC P0156 HO2S (Bank-2 Sensor-2) Circuit...
• 234. DTC P0161 HO2S (Bank-2 Sensor-2) Heater ...
• 236. DTC P0171 Fuel System Too Lean (Bank-1) ...
• 238. DTC P0174 Fuel System Too Lean (Bank-2) ...
• 240. DTC P0300 Random Misfire Detected
• 242. DTC P0325 (DTC No.43) Knock Sensor Circu...
• 244. DTC P0335 Crankshaft Position Sensor Cir...
• 246. DTC P0340 Camshaft Position Sensor Circu...
• 249. DTC P0400 Exhaust Gas Recirculation Flow...
• 252. DTC P0403 (DTC No.51) Exhaust Gas Recirc...
• 254. DTC P0420 Catalyst System (Bank-1) Effic...
• 257. DTC P0443 EVAP Control System Purge Cont...
• 259. EVAP canister purge valve and its circui...
• 261. EVAP canister purge system check
• 262. DTC P0460 Fuel Level Sensor Circuit High...
• 264. DTC P0500 Vehicle Speed Sensor Malfuncti...
• 267. DTC P0505 Idle Air Control System Malfun...
• 270. DTC P0601 Internal Control Module Memory...
• 271. DTC P1408 Manifold Absolute Pressure Sen...
• 273. DTC P1450 Barometric Pressure Sensor Cir...
• 275. DTC P1500 Engine Start Signal Circuit Ma...
• 290. Special Tool
• 292. ENGINE MECHANICAL (G16 ENGINE)
• 293. General Description
• 294. Engine Lubrication
• 295. On-Vehicle Service
• 296. Engine Vacuum Check
• 297. Oil Pressure Check
• 299. Valve Lash (Clearance)
• 300. Air Cleaner Element
• 301. Cylinder Head Cover
• 302. Throttle Body and Intake Manifold
• 305. Exhaust Manifold
• 307. Timing Belt and Belt Tensioner
• 312. Oil Pan and Oil Pump Strainer
• 316. Oil Pump
• 322. Rocker Arms, Rocker Arm Shaft and Camsha...
• 332. Valves and Cylinder Head
• 344. Piston, Piston Rings, Connecting Rods an...
• 354. Unit Repair Overhaul
• 360. Main Bearings, Crankshaft and Cylinder B...
• 373. Special Tool
• 374. Required Service Material
• 375. Tightening Torque Specifications
• 377. General Description
• 378. Engine Lubrication
• 379. On-Vehicle Service
• 380. Engine Vacuum Check
• 381. Oil Pressure Check
• 382. Air Cleaner Element
• 384. Throttle Body and Intake Manifold
• 391. Exhaust Manifold
• 395. Cylinder Head Covers
• 397. Oil Pan and Oil Pump Strainer
• 401. Timing Chain Cover
• 405. Oil Pump
• 409. LH (No.1) Bank 2nd Timing Chain and Chai...
• 415. 1st Timing Chain and Chain Tensioner
• 423. RH (No.2) Bank 2nd Timing Chain and Chai...
• 428. Oil Pump Chain
• 432. Camshaft and Valve Lash Adjuster
• 440. Valve Lash Adjuster Noise Diagnosis
• 441. Valves and Cylinder Heads
• 454. Piston, Piston Rings, Connecting Rods an...
• 467. Unit Repair Overhaul
• 472. Main Bearings, Crankshaft and Cylinder B...
• 485. Special Tool
• 487. Required Service Material
• 490. ENGINE MECHANICAL (J20 ENGINE)
• 491. General Description
• 492. Engine Lubrication
• 493. On-Vehicle Service
• 495. Engine Vacuum Check
• 496. Oil Pressure Check
• 497. Air Cleaner Element
• 498. Throttle Body and Intake Manifold
• 501. Exhaust Manifold
• 504. Cylinder Head Cover
• 505. Oil Pan and Oil Pump Strainer
• 509. Oil Pump
• 513. Timing Chain Cover
• 518. 2nd Timing Chain and Chain Tensioner
• 524. 1st Timing Chain and Chain Tensioner
• 530. Camshafts and Valve Lash Adjusters
• 539. Valves and Cylinder Head
• 552. Pistons, Piston Rings, Connecting Rods a...
• 566. Engine Mountings
• 567. Unit Repair Overhaul
• 572. Main Bearings, Crankshaft and Cylinder B...
• 587. Special Tool
• 589. Required Service Material
• 593. General Description
• 594. Cooling System Component
• 595. For J20 engine model
• 596. For H25 engine model
• 597. Cooling System Circulation
• 599. Thermostat
• 600. Cooling Fan Clutch
• 602. Diagnosis
• 603. Maintenance
• 604. Cooling System Service
• 605. Cooling System Flush and Refill
• 606. Cooling Fan Belt Tension Check and Adjus...
• 608. On-Vehicle Service
• 611. Thermostat
• 613. Cooling Fan Belt
• 614. Cooling Fan and Fan Clutch
• 615. Radiator
• 617. Water Pump
• 622. Engine Coolant Temperature (ECT) Sensor
• 624. Fuel system
• 625. Diagnosis
• 626. Fuel Pump
• 627. Fuel Lines
• 628. Fuel Filler Cap
• 631. Tightening Torque Specification
• 632. ENGINE AND EMISSION CONTROL SYSTEM (G16/...
• 634. General Description
• 639. Air Intake System Description
• 641. Fuel Delivery System Description
• 642. Electronic Control System Description
• 654. Diagnosis
• 656. Accelerator Cable Adjustment
• 657. Idle Speed/Idle Air Control (IAC) Duty I...
• 658. Idle mixture inspection/adjustment (vehi...
• 659. Air Intake System
• 661. Idle air control valve (IAC valve)
• 662. Fuel Delivery System
• 664. Fuel pump
• 665. Fuel pressure regulator
• 666. Fuel injector
• 670. Electronic Control System
• 671. Mass air flow sensor (MAF sensor)
• 672. Intake air temperature (IAT) sensor
• 674. Throttle position sensor (TP sensor)
• 675. Engine coolant temperature sensor (ECT s...
• 676. Heated oxygen sensor-1 and -2 (HO2S-1 an...
• 678. Vehicle speed sensor (VSS)
• 679. Crankshaft position sensor (G16 engine)
• 680. Crankshaft position sensor (J20 engine)
• 682. Fuel level sensor (Sender gauge)
• 683. Main relay
• 685. Fuel pump relay
• 686. A/C compressor relay and condenser fan m...
• 687. Fuel cut operation
• 689. Evaporative emission control system
• 691. PCV system
• 696. General Description
• 699. Air Intake System Description
• 700. Fuel Delivery System Description
• 701. Electronic Control System Description
• 703. Engine and Emission Control System Flow ...
• 708. Diagnosis
• 709. On-Vehicle Service
• 710. Accelerator Cable Adjustment
• 711. A/T Throttle Cable Adjustment
• 714. Idle mixture inspection/adjustment
• 715. Air Intake System
• 718. Idle air control valve (IAC valve)
• 719. Fuel Delivery System
• 721. Fuel pump
• 722. Fuel pressure regulator
• 723. Fuel injector
• 727. Electronic Control System
• 728. Mass air flow sensor (MAF sensor)
• 729. Intake air temperature (IAT) sensor
• 730. Throttle position sensor (TP sensor)
• 732. Engine coolant temperature sensor
• 733. Heated oxygen sensor (sensor 1)
• 734. Heated oxygen sensor (sensor 2)
• 735. Vehicle speed sensor (VSS)
• 736. Crankshaft position sensor
• 737. Main relay
• 738. Fuel pump relay
• 739. Fuel cut operation
• 741. Evaporative emission control system
• 745. General Description
• 746. System Wiring
• 747. Components
• 748. Diagnosis
• 750. On-Vehicle Service
• 753. High-Tension Cord
• 754. Ignition Coil Assembly (Igniter and Igni...
• 755. Spark Plug
• 757. Ignition Timing Adjusting Resistor (If E...
• 758. Noise Suppressor
• 759. Tightening Torque Specification
• 761. General Description
• 762. System Wiring
• 763. Components
• 764. Diagnosis
• 766. On-Vehicle Service
• 769. Ignition Coil Assembly (Igniter and Igni...
• 770. Spark Plug
• 771. CMP Sensor
• 773. Noise Suppressor
• 775. Tightening Torque Specification
• 777. General Description
• 778. Starting Motor
• 779. Diagnosis
• 781. Unit Repair Overhaul
• 784. Reassembly
• 786. Inspection
• 790. Performance Test
• 792. Specifications
• 793. Required Service Material
• 794. Charging system
• 795. General Description
• 796. Built-in indicator (If equipped)
• 797. Care of battery
• 798. Generator
• 800. Diagnosis
• 801. Hydrometer test
• 802. Generator
• 803. Undercharged battery
• 805. Overcharged battery
• 806. On-Vehicle Service
• 807. Dismounting
• 809. Unit Repair Overhaul
• 810. Remounting
• 811. Disassembly [60 A type]
• 814. Disassembly [70 A and 80 A types]
• 817. Inspection [60 A type]
• 819. Inspection [70 A and 80 A types]
• 821. Replace brush
• 822. Reassembly [60 A type]
• 823. Reassembly [70 A and 80 A types]
• 826. Specifications
• 829. General Description
• 831. Maintenance
• 832. On-Vehicle Service