Suzuki Engine 2002 GRAND VITARA SQ625 User Manual

Important
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.
The circle with a slash in this manual means “Don’t do this” or “Don’t let this happen”.
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.

Suzuki Engine 2002 GRAND VITARA SQ625 Specifications

General

Brand	Suzuki
Model	Engine 2002 GRAND VITARA SQ625
Category	Engine
Language	English

Summary

Important Safety and Usage Notes

Service Manual Intent and Qualifications

Highlights that the service manual is for authorized dealers and qualified mechanics only, emphasizing risks of improper repair.

Air Bag System Service Precautions

Stresses that air bag system service must be performed by authorized dealers due to severe injury risks from unintentional activation.

Section 6: Engine General Information and Diagnosis

Engine General Information and Diagnosis (G16/J20 Engines)

Provides general information and diagnostic procedures for G16 and J20 engines.

Engine Mechanical (G16 Engine)

Details mechanical aspects of the G16 engine.

Engine Mechanical (J20 Engine)

Details mechanical aspects of the J20 engine.

Engine Cooling System

Covers the engine cooling system, including components and procedures.

Engine Fuel System

Details the engine fuel system, including components and procedures.

Engine and Emission Control System (G16/J20 Engines)

Explains the engine and emission control systems for G16 and J20 engines.

Ignition System (G16 Engine)

Describes the ignition system for the G16 engine.

Ignition System (J20/H25 Engines)

Describes the ignition system for the J20 and H25 engines.

Cranking System

Covers the cranking system, including components and procedures.

Charging System

Details the charging system, including components and procedures.

Engine Diagnosis Procedures

Engine Diagnosis General Description

Provides an overview of the ECM's role in controlling engine and emission systems and diagnosing troubles.

On-Board Diagnostic System (Vehicle without Diagnosis Connector)

Freeze Frame Data

Priority of Freeze Frame Data Storage

Data Link Connector (DLC) Information

DLC Pin Assignment and Usage

Troubleshooting Precautions

ECM (PCM) Replacement or Substitution

Provides checks to perform before substituting a known-good ECM to prevent damage.

Engine Diagnostic Flow Table

Step 1: Customer Complaint Analysis

Step 2: DTC and Freeze Frame Data Check

Explains checking, recording, and clearing DTCs and freeze frame data.

Step 3 and 4: Visual Inspection

Step 5: Trouble Symptom Confirmation

Step 6 and 7: DTC/Freeze Frame Data Recheck

Engine Mechanical (G16 Engine)

Engine Mechanical (H25 Engine)

Engine Mechanical (J20 Engine)

Engine Lubrication System

Unit Repair Overhaul: Engine Assembly

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

General Description of Engine and Emission Control System

Fuel Delivery System Description

Electronic Control System Description

Diagnosis Procedures

Outlines diagnostic procedures including DTC checks and tables.

On-Vehicle Service Procedures

Details various on-vehicle service checks for engine and emission control systems.

Section 6F1: Ignition System (For G16 Engine)

General Description of Ignition System

Describes the distributorless ignition system, its components, and operation.

Ignition System Wiring

Ignition Diagnosis

Covers possible causes of ignition system failures and diagnostic flow tables.

On-Vehicle Service: Ignition Spark Check

On-Vehicle Service: Ignition Timing Check and Adjustment

Ignition Coil Assembly (Igniter and Ignition Coil)

Provides removal, inspection, and installation procedures for the ignition coil assembly.

Spark Plug

CMP Sensor

Section 6G: Cranking System

Starting Motor

Diagnosis: Starting System

Covers possible symptoms and causes of starting system troubles.

Unit Repair Overhaul: Dismounting and Remounting

Inspection: Magnetic Switch

Section 6H: Charging System

Battery Care

Generator

Diagnosis: Battery

Covers common causes of battery failure and visual inspection.

Diagnosis: Generator

Details faulty indication lamp operation and common generator issues.