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- 2000 Grand Vitara SQ416
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Suzuki 2000 Grand Vitara SQ416 Service Manual
YH4
GRAND
vol.2
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 De-
scription” in air bag system section in order
to confirm whether you are performing ser-
vice on or near the air bag system compo-
nents or wiring. Please observe all WARN-
INGS 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. Fail-
ure 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 recom-
mends that the air bag system be repaired
first, to help avoid unintended air bag sys-
tem activation.
Do not modify the steering wheel, instru-
ment panel or any other air bag system com-
ponent (on or around air bag system compo-
nents or wiring). Modifications can adverse-
ly affect air bag system performance and
lead to injury.
If the vehicle will be exposed to tempera-
tures over 93 C (200 F) (for example, during
a paint baking process), remove the air bag
system components (air bag (inflator) mod-
ule, sensing and diagnostic module (SDM),
seat belt pretensioner (if equipped) before-
hand to avoid component damage or unin-
tended activation.
IMPORTANT
WARNING/CAUTION /NOTE
Please read this manual and follow its instructions
carefully. To emphasize special information, the
words WARNING, CAUTION and NOTE have spe-
cial meanings. Pay special attention to the messages
highlighted by these signal words.
NOTE:
Indicates special information to make mainte-
nance easier or instructions clearer.
WARNING:
Indicates a potential hazard that could result
in death or injury.
CAUTION:
Indicates a potential hazard that could result
in vehicle damage.
WARNING:
This service manual is intended for authorized
SUZUKI dealers and qualified service me-
chanics only. Inexperienced mechanics or
mechanics without the proper tools and
equipment may not be able to properly per-
form the services described in this manual.
Improper repair may result in injury to the me-
chanic and may render the vehicle unsafe for
the driver and passengers.
Summary of 2000 Grand Vitara SQ416
Page 1
Yh4 grand vol.2 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 de- scripti...
Page 2: Foreword
Yh4 grand vol.2 () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x () x foreword this manual (volumes 1 and 2) contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (service) an...
Page 3: Related Manual
Yh4 grand vol.2 related manual manual name manual no. Applicability sq416 / sq420 / sq625 unit repair manual 99501-65d01-xxx transmission, transfer and differentials (front and rear) of sq series. Sq416 / sq420 / sq625 wiring diagram manual 99512-65d10-015 applicable model mentioned in foreword of t...
Page 4
Yh4 grand vol.2 0a 0b 1a 1b 3 3a 3b1 3c 3c1 3d 3e 3f 4a2 4b 5 6 7a 5a 5b 5c 5e1 6a1 6a2 6a4 6b 6c 6e1 6e2 6f1 6f2 6g 6g1 6h 6k 7a1 7b1 7c1 7d 7e 7f 8 8b 8c 8d 8g 9 10 10a 8a 10b 6-1 engine general information and diagnosis (g16 / j20) general information and diagnosis (h25) engine mechanical (g16) e...
Page 5: Section 6
Yh4 grand vitara 6 engine general information and diagnosis (g16 / j20 engines) 6-1 section 6 engine general information and diagnosis (g16/j20 engines) warning: for vehicles equipped with supplemental restraint (air bag) system: service on and around the air bag system components or wiring must be ...
Page 6
Yh4 grand vitara 6-2 engine general information and diagnosis (g16 / j20 engines) general information 6- 3 . . . . . . . . . . . . . . Engine diagnosis 6- 6 . . . . . . . . . . . . . . . . . . . General description 6- 6 . . . . . . . . . . . . . . . . . . . . On-board diagnostic system 6- 6 . . . . ...
Page 7: General Information
Yh4 grand vitara 1 2 3 4 1. No.1 cylinder 2. No.2 cylinder 3. No.3 cylinder 4. No.4 cylinder g16 j20 engine general information (g16 / j20 engines) 6-3 general information statement of cleanliness and care an automobile engine is a combination of many machined, honed, polished and lapped surfaces wi...
Page 8
Yh4 grand vitara 6-4 engine general information (g16 / j20 engines) precaution on fuel system service work must be done with no smoking, in a well-ventilated area and away from any open flames. As fuel feed line (between fuel pump and fuel pressure regulator) is still under high fuel pressure even a...
Page 9
Yh4 grand vitara 1. Fuel pump relay 2. Fuse box left hand steering vehicle right hand steering vehicle 1. Fuel pump relay 2. Junction (fuse) box left hand steering vehicle right hand steering vehicle [canvas top model] engine general information (g16 / j20 engines) 6-5 fuel pressure relief procedure...
Page 10: Engine Diagnosis
Yh4 grand vitara 2 3 1. Malfunction indicator lamp (mil) 2. Data link connector (dlc) 3. Suzuki scan tool (tech 1) or 6-6 engine diagnosis (g16 / j20 engines) engine diagnosis general description this vehicle is equipped with an engine and emission control system which are under control of ecm (pcm)...
Page 11
Yh4 grand vitara (1st) 1st, 2nd or 3rd in parentheses here represents which position in the order the malfunction is detected. Engine diagnosis (g16 / j20 engines) 6-7 warm-up cycle a “warm-up cycle” means sufficient vehicle operation such that the coolant temperature has risen by at least 22 _ c (4...
Page 12
Yh4 grand vitara body ground ecm (pcm) ground k line of iso 9141 suzuki serial data line 6-8 engine diagnosis (g16 / j20 engines) frame malfunction detected order frame 1 frame 2 frame 3 frame 4 1 2 3 4 freeze frame data to be updated 1st freeze frame data 2nd freeze frame data 3rd freeze frame data...
Page 13
Yh4 grand vitara or engine diagnosis (g16 / j20 engines) 6-9 on-board diagnostic system (vehicle without monitor connector) ecm diagnosis troubles which may occur in the area including the following parts when the ignition switch is on and the engine is run- ning, and indicates the result by turning...
Page 14
Yh4 grand vitara 6-10 engine diagnosis (g16 / j20 engines) body ground ecm (pcm) ground k line of iso 9141 suzuki serial data line data link connector (dlc) dlc is in compliance with saej1962 in its installation position, the shape of connector and pin assignment. K line of iso 9141 is used for suzu...
Page 15
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-11 precaution in diagnosing trouble don’t disconnect couplers from ecm (pcm), battery cable from battery, ecm (pcm) ground wire harness from engine or main fuse before confirming diagnostic information (dtc, freeze frame data, etc.) stored in e...
Page 16
Yh4 grand vitara 6-12 engine diagnosis (g16 / j20 engines) engine diagnostic flow table refer to the following pages for the details of each step. Step action yes no 1 customer complaint analysis 1) perform customer complaint analysis. Was customer complaint analysis performed? Go to step 2. Perform...
Page 17
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-13 1. Customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required...
Page 18
Yh4 grand vitara 6-14 engine diagnosis (g16 / j20 engines) customer problem inspection form (example) user name: model: vin: date of issue: date reg. Date of problem: mileage: problem symptoms v difficult starting v poor driveability v no cranking v no initial combustion v poor starting at ( v cold/...
Page 19
Yh4 grand vitara or engine diagnosis (g16 / j20 engines) 6-15 malfunction indicator lamp (mil) check 1) turn on ignition switch (but the engine at stop) and check that mil lights. If mil does not light up or dims, go to “diagnostic flow table a-1” for troubleshooting. If mil flushes, go to “diagnost...
Page 20
Yh4 grand vitara 6-16 engine diagnosis (g16 / j20 engines) diagnostic trouble code (dtc) clearance [using scan tool] 1) connect generic scan tool or suzuki scan tool (tech-1) to data link connector in the same manner as when making this connec- tion for dtc check. 2) turn ignition switch off and the...
Page 21
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-17 fail-safe table when any of the following dtcs is detected, ecm (pcm) enters fail-safe mode as long as malfunction continues to exist but that mode is canceled when ecm detects normal condition after that. Dtc no. Trouble area fail safe oper...
Page 22
Yh4 grand vitara 6-18 engine diagnosis (g16 / j20 engines) diagnostic trouble code (dtc) table dtc no. Detecting item detecting condition (dtc will set when detecting:) mil (vehicle without monitor connec- tor) mil (vehicle with monitor connec- tor) p0100 (no.34) mass air flow circuit sensor output ...
Page 23
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-19 dtc no. Detecting item detecting condition (dtc will set when detecting:) mil (vehicle with egr valve) mil (vehicle without egr valve) p0300 p0301 p0302 p0303 random misfire detected cylinder 1 misfire detected cylinder 2 misfire detected cy...
Page 24
Yh4 grand vitara 6-20 engine diagnosis (g16 / j20 engines) dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0705 (no.72) transmission range switch circuit malfunction p0715 (no.76) input/ turbine speed sensor circuit malfunction p0720 (no.75) output speed sensor circuit...
Page 25
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-21 +63 _ f –9 _ f scan tool data as the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in g...
Page 26
Yh4 grand vitara 6-22 engine diagnosis (g16 / j20 engines) scan tool data condition normal condition/ reference value other oxygen sensor b1 s1 (ho2s-1 output voltage) at specified idle speed after warming up. 0.01 – 0.95 v oxygen sensor b1 s2 (ho2s-2 output voltage) when engine is running at 2000 r...
Page 27
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-23 scan tool data condition normal condition/ reference value other vss (for 4-a/t) (vehicle speed sensor) at stop. 0 km/h 0 mph : gear position (for 4-a / t) ignition switch on, selector lever is shifted at “r”, “d”, “2” or “l” range and vehic...
Page 28
Yh4 grand vitara 6-24 engine diagnosis (g16 / j20 engines) coolant temp (engine coolant temp., _ c/ _ f) it is detected by engine coolant temp. Sensor. Intake air temp ( _ c/ _ f) it is detected by intake air temp. Sensor. Desire idle (desired idle speed rpm) the desired idle speed is an ecm interna...
Page 29
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-25 total fuel trim (%) the value of total fuel trim is obtained by putting val- ues of short term fuel trim and long term fuel trim to- gether. This value indicates how much correction is necessary to keep the air/fuel mixture stoichiomet- rica...
Page 30
Yh4 grand vitara 6-26 engine diagnosis (g16 / j20 engines) vss (4-a / t) (km/h, mph) it is computed by using pulse signals from vehicle (output) speed sensor on 4-speed automatic trans- mission. Gear position (1st, 2nd, 3rd or 4th) the gear position is determined on the basis of the command state si...
Page 31
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-27 operation visual inspection visually check following parts and systems. Inspection item referring section engine oil – – – – – level, leakage engine coolant – – – – – level, leakage fuel – – – – – level, leakage a / t fluid – – – – – level, ...
Page 32
Yh4 grand vitara 6-28 engine diagnosis (g16 / j20 engines) engine basic check this check is very important for troubleshooting when ecm (pcm) has detected no dtc and no abnormality has been found in visual inspection. Follow the flow table carefully. Step action yes no 1 was “engine diag. Flow table...
Page 33
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-29 engine diagnosis table perform troubleshooting referring to following table when ecm (pcm) has detected no dtc and no abnormality has been found in visual inspection and engine basic inspection previously. Condition possible cause reference ...
Page 34
Yh4 grand vitara 6-30 engine diagnosis (g16 / j20 engines) condition possible cause reference item improper engine idling or engine fails to idle ignition system out of order. Faulty spark plug faulty ignition coil with ignitor fuel system out of order. Fuel pressure out of specification engine over...
Page 35
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-31 condition possible cause reference item surges (engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and down with no change in the accelerator pedal.) ignition system out of order. Defective spark plug (e...
Page 36
Yh4 grand vitara 6-32 engine diagnosis (g16 / j20 engines) condition possible cause reference item overheating inoperative thermostat poor water pump performance clogged or leaky radiator improper engine oil grade clogged oil filter or oil strainer poor oil pump performance dragging brakes slipping ...
Page 37
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-33 condition possible cause reference item low oil pressure improper oil viscosity malfunctioning oil pressure switch clogged oil strainer functional deterioration of oil pump worn oil pump relief valve excessive clearance in various sliding pa...
Page 38
Yh4 grand vitara 1. Pcm (ecm) 2. Pcm (ecm) connector (viewed from harness side) 6-34 engine diagnosis (g16 / j20 engines) inspection of pcm (ecm) and its circuits pcm (ecm) and its circuits can be checked at pcm (ecm) wiring couplers by measuring voltage and resistance. Caution: pcm / ecm cannot be ...
Page 39
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-35 e61 terminal circuit normal voltage condition 1 power source for co adjusting resistor (if equipped) 4.75 – 5.25 v ignition switch on 2 power source for back up 10 – 14 v ignition switch on and off 3 heater of ho2s 2 (if equipped) 10 – 14 v ...
Page 40
Yh4 grand vitara 6-36 engine diagnosis (g16 / j20 engines) c51-3 e61 terminal circuit normal voltage condition 25 ——— —— ——— 26 heated oxygen sensor-2 (if equipped) 0.01 – 0.95 v while engine running at 2000 r / min. For 3 min. Or longer after warming up. 27 ——— —— ——— 28 fuel level sensor 0 – 6 v i...
Page 41
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-37 c51-1 (a/t) c51-3 terminal circuit normal voltage condition 12 ground for ho2s-1 shield wire —— ——— 13 power source for tp sensor 4 75 5 25 v ignition switch on 14 power source for map sensor 4.75 – 5.25 v ignition switch on 15 power source ...
Page 42
Yh4 grand vitara 6-38 engine diagnosis (g16 / j20 engines) c51-2 c51-1 (a/t) terminal circuit normal voltage condition 22 a / t output speed sensor (–) about 2.5 v ignition switch on 23 a / t output speed sensor (+) about 2.5 v ignition switch on 24-25 ——— —— ——— 26 4wd low switch 0 – 1 v ignition s...
Page 43
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-39 c51-2 terminal circuit normal voltage condition 25 vehicle speed sensor deflects between 0 – 1 v and over 4 v ignition switch on, rear right tire turned slowly with rear left tire locked 26 camshaft position sensor (+) deflects between 0 – 1...
Page 44
Yh4 grand vitara 6-40 engine diagnosis (g16 / j20 engines) 1. Ecm / pcm coupler disconnected 2. Ohmmeter resistance check 1) disconnect couplers from ecm / pcm with ignition switch off. Caution: never touch terminals of ecm / pcm itself or connect voltmeter or ohmmeter. 2) check resistance between e...
Page 45
Yh4 grand vitara 1. Ecm (pcm) 2. To ignition switch 3. Main fuse 4. Main relay 5. Monitor connector (if equipped) engine diagnosis (g16 / j20 engines) 6-41 table a-1 malfunction indicator lamp circuit check – mil does not come “on” or dims at ignition switch on (but engine at stop) wiring diagram ci...
Page 46
Yh4 grand vitara 6-42 engine diagnosis (g16 / j20 engines) table a-2 malfunction indicator lamp circuit check – mil remains “on” after engine starts wiring diagram / circuit description refer to table a-1. Inspection step action yes no 1 dtc check: 1) with ignition switch off, install scan tool. 2) ...
Page 47
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-43 c51-3-6 c51-3-4 c51-3-15 c51-3-17 c51-3-20 c51-2-28 1. To ignition switch 2. Main fuse 3. Main relay table a-5 ecm (pcm) power and ground circuit check – mil doesn’t light at ignition switch on and engine doesn’t start though it is cranked u...
Page 48
Yh4 grand vitara 6-44 engine diagnosis (g16 / j20 engines) table a-5 inspection step action yes no 1 main relay operating sound check: is operating sound of main relay heard at ignition switch on? Go to step 5. Go to step 2. 2 fuse check: is main “fi” fuse in good condition? Go to step 3. Check for ...
Page 49
Yh4 grand vitara 1. Main fuse 2. Main relay 3. Mass air flow sensor engine diagnosis (g16 / j20 engines) 6-45 dtc p0100 (dtc no.33, 34) mass air flow circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area following conditions are detected for...
Page 50
Yh4 grand vitara 6-46 engine diagnosis (g16 / j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 maf sensor check: 1) connect scan tool to dlc with ignition switch off. 2) start engine and check maf value displa...
Page 51
Yh4 grand vitara 1. Iat sensor engine diagnosis (g16 / j20 engines) 6-47 dtc p0110 (dtc no.23, 25) intake air temp. (iat) circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area following conditions are detected. D engine running d high intake...
Page 52
Yh4 grand vitara 6-48 engine diagnosis (g16 / j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check iat sensor and its circuit. 1) connect scan tool with ignition switch off. 2) turn ignition switch on. 3) ch...
Page 53
Yh4 grand vitara 1. Ect sensor 2. To combination (ect) meter engine diagnosis (g16 / j20 engines) 6-49 dtc p0115 (dtc no.14,15) engine coolant temp. Sensor circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area following conditions are detect...
Page 54
Yh4 grand vitara 6-50 engine diagnosis (g16 / j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check ect sensor and its circuit. 1) connect scan tool with ignition switch off. 2) turn ignition switch on. 3) ch...
Page 55
Yh4 grand vitara c51-3-13 1. Throttle position sensor engine diagnosis (g16 / j20 engines) 6-51 dtc p0120 (dtc no.21, 22) throttle position circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area following conditions are detected for 5 sec. Co...
Page 56
Yh4 grand vitara 6-52 engine diagnosis (g16 / j20 engines) troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check tp sensor and its circuit. 1) connect scan tool to dlc with ignition switch off and then turn ignition switc...
Page 57
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-53 dtc p0121 throttle position range/performance probrem wiring diagram refer to previous page (dtc p0120). Dtc detecting condition and trouble area dtc detecting condition trouble area throttle opening change is smaller than specification whil...
Page 58
Yh4 grand vitara 6-54 engine diagnosis (g16 / j20 engines) at idle position fully open throttle opening 3.4 – 4.7 v 0.5 – 1.2 v 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and clear dtc, pending dtc and freeze frame data by using scan tool and start en- gine. 3) ...
Page 59
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-55 1. To ignition switch 2. Ho2s-1 3. Fuse box dtc p0130 (dtc no.13) ho2s-1 circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area following conditions are detected in idle state while r...
Page 60
Yh4 grand vitara 6-56 engine diagnosis (g16 / j20 engines) dtc confirmation procedure warning: d when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D road test should be car...
Page 61
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-57 normal 0.6 v 0.3 v ng ng ng troubleshooting (dtc p0130) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ho2s-1 output voltage check: 1) connect scan tool to dlc with ignition swi...
Page 62
Yh4 grand vitara 6-58 engine diagnosis (g16 / j20 engines) dtc p0133 ho2s-1 circuit slow response wiring diagram refer to page (dtc p0130). Dtc detecting condition and trouble area dtc detecting condition trouble area following conditions are detected in idle state while running under driving condit...
Page 63
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-59 dtc p0134 ho2s-1 no activity detected wiring diagram refer to page (dtc p0130). Dtc detecting condition and trouble area dtc detecting condition trouble area following conditions are detected in vehicle running state while running under driv...
Page 64
Yh4 grand vitara 6-60 engine diagnosis (g16 / j20 engines) dtc p0135 ho2s-1 heater circuit malfunction wiring diagram refer to dtc p0130 section. Dtc detecting condition and trouble area dtc detecting condition trouble area following condition is detected when ho2s heater is electrically live. D cur...
Page 65
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-61 troubleshooting (dtc p0135) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ho2s-1 heater check: 1) disconnect ho2s-1 coupler with ignition switch off. 2) check resistance betwee...
Page 66
Yh4 grand vitara 6-62 engine diagnosis (g16 / j20 engines) 1. To ignition switch dtc p0136 ho2s-2 circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area dtc will set when any one of following conditions is detected. 4.5 v or more ho2s circuit...
Page 67
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-63 dtc confirmation procedure warning: d when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D road test should be car...
Page 68
Yh4 grand vitara 6-64 engine diagnosis (g16 / j20 engines) dtc p0141 ho2s-2 heater circuit malfunction wiring diagram refer to dtc p0136 section. Dtc detecting condition and trouble area dtc detecting condition trouble area following condition is detected when ho2s-2 heater operates. D current of ho...
Page 69
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-65 troubleshooting (dtc p0141) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ho2s-2 heater check: 1) disconnect ho2s-2 coupler with ignition switch off. 2) check resistance betwee...
Page 70
Yh4 grand vitara 6-66 engine diagnosis (g16 / j20 engines) dtc p0171 fuel system too lean dtc p0172 fuel system too rich system diagram refer to section 6e1. Dtc detecting condition and possible cause dtc detecting condition possible cause when running after engine warmed d short term fuel trim exce...
Page 71
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-67 troubleshooting (dtc p0171 / p0172) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag flow diag. Flow table”. 2 is there dtc(s) other than “dtc p0171 / p0172”? Go to applicable dtc flow table. Go ...
Page 72
Yh4 grand vitara 6-68 engine diagnosis (g16 / j20 engines) dtc p0300 dtc p0301, p0302, p0303, p0304 dtc p0300 random misfire detected dtc p0301 cylinder 1 misfire detected dtc p0302 cylinder 2 misfire detected dtc p0303 cylinder 3 misfire detected dtc p0304 cylinder 4 misfire detected system descrip...
Page 73
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-69 troubleshooting (dtc p0300/p0301/p0302/p0303/p0304) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ignition system inspection: 1) check spark plug and ignition spark of cylinder...
Page 74
Yh4 grand vitara 1. Knock sensor 6-70 engine diagnosis (g16 / j20 engines) dtc p0325 (dtc no.43) knock sensor circuit malfunction circuit description dtc detecting condition trouble area knock sensor output voltage: 3.98 v or more knock sensor output voltage: 0.90 v or less “b” circuit open or short...
Page 75
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-71 fig. 1 for step 3.
Page 76
Yh4 grand vitara 6-72 engine diagnosis (g16 / j20 engines) g16 engine j20 engine oscilloscope waveforms g16 engine j20 engine 2 v / div. Waveforms at specified idle speed 10 ms / div. 2 v / div. Waveforms at specified idle speed 10 ms / div. 1. Ckp sensor 2. Crankshaft timing belt pulley 3. Sensor p...
Page 77
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-73 dtc detecting condition and trouble area dtc detecting condition trouble area ckp sensor signal is not input while 20 pulses of cmp sensor signal are input after engine start. D ckp sensor circuit d ckp sensor d ecm (pcm) dtc confirmation pr...
Page 78
Yh4 grand vitara 6-74 engine diagnosis (g16 / j20 engines) g16 engine j20 engine g16 engine j20 engine starter motor sensor plate troubleshooting (dtc p0335) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ckp sensor and its circuit resi...
Page 79
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-75 g16 engine j20 engine oscilloscope waveforms g16 engine j20 engine 2 v / div. 2 v / div. Waveforms at specified idle speed waveforms at specified idle speed 20 ms / div. 20 ms / div. 1. Signal rotor on camshaft 2. Cmp sensor 3. To main relay...
Page 80
Yh4 grand vitara 6-76 engine diagnosis (g16 / j20 engines) dtc confirmation procedure note: check to make sure that the following conditions are satisfied when using this dtc confirmation pro- cedure. D intake air temp.: – 8 _ c, 18 _ f or higher d engine coolant temp.: – 8 – 110 _ c (18 – 230 _ f) ...
Page 81
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-77 troubleshooting (dtc p0340 / dtc no.42) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is engine cranked? Go to step 3. Go to “cranking system” section. 3 is there dtc p1500 (en...
Page 82
Yh4 grand vitara 6-78 engine diagnosis (g16 / j20 engines) 1 2 2 1 2 1 1 “v / r” 1. Cmp sensor 2. Rotor 1. Cmp sensor 2. Coupling 1. Cmp sensor coupler 1. Cmp sensor 2. Magnetic substance (iron) 1. Mirror 2. Signal rotor g16 j20 g16 j20 step action yes no 8 g16 engine: check signal rotor for the fol...
Page 83
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-79 1. Egr valve 2. Intake manifold 3. Exhaust gas 4. Sensed information 5. Main fuse 6. Main relay 7. Map sensor 8. Fuse box ecm (pcm) dtc p0400 exhaust gas recirculation flow malfunction system/ wiring diagram.
Page 84
Yh4 grand vitara 1) and 2) vehicle speed km / h (mph) 6-80 engine diagnosis (g16 / j20 engines) dtc detecting condition and trouble area dtc detecting condition trouble area during deceleration (engine speed high with closed throttle position) in which fuel cut is involved, difference in intake mani...
Page 85
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-81 troubleshooting (dtc p0400) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 is there dtc p0403 (egr circuit malfunction)? Go to dtc p0403 diag. Flow table. Go to step 3. 3 do you...
Page 86
Yh4 grand vitara 6-82 engine diagnosis (g16 / j20 engines) 1. Main fuse 2. Main relay 3. Egr valve 4. Fuse box dtc p0403 (dtc no.51) exhaust gas recirculation circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area low voltage is detected at e...
Page 87
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-83 20 – 24 at 20 _ c, 68 _ f infinity ( 8 ) troubleshooting (dtc p0403 / dtc no.51) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 egr valve check: 1) with ignition switch off, dis...
Page 88
Yh4 grand vitara 6-84 engine diagnosis (g16 / j20 engines) 1. Heated oxygen sensor-1 2. Heated oxygen sensor-2 3. Warm up three way catalytic converter (wu-twc, if equipped) 4. Three way catalytic converter dtc p0420 catalyst system efficiency below threshold system diagram circuit description exhau...
Page 89
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-85 dtc confirmation procedure warning: d when performing a road test, select a place where there is no traffic or possibility of a traffic accident and be very careful during testing to avoid occurrence of an accident. D road test should be car...
Page 90
Yh4 grand vitara 6-86 engine diagnosis (g16 / j20 engines) 1. Main relay 2. Main fuse 3. Evap canister purge valve 4. Fuse box dtc p0443 evap control system purge control valve circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area monitor si...
Page 91
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-87 troubleshooting (dtc p0443) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check evap canister purge system for operation referring to “evap canister purge system check”. Is che...
Page 92
Yh4 grand vitara 6-88 engine diagnosis (g16 / j20 engines) 1. Purge hose 1. Hose “a” 2. Hose “b” 3. Evap canister purge valve evap canister purge system check 1) warm up engine to normal operating temperature. 2) hoist vehicle so that all wheels rotate freely. 3) set m / t in “neutral” or a / t in “...
Page 93
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-89 1. Speedometer 2. To main relay 3. Vehicle speed sensor dtc p0500 (dtc no.24) vehicle speed sensor malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area vehicle speed signal not inputted alt...
Page 94
Yh4 grand vitara 6-90 engine diagnosis (g16 / j20 engines) troubleshooting (dtc p0500 / dtc no.24) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 does speedometer indicate vehicle speed? Faulty “bl / y” wire or poor c51-2-25 connection....
Page 95
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-91 1. Throttle body 2. Idle air control valve 3. Ecm (pcm) 4. Sensed information 5. Main fuse 6. Main relay 7. Fuse box dtc p0505 idle air control system malfunction system/ wiring diagram dtc detecting condition and trouble area dtc detecting ...
Page 96
Yh4 grand vitara 6-92 engine diagnosis (g16 / j20 engines) 1) connect scan tool to dlc with ignition switch off. 2) turn on ignition switch and clear dtc, pending dtc and freeze frame data by using scan tool and warm up engine completely. 3) run engine at idle speed for 1 min. 4) check dtc and pendi...
Page 97
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-93 dtc p0601 (dtc no.71) internal control module memory check sum error system description internal control module is installed in ecm (pcm). Dtc detecting condition and trouble area dtc detecting condition trouble area data write error or chec...
Page 98
Yh4 grand vitara 6-94 engine diagnosis (g16 / j20 engines) 1. Manifold absolute pressure sensor dtc p1408 manifold absolute pressure sensor circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area d while engine is running after being warmed up...
Page 99
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-95 troubleshooting (dtc p1408) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 map sensor signal check: 1) remove ecm (pcm) cover. 2) check voltage between c51-3-8 and c51-3-22 unde...
Page 100
Yh4 grand vitara 6-96 engine diagnosis (g16 / j20 engines) dtc p1450 barometric pressure sensor circuit malfunction dtc p1451 barometric pressure sensor performance problem system description barometric pressure sensor is installed in ecm (pcm). Dtc detecting condition and trouble area dtc detecting...
Page 101
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-97 1. Starting motor 2. Transmission range sensor (switch) 3. Engine start switch in ignition (main) switch dtc p1500 engine starter signal circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trou...
Page 102
Yh4 grand vitara 6-98 engine diagnosis (g16 / j20 engines) 1. Fuse box 2. Main fuse box 3. To dlc dtc p1510 ecm back-up power supply malfunction wiring diagram circuit description battery voltage is supplied to keep dtc memory, values that ecm has learned to control engine, etc. In ecm even when ign...
Page 103
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-99 1. Main relay 2. Fuel pump relay 3. Main fuse 4. To ignition switch 5. Fuel pump 6. Fuse box 1. Service wire left hand steering vehicle right hand steering vehicle left hand steering vehicle right hand steering vehicle table b-1 fuel pump ci...
Page 104
Yh4 grand vitara 6-100 engine diagnosis (g16 / j20 engines) 13 – 16 at 20 _ c, 68 _ f 1. Main relay 2. Injector no.1 3. Injector no.2 4. Injector no.3 5. Injector no.4 6. To ignition switch table b-2 fuel injectors and circuit inspection wiring diagram inspection step action yes no 1 check injector ...
Page 105
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-101 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. Fuel filter 5. Fuel pump (a): gauge (b): hose (c): attachment table b-3 fuel pressure inspection system diagram inspection note: before using following flow table, check to make sur...
Page 106
Yh4 grand vitara 6-102 engine diagnosis (g16 / j20 engines) step action yes no 8 with fuel pump operated and fuel return hose blocked by pinching it, is fuel pressure applied? Faulty fuel pressure regulator. Shortage of fuel or fuel pump or its circuit defective (refer to table b-1 “fuel pump circui...
Page 107
Yh4 grand vitara 1. Throttle body 2. Idle air control valve 3. Ecm (pcm) 4. Sensed information 5. Main relay engine diagnosis (g16 / j20 engines) 6-103 table b-4 idle air control system inspection wiring diagram inspection step action yes no 1 check engine idle speed and iac duty referring to “idle ...
Page 108
Yh4 grand vitara 6-104 engine diagnosis (g16 / j20 engines) step action yes no 4 was idle speed within specification in step 1? Check for following: – vacuum leaks – air inhaling – evap canister purge control system – accessory engine load – stuck of pcv valve – clog of idle air passage – maf sensor...
Page 109
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-105 a/c control module (amplifier) table b-5 a/c signal circuits inspection (if equipped) wiring diagram inspection step action yes no 1 check a / c signal circuit. 1) check voltage at terminal e61-17 with ignition switch on. A / c switch and /...
Page 110
Yh4 grand vitara 6-106 engine diagnosis (g16 / j20 engines) to ignition switch rear def fuse in j/b main fuse a/c fuse a/c condenser fan motor relay a/c condenser fan motor table b-6 a/c condenser fan motor relay control system inspection (if equipped) wiring diagram inspection warning: keep hands, ...
Page 111: Special Tools
Yh4 grand vitara engine diagnosis (g16 / j20 engines) 6-107 1. Pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. Attachment 09919-46010 4. Checking tool set 09912-58421 4-1. Tool body & washer 4-2. Body plug 4-3. Body attachment 4-4. Holder 4-5. Return hose & clamp 4-6. Body attachment-2 & ...
Page 112: Section 6-1
Yh4 grand vitara 6-1 engine general information and diagnosis (h25 engine) 6-1-1 general information 6-1- 4 . . . . . . . . . . . . . . Statement of cleanliness and care 6-1- 4 . . . . . General information on engine service 6-1- 5 . . Precaution on fuel system service 6-1- 6 . . . Section 6-1 engin...
Page 113
Yh4 grand vitara fuel pressure relief procedure 6-1- 7 . . . . . . Fuel leakage check procedure 6-1- 8 . . . . . . Engine diagnosis 6-1- 9 . . . . . . . . . . . . . . . . . . . General description 6-1- 9 . . . . . . . . . . . . . . . . . . . On-board diagnostic system (vehicle without monitor connec...
Page 114
Yh4 grand vitara engine general information and diagnosis (h25 engine) 6-1-3 dtc p1408 manifold absolute pressure sensor circuit malfunction 6-1-114 . . Dtc p1450 barometric pressure sensor circuit malfunction 6-1-116 . . . . . . . . . Dtc p1451 barometric pressure sensor performance problem 6-1-116...
Page 115: General Information
Yh4 grand vitara 6-1-4 engine (h25 engine) crank shaft pulley side 6 4 1. No.1 cylinder 2. No.2 cylinder 3. No.3 cylinder 4. No.4 cylinder 5. No.5 cylinder 6. No.6 cylinder 7. Lh (no.1) bank 8. Rh (no.2)bank h25 general information statement of cleanliness and care an automobile engine is a combinat...
Page 116
Yh4 grand vitara engine (h25 engine) 6-1-5 general information on engine service the following information on engine service should be noted carefully, as it is important in pre- venting damage, and in contributing to reliable en- gine performance. When raising or supporting engine for any reason, d...
Page 117
Yh4 grand vitara 6-1-6 engine (h25 engine) clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end. Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end. Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end. With short pipe, fit hose as far as it re...
Page 118
Yh4 grand vitara engine (h25 engine) 6-1-7 1. Fuel pump relay 2. Fuse box 1. Fuel pump relay 2. Fuse box left hand steering vehicle right hand steering vehicle fuel pressure relief procedure caution: this work must not be done when engine is hot. If done so, it may cause adverse effect to catalyst. ...
Page 119
Yh4 grand vitara 6-1-8 engine (h25 engine) fuel leakage check procedure after performing any service on fuel system, check to make sure that there are no fuel leakages as follows. 1) turn on ignition switch for 3 seconds (to operate fuel pump) and then turn it off. Repeat this (on and off) 3 or 4 ti...
Page 120: Engine Diagnosis
Yh4 grand vitara engine (h25 engine) 6-1-9 1 2 or engine diagnosis general description this vehicle is equipped with an engine and emission control system which are under control of ecm (pcm). The engine and emission control system in this vehicle are controlled by ecm (pcm). Ecm (pcm) has an on- bo...
Page 121
Yh4 grand vitara 6-1-10 engine (h25 engine) 1. Trouble code p0102 (1st) 2. Coolant temp. 80 _ c 3. Engine speed 750 rpm 4. Short ft b1 – 0.8 % 5. Short ft b2 – 0.1 % 6. Long ft b1 – 1.3 % 7. Long ft b2 – 1.5 % 8. Calc load 20.5 % 9. Fuel system b1 closed 10. Fuel system b2 closed 11. Map 30.6 kpa 12...
Page 122
Yh4 grand vitara engine (h25 engine) 6-1-11 suzuki serial data line body ground ecm ground serial data line (k line of iso 9141) frame mal- function detected order in the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the malfunction is detected. Thes...
Page 123
Yh4 grand vitara 6-1-12 engine (h25 engine) or on-board diagnostic system (vehicle with monitor connector) ecm diagnosis troubles which may occur in the area including the following parts when the ignition switch is on and the engine is run- ning, and indicates the result by turning on or flashing m...
Page 124
Yh4 grand vitara engine (h25 engine) 6-1-13 body ground ecm (pcm) ground k line of iso 9141 suzuki serial data line data link connector (dlc) dlc in compliance with sae j1962 in its installation position, the shape of connector and pin assignment. K line of iso 9141 is used for suzuki scan tool to c...
Page 125
Yh4 grand vitara 6-1-14 engine (h25 engine) precaution in diagnosing trouble don’t disconnect couplers from ecm (pcm), battery cable from battery, ecm (pcm) ground wire harness from engine or main fuse before confirming diagnostic information (dtc, freeze frame data, etc.) stored in ecm (pcm) memory...
Page 126
Yh4 grand vitara engine (h25 engine) 6-1-15 engine diagnostic flow table refer to following pages for the detail of each step. Step action yes no 1 customer complaint analysis 1) perform customer complaint analysis. Was customer complaint analysis performed? Go to step 2. Perform customer complaint ...
Page 127
Yh4 grand vitara 6-1-16 engine (h25 engine) 1. Customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form will facilitate collecting information to the point required for proper ana...
Page 128
Yh4 grand vitara engine (h25 engine) 6-1-17 2. Diagnostic trouble code (dtc) / freeze frame data check first, check dtc, referring to “diagnostic trouble code check” in this section. If dtc is indicated, re- cord dtc and freeze frame data. After that clear dtc referring to “diagnostic trouble code c...
Page 129
Yh4 grand vitara 6-1-18 engine (h25 engine) 5. Trouble symptom confirmation based on information obtained in step 1 “customer complaint analysis” and step 2 “dtc / freeze frame data check”, confirm trouble symptoms. Also, reconfirm dtc according to “dtc conformation procedure” described in each “dtc...
Page 130
Yh4 grand vitara engine (h25 engine) 6-1-19 9. Troubleshooting for dtc based on the dtc indicated in step 6 or 7 and referring to the applicable dtc diag. Flow table in this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, ecm (pcm) or other pa...
Page 131
Yh4 grand vitara 6-1-20 engine (h25 engine) or malfunction indicator lamp (mil) check 1) turn on ignition switch (but the engine at stop) and check that mil (1) lights. If mil does not light up, go to “diagnostic flow table a-1” for troubleshooting. 2) start engine and check that mil turns off. If m...
Page 132
Yh4 grand vitara engine (h25 engine) 6-1-21 diagnostic trouble code (dtc) clearance [using scan tool] 1) with ignition switch off, connect generic scan tool or suzuki scan tool (tech-1) to data link connector (dlc). 2) turn ignition switch on. 3) erase dtc according to instructions displayed on scan...
Page 133
Yh4 grand vitara 6-1-22 engine (h25 engine) diagnostic trouble code (dtc) table dtc no. Detecting item detecting condition (dtc will set when detecting:) mil (vehicle without monitor connector mil (vehicle with monitor connector p0100 (no.34) mass air flow circuit sensor output too low 1 driving 1 d...
Page 134
Yh4 grand vitara engine (h25 engine) 6-1-23 dtc no. Detecting item detecting condition (dtc will set when detecting:) mil (vehicle without monitor connector mil (vehicle with monitor connector p0154 (no.26) ho2s (bank 2 – sensor 1) no activity detected output voltage of ho2s-1 fails to go above spec...
Page 135
Yh4 grand vitara 6-1-24 engine (h25 engine) dtc no. Detecting item detecting condition (dtc will set when detecting:) mil (vehicle without monitor connector mil (vehicle with monitor connector p0420 catalyst system efficiency below threshold (bank 1) output waveforms of ho2s-1 and ho2s-2 are similar...
Page 136
Yh4 grand vitara engine (h25 engine) 6-1-25 dtc no. Detecting item detecting condition (dtc will set when detecting:) mil p0705 (no.72) transmission range circuit malfunction p0715 (no.76) input/ turbine speed sensor circuit malfunction p0720 (no.75) a / t vss signal circuit malfunction p0741 torque...
Page 137
Yh4 grand vitara 6-1-26 engine (h25 engine) fail-safe table when any of the following dtcs is detected, ecm enters fall-safe mode as long as malfunction continues to exist but that mode is canceled when ecm detects normal condition after that. Dtc no. Trouble area fail safe operation fail safe mode ...
Page 138
Yh4 grand vitara engine (h25 engine) 6-1-27 +36 _ f –9 _ f scan tool data as the data values given below are standard values estimated on the basis of values obtained from the normally operating vehicles by using a scan tool, use them as reference values. Even when the vehicle is in good condition, ...
Page 139
Yh4 grand vitara 6-1-28 engine (h25 engine) scan tool data condition normal condition / reference value other throttle pos (absolute throttle position) ignition switch on / warmed up accelerator pedal released. 10 5 % (absolute throttle position) on / warmed u engine stopped. Accelerator pedal depre...
Page 140
Yh4 grand vitara engine (h25 engine) 6-1-29 scan tool data condition normal condition/ reference value other electric load ignition on, small light off off : ignition switch on, small light on on : vss (for 4-a/t) (vehicle speed sensor) at stop. 0 km/h 0 mph : gear position (for 4-a/t) ignition swit...
Page 141
Yh4 grand vitara 6-1-30 engine (h25 engine) coolant temp (engine coolant temp., _ c/ _ f) it is detected by engine coolant temp. Sensor. Intake air temp ( _ c/ _ f) it is detected by intake air temp. Sensor. Desire idle (desired idle speed rpm) the desired idle speed is an ecm (pcm) internal pa- ram...
Page 142
Yh4 grand vitara engine (h25 engine) 6-1-31 fuel system b1 (fuel system bank 1 status) fuel system b2 (fuel system bank 2 status) air / fuel ratio feedback loop status displayed as one of the followings. Open: open loop-has not yet satisfied conditions to go closed loop. Closed: closed loop-using ox...
Page 143
Yh4 grand vitara 6-1-32 engine (h25 engine) gear position (1st, 2nd, 3rd or 4th) the gear position is determined on the basis of the command state signals generated from pcm to shift solenoids a and b ( # 1 and # 2) and displayed as shown in the table below. Throt pos level (throttle position level ...
Page 144
Yh4 grand vitara engine (h25 engine) 6-1-33 engine diagnosis table perform troubleshooting referring to following table when ecm (pcm) has detected no dtc and no abnormality has been found in visual inspection and engine basic inspection previously. Condition possible cause reference item hard start...
Page 145
Yh4 grand vitara 6-1-34 engine (h25 engine) condition possible cause reference item improper engine idling or engine fails to idle ignition system out of order. Faulty spark plug faulty ignition coil with ignitor fuel system out of order. Fuel pressure out of specification engine overheating. Engine...
Page 146
Yh4 grand vitara engine (h25 engine) 6-1-35 condition possible cause reference item surges (engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and down with no change in the accelerator pedal.) ignition system out of order. Defective spark plug (excess carbon de...
Page 147
Yh4 grand vitara 6-1-36 engine (h25 engine) condition possible cause reference item overheating inoperative thermostat poor water pump performance clogged or leaky radiator improper engine oil grade clogged oil filter or oil strainer poor oil pump performance dragging brakes slipping clutch blown cy...
Page 148
Yh4 grand vitara engine (h25 engine) 6-1-37 condition possible cause reference item low oil pressure improper oil viscosity malfunctioning oil pressure switch clogged oil strainer functional deterioration of oil pump worn oil pump relief valve excessive clearance in various sliding parts engine oil ...
Page 149
Yh4 grand vitara 6-1-38 engine (h25 engine) 1. Glove box 2. Engine ground 1. Ecm (pcm) 2. Connector (viewed from harness side) ecm (pcm) substitution when substituting a known-good ecm (pcm), check for following conditions. Neglecting this check may cause damage to known- good ecm (pcm). – resistanc...
Page 150
Yh4 grand vitara engine (h25 engine) 6-1-39 terminal circuit normal voltage condition e61 1 fuel pump relay 0 – 2.5 v for 3 sec. After ignition switch on or while engine running. E61-1 fuel pump relay 10 – 14 v after 3 sec. From ignition switch on with engine stopped. E61-2 ——— ——— ——— e61-3 ——— ———...
Page 151
Yh4 grand vitara 6-1-40 engine (h25 engine) terminal circuit normal voltage condition e61-21, 22 ——— ——— ——— immobilizer indicator lamp (vehicle 0 – 1 v ignition switch on e61-23 ( without monitor connector) 10 – 14 v engine running e61-23 duty output terminal (vehicle with monitor connector) 0 – 1 ...
Page 152
Yh4 grand vitara engine (h25 engine) 6-1-41 terminal circuit normal voltage condition c51-3-9 camshaft position sensor (pos) deflects between 0 – 1 v and 4 – 6 v ignition switch on, crankshaft turned slowly. C51-3-10 camshaft position sensor (ref) deflects between 0 – 1 v and 4 – 6 v ignition switch...
Page 153
Yh4 grand vitara 6-1-42 engine (h25 engine) terminal circuit normal voltage condition c51-1-6 shift solenoid a (a / t vehicle) 10 – 14 v ignition switch on c51 1 7 4wd lamp (if equipped) 10 – 14 v ignition switch on, transfer lever: n or 2h range c51-1-7 4wd lamp (if equipped) 0 – 1 v ignition switc...
Page 154
Yh4 grand vitara engine (h25 engine) 6-1-43 terminal circuit normal voltage condition c51-2-14 iac valve (stepper motor coil 2) ——— ——— c51-2-15 iac valve (stepper motor coil 1) ——— ——— c51-2-16 egr valve (stepper motor coil 4) (if equipped) 0 – 1 v ignition switch on c51-2-17 egr valve (stepper mot...
Page 155
Yh4 grand vitara 6-1-44 engine (h25 engine) resistance check 1) disconnect ecm couplers (1) from ecm with ignition switch off. Caution: never touch terminals of ecm itself or connect voltmeter or ohmmeter (2). 2) check resistance between each pair of terminals of discon- nected couplers as listed in...
Page 156
Yh4 grand vitara engine (h25 engine) 6-1-45 terminal circuit standard resistance condition c51-1-1 – body ground shift solenoid-b c51-1-2 – body ground tcc solenoid 11 – 15 — c51-1-6 – body ground shift solenoid-a c51-1-8 – c51-1-16 a / t input speed sensor 560 – 680 — c51-1-9 – c51-1-10 a / t outpu...
Page 157
Yh4 grand vitara 6-1-46 engine (h25 engine) terminal arrangement of ecm (pcm) coupler viewed from harness side 1. Battery 2. Ignition switch 3. Ecm / pcm 4. Mil 5. Fuse box 6. Main fuse 7. Monitor connector table a-1 malfunction indicator lamp circuit check mil does not come on or mil dimms at ignit...
Page 158
Yh4 grand vitara engine (h25 engine) 6-1-47 troubleshooting step action yes no 1 test switch terminal check (vehicle with monitor connector): (1) check test switch terminal of monitor connector for being grounded. (2) with ignition switch on leaving engine off, measure voltage between e61-16 and gro...
Page 159
Yh4 grand vitara 6-1-48 engine (h25 engine) table a-2 malfunction indicator lamp circuit check mil remains on after engine starts wiring diagram / circuit description refer to table a-1. Troubleshooting step action yes no 1 dtc check: (1) with ignition switch off, install scan tool. (2) start engine...
Page 160
Yh4 grand vitara engine (h25 engine) 6-1-49 table a-4 malfunction indicator lamp check mil does not flash or just remains on even with grounding diagnosis switch terminal (vehicle with monitor connector) wiring diagram / circuit description refer to table a-1. Troubleshooting step action yes no 1 mi...
Page 161
Yh4 grand vitara 6-1-50 engine (h25 engine) terminal arrangement of ecm (pcm) coupler viewed from harness side 1. Battery 2. Ignition switch 3. Main fuse 4. Main relay table a-5 ecm (pcm) power and ground circuit check mil does not light at ignition switch on and engine does not start though it is c...
Page 162
Yh4 grand vitara engine (h25 engine) 6-1-51 troubleshooting step action yes no 1 main relay operating sound check: is operating sound of main relay heard at ignition switch on? Go to step 5. Go to step 2. 2 fuse check: is fuse 8 in good condition? Go to step 3. Check for short in circuits connected ...
Page 163
Yh4 grand vitara 6-1-52 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Main relay 2. Mass air flow sensor dtc p0100 mass air flow sensor circuit malfunction (dtc no.33, 34) wiring diagram dtc detecting condition and trouble area dtc detecting condition tr...
Page 164
Yh4 grand vitara engine (h25 engine) 6-1-53 fig. For step 2 dtc confirmation procedure note: check to make sure that following conditions are satisfied when using this dtc confirmation proce- dure. Warning: d when performing a road test, select a place where there is no traffic or possibility of a t...
Page 165
Yh4 grand vitara 6-1-54 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Iat sensor dtc p0110 intake air temp. Circuit malfunction (dtc no.23, 25) wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area less than 0.16 v ...
Page 166
Yh4 grand vitara engine (h25 engine) 6-1-55 fig. For step 3 fig. For step 6 d intake air temperature: between – 14 _ c and 70 _ c (68 _ f and 158 _ f) d atmospheric pressure: higher than 560 mmhg (altitude: lower than 2790 m (9150 ft)) (1) with ignition switch off, connect scan tool. (2) turn on ign...
Page 167
Yh4 grand vitara 6-1-56 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Ect sensor 2. Combination meter dtc p0115 engine coolant temp. Circuit malfunction (dtc no.14, 15) wiring diagram dtc detecting condition and trouble area dtc detecting condition troub...
Page 168
Yh4 grand vitara engine (h25 engine) 6-1-57 fig. For step 5 fig. For step 6 d atmospheric pressure: higher than 560 mmhg (altitude: lower than 2790 m (9150 ft)) d intake air temperature: between – 14 _ c and 70 _ c (6.8 _ f and 158 _ f) (1) with ignition switch off, connect scan tool. (2) turn on ig...
Page 169
Yh4 grand vitara 1. Throttle position sensor terminal arrangement of ecm (pcm) coupler (viewed from harness side) 6-1-58 engine (h25 engine) dtc p0120 throttle position circuit malfunction (dtc no.21, 22) wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area tp...
Page 170
Yh4 grand vitara engine (h25 engine) 6-1-59 fig. For step 2 dtc troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 tp sensor reference voltage check: (1) wit ignition switch off, disconnect c30-3 coupler. (2) check voltage b...
Page 171
Yh4 grand vitara 6-1-60 engine (h25 engine) dtc p0121 throttle position circuit performance problem wiring diagram refer to dtc p0120 (dtc no.21, 22). Dtc detecting condition and trouble area dtc detecting condition trouble area throttle opening is detected as small (rationality-low) while engine is...
Page 172
Yh4 grand vitara engine (h25 engine) 6-1-61 + fig. For step 5 – dtc troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 tp sensor signal check: (1) remove ecm (pcm) cover. (2) start engine and warm up for normal operating tem...
Page 173
Yh4 grand vitara 6-1-62 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Ho2s heater relay 2. Ho2s dtc p0130 ho2s (bank-1 sensor-1) circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area minimum ho2s...
Page 174
Yh4 grand vitara engine (h25 engine) 6-1-63 note: check to make sure that following conditions are satisfied when using this dtc confirmation proce- dure. D intake air temperature: between – 14 _ c and 70 _ c (6.8 _ f and 158 _ f) d atmospheric pressure: higher than 560 mmhg (altitude: lower than 27...
Page 175
Yh4 grand vitara 6-1-64 engine (h25 engine) dtc p0133 ho2s (bank-1 sensor-1) circuit slow response wiring diagram refer to dtc p0130. Dtc detecting condition and trouble area dtc detecting condition trouble area hi / low switch cycle average of ho2s voltage is longer than 5 sec. Ho2s ho2s circuit ec...
Page 176
Yh4 grand vitara engine (h25 engine) 6-1-65 dtc p0134 ho2s (bank-1 sensor-1) no activity detected (dtc no.13) wiring diagram refer to dtc p0130. Dtc detecting condition and trouble area dtc detecting condition trouble area ho2s voltage is lower than 0.5 v. Ho2s ho2s circuit fuel injector fuel pressu...
Page 177
Yh4 grand vitara 6-1-66 engine (h25 engine) step action yes no 3 ho2s voltage check: (1) remove ecm (pcm) cover. (2) start engine and check voltage between c51-3-4 and c51-3-21 while repeating racing engine. Does the voltage indicate 0.5 v or more even at once? Poor c51-3-4 and / or c51-3-21 termina...
Page 178
Yh4 grand vitara engine (h25 engine) 6-1-67 dtc p0135 ho2s (bank-1 sensor-1) heater circuit malfunction wiring diagram refer to dtc p0130. Dtc detecting condition and trouble area dtc detecting condition trouble area current of ho2s heater is higher than specified value or lower than specified value...
Page 179
Yh4 grand vitara 6-1-68 engine (h25 engine) a fig. For step 2, 3 a. Ho2s heater relay.
Page 180
Yh4 grand vitara engine (h25 engine) 6-1-69 terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Ho2s heater relay 2. Ho2s dtc p0136 ho2s (bank-1 sensor-2) circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detection condition trouble area maximum ho2s...
Page 181
Yh4 grand vitara 6-1-70 engine (h25 engine) d intake air temperature: between – 14 _ c and 70 _ c (6.8 _ f and 158 _ f) d atmospheric pressure: higher than 560 mmhg (altitude: lower than 2790 m (9150 ft)) d following dtcs are not detected: p0110 (no.23, 25), p0335, p0460, p1450 and p1451 (1) with ig...
Page 182
Yh4 grand vitara engine (h25 engine) 6-1-71 dtc p0141 ho2s (bank-1 sensor-2) heater circuit malfunction wiring diagram refer to dtc p0136. Dtc detecting condition and trouble area dtc detecting condition trouble area current of ho2s heater is higher than specified value or lower than specified value...
Page 183
Yh4 grand vitara 6-1-72 engine (h25 engine) a fig. For step 2, 3 a. Ho2s heater relay step action yes no 4 ho2s heater control circuit check: (1) with ignition switch off, install ho2s heater relay. (2) with ignition switch on leaving engine off, check voltage between c51-3-17 and ground. Is the vol...
Page 184
Yh4 grand vitara engine (h25 engine) 6-1-73 terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Ho2s heater relay 2. Ho2s dtc p0150 ho2s (bank-2 sensor-1) circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area minimum ho2s...
Page 185
Yh4 grand vitara 6-1-74 engine (h25 engine) warning: d when performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during to avoid occurrence of an accident. D road test, should be carried out with 2 person, a driver and tester, on a le...
Page 186
Yh4 grand vitara engine (h25 engine) 6-1-75 dtc p0153 ho2s (bank-2 sensor-1) circuit slow response wiring diagram refer to dtc p0150 (dtc no.26). Dtc detecting condition and trouble area dtc detecting condition trouble area hi / low switch cycle average of ho2s voltage is longer than 5 sec. Ho2s ho2...
Page 187
Yh4 grand vitara 6-1-76 engine (h25 engine) dtc p0154 ho2s (bank-2 sensor-1) no activity detected (dtc no.26) wiring diagram refer to dtc p0150. Dtc detecting condition and trouble area dtc detecting condition trouble area ho2s voltage is lower than 0.5 v. Ho2s ho2s circuit fuel injector fuel pressu...
Page 188
Yh4 grand vitara engine (h25 engine) 6-1-77 step action yes no 3 ho2s voltage check: (1) remove ecm (pcm) cover. (2) start engine and check voltage between c51-3-15 and c51-3-21 while repeating racing engine. Does the voltage indicate 0.5 v or more even at once? Poor c51-3-15 and / or c51-3- 21 term...
Page 189
Yh4 grand vitara 6-1-78 engine (h25 engine) dtc p0155 ho2s (bank-2 sensor-1) heater circuit malfunction wiring diagram refer to dtc p0150. Dtc detecting condition and trouble area dtc detecting condition trouble area current of ho2s heater is higher than specified value or lower than specified value...
Page 190
Yh4 grand vitara engine (h25 engine) 6-1-79 a fig. For step 2, 3 a. Ho2s heater relay.
Page 191
Yh4 grand vitara 6-1-80 engine (h25 engine) 25 24 terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Ho2s heater relay 2. Ho2s dtc p0156 ho2s (bank-2 sensor-2) circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detection condition trouble area maximu...
Page 192
Yh4 grand vitara engine (h25 engine) 6-1-81 d intake air temperature: between – 14 _ c and 70 _ c (6.8 _ f and 158 _ f) d atmospheric pressure: higher than 560 mmhg (altitude: lower than 2790 m (9150 ft)) d following dtcs are not detected: p0110 (no.23, 25), p0335, p0460, p01450 and p01451 (1) with ...
Page 193
Yh4 grand vitara 6-1-82 engine (h25 engine) dtc p0161 ho2s (bank-2 sensor-2) heater circuit malfunction wiring diagram refer to dtc p0156. Dtc detecting condition and trouble area dtc detecting condition trouble area current of ho2s heater is higher than specified value or lower than specified value...
Page 194
Yh4 grand vitara engine (h25 engine) 6-1-83 a fig. For step 2, 3 a. Ho2s heater relay step action yes no 4 ho2s heater control circuit check: (1) with ignition switch off, install ho2s heater relay. (2) with ignition switch on leaving engine off, check voltage between c51-3-16 and ground. Is the vol...
Page 195
Yh4 grand vitara 6-1-84 engine (h25 engine) dtc p0171 fuel system too lean (bank-1) dtc p0172 fuel system too rich (bank-1) dtc detecting condition and trouble area dtc detecting condition trouble area p0171 total fuel trim of bank-1 is higher than 33 %. P0172 total fuel trim of bank-1 is lower than...
Page 196
Yh4 grand vitara engine (h25 engine) 6-1-85 step action yes no 6 check fuel injector circuit referring to “table b-3” in this section. Is it in good condition? Go to step 7. Repair or replace. 7 check fuel level sensor referring to “engine and emission control” section. Is check result satisfactory?...
Page 197
Yh4 grand vitara 6-1-86 engine (h25 engine) dtc p0174 fuel system too lean (bank-2) dtc p0175 fuel system too rich (bank-2) dtc detecting condition and trouble area dtc detecting condition trouble area p0174 total fuel trim of bank-2 is higher than 33 %. P0175 total fuel trim of bank-2 is lower than...
Page 198
Yh4 grand vitara engine (h25 engine) 6-1-87 step action yes no 6 check fuel injector circuit referring to “table b-3” in this section. Is it in good condition? Go to step 7. Repair or replace. 7 check fuel level sensor referring to “engine and emission control” section. Is check result satisfactory?...
Page 199
Yh4 grand vitara 6-1-88 engine (h25 engine) dtc p0300 random misfire detected dtc p0301 cylinder 1 misfire detected dtc p0302 cylinder 2 misfire detected dtc p0303 cylinder 3 misfire detected dtc p0304 cylinder 4 misfire detected dtc p0305 cylinder 5 misfire detected dtc p0306 cylinder 6 misfire det...
Page 200
Yh4 grand vitara engine (h25 engine) 6-1-89 dtc troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ignition system inspection: (1) check spark plug and ignition spark of cylinder where misfire occurs, referring to “ignition ...
Page 201
Yh4 grand vitara 6-1-90 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Ckp sensor dtc p0335 crankshaft position sensor circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area ckp sensor signal is no...
Page 202
Yh4 grand vitara engine (h25 engine) 6-1-91 fig. For step 3 dtc troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 ckp sensor and its circuit resistance check: (1) with ignition switch off, disconnect ecm (pcm) coupler (c51-...
Page 203
Yh4 grand vitara 6-1-92 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Cmp sensor 2. Main relay dtc p0340 camshaft position sensor circuit malfunction (dtc no.42) wiring diagram system description cmp sensor detects ref signal and pos signal. Ref signal: ...
Page 204
Yh4 grand vitara engine (h25 engine) 6-1-93 dtc confirmation procedure note: check to make sure that following conditions are satisfied when using this dtc confirmation proce- dure. Intake air temperature: between – 14 c and 70 c (6.8 f and 158 f) atmospheric pressure: higher than 560 mmhg (altitude...
Page 205
Yh4 grand vitara 6-1-94 engine (h25 engine) fig. For step 4 1. Disconnected cmp sensor coupler 2. “bi / b” wire terminal 3. “gr / y” wire terminal.
Page 206
Yh4 grand vitara engine (h25 engine) 6-1-95 terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Egr valve 2. Intake manifold 3. Exhaust gas 1. Egr valve (stepper motor) 2. Main relay 1 3 2 dtc p0400 exhaust gas recirculation flow malfunction (dtc no.51) system/ wiring diagram.
Page 207
Yh4 grand vitara 6-1-96 engine (h25 engine) system description egr system consists of egr valve and its passage. Ecm (pcm) judges egr valve opening based on following items. (engine speed, engine load, engine coolant temperature, intake air temperature and vehicle speed) if egr system is in good con...
Page 208
Yh4 grand vitara engine (h25 engine) 6-1-97 fig. For step 4 fig. For step 5 1. Egr valve 2. Connector step action yes no 5 egr valve stepper motor coil circuit check: (1) with ignition switch off, connect egr coupler and disconnect ecm (pcm) couplers. (2) check resistance between c51-2-20 and c51-2-...
Page 209
Yh4 grand vitara 6-1-98 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Warm up twc converter (bank 2) 2. Warm up twc converter (bank 1) 3. Twc converter 4. Ho2s (bank 2, sensor 2) 5. Ho2s (bank 2, sensor 1) 6. Ho2s (bank 1, sensor 1) 7. Ho2s (bank 1, sens...
Page 210
Yh4 grand vitara engine (h25 engine) 6-1-99 dtc detecting condition and trouble area dtc detecting condition trouble area output waveform of ho2s (s-2) becomes similar to that of ho2s (s-1). Twc converter exhaust system ho2s (sensor 2) ho2s (sensor 2) circuit ecm (pcm) dtc confirmation procedure not...
Page 211
Yh4 grand vitara 6-1-100 engine (h25 engine) 1. Main fuse 2. Main relay 3. Evap canister purge valve dtc p0443 evap control system purge control valve circuit malfunction wiring diagram dtc detecting condition and trouble area dtc detecting condition trouble area monitor signal of evap canister purg...
Page 212
Yh4 grand vitara engine (h25 engine) 6-1-101 troubleshooting (dtc p0443) step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 check evap canister purge system for operation referring to “evap canister purge system” check. Is check result sati...
Page 213
Yh4 grand vitara 6-1-102 engine (h25 engine) 2 evap canister purge valve and its circuit check. 1) disconnect vacuum hoses from vacuum pipes. 2) with ignition switch on, blow into hose “a”. Air should not come out of hose “b”. Using suzuki scan tool 3) connect suzuki scan tool (1) to dlc (2) with ig...
Page 214
Yh4 grand vitara engine (h25 engine) 6-1-103 4) with ignition switch off, disconnect coupler from evap canis- ter purge valve. 5) check resistance between two terminals of evap canister purge valve. Resistance of evap canister purge valve: 28 – 36 at 20 c (68 f) if resistance is as specified, procee...
Page 215
Yh4 grand vitara 6-1-104 engine (h25 engine) 1. Purge hose evap canister purge system check 1) warm up engine to normal operating temperature. 2) hoist vehicle so that all wheels rotate freely. 3) set m / t in “neutral” or a / t in “p” position and parking brake. 4) disconnect purge hose from evap c...
Page 216
Yh4 grand vitara engine (h25 engine) 6-1-105 1. Fuel level meter in combination meter 2. Fuel level sensor dtc p0460 fuel level sensor circuit high input wiring diagram / circuit description dtc detecting condition and trouble area dtc detecting condition trouble area fuel level sensor voltage highe...
Page 217
Yh4 grand vitara 6-1-106 engine (h25 engine) dtc troubleshooting step action yes no 1 was “engine diag. Flow table” performed? Go to step 2. Go to “engine diag. Flow table”. 2 fuel level sensor signal circuit check: (1) with ignition switch off, disconnect g10 of combination meter coupler. (2) remov...
Page 218
Yh4 grand vitara engine (h25 engine) 6-1-107 terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Vehicle speed sensor 2. Main relay 3. Speedometer dtc p0500 vehicle speed sensor malfunction (dtc no.24) wiring diagram circuit description refer to “engine and emission control” sect...
Page 219
Yh4 grand vitara 6-1-108 engine (h25 engine) warning: when performing a road test, select a place where there is no traffic or possibility of a traffic accident and very careful during to avoid occurrence of an accident. Road test, should be carried out with 2 person, a driver and tester, on a level...
Page 220
Yh4 grand vitara engine (h25 engine) 6-1-109 fig. For step 3 fig. For step 4, 6 fig. For step 5 – + v step action yes no 6 speedometer circuit check: (1) with ignition switch off, disconnect g11 coupler from combination meter. (2) with ignition switch on leaving engine off, check voltage between c20...
Page 221
Yh4 grand vitara 6-1-110 engine (h25 engine) cold hot terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Iac valve 2. Fast idle control system 3. Bypass air 4. Engine coolant 5. Main relay dtc p0505 idle air control system malfunction system/ wiring diagram.
Page 222
Yh4 grand vitara engine (h25 engine) 6-1-111 system/ circuit description refer to “engine and emission control” section. Dtc detecting condition and trouble area dtc detecting condition trouble area idle engine speed is lower than desired engine speed 100 r / min. Though iac valve opening is about 1...
Page 223
Yh4 grand vitara 6-1-112 engine (h25 engine) fig. For step 5 step action yes no 6 air intake system check: (1) check air intake system for clog and air inhabit. (2) check fast idle up system referring to “engine and emission control” section. Are they in good condition? Go to step 7. Repair or repla...
Page 224
Yh4 grand vitara engine (h25 engine) 6-1-113 dtc p0601 internal control module memory check sum error system description internal control module is installed in ecm (pcm). Dtc detecting condition and trouble area dtc detecting condition trouble area check sum is not equal to specified value. Ecm (pc...
Page 225
Yh4 grand vitara 6-1-114 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Map sensor dtc p1408 manifold absolute pressure sensor circuit malfunction wiring diagram circuit description refer to “engine and emission control” section. Dtc detecting condition a...
Page 226
Yh4 grand vitara engine (h25 engine) 6-1-115 fig. For step 3 intake air temperature: between 5 c and 70 c (6.8 f and 158 f) atmospheric pressure: higher than 560 mmhg (altitude: lower than 2790 m (9150 ft)) (1) with ignition switch off, connect scan tool. (2) turn on ignition switch and clear dtc by...
Page 227
Yh4 grand vitara 6-1-116 engine (h25 engine) dtc p1450 barometric pressure sensor circuit malfunction dtc p1451 barometric pressure sensor performance problem system description barometric pressure sensor is installed in ecm (pcm). Dtc detecting condition and trouble area dtc detecting condition tro...
Page 228
Yh4 grand vitara engine (h25 engine) 6-1-117 applying vacuum displayed value on scan tool 0 barometric pressure (approx. 100 kpa, 760 mmhg) 27 kpa 200 mmhg barometric pressure – 27 kpa (approx. 73 kpa, 560 mmhg 67 kpa 500 mmhg barometric pressure – 67 kpa (approx. 33 kpa, 260 mmhg) fig. For step 3 d...
Page 229
Yh4 grand vitara 6-1-118 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) 1. Ignition switch 2. Transmission range switch dtc p1500 engine start signal circuit malfunction wiring diagram circuit description engine start signal is sent from engine starter circu...
Page 230
Yh4 grand vitara engine (h25 engine) 6-1-119 dtc confirmation procedure note: check to make sure that following conditions are satisfied when using this dtc confirmation proce- dure. Intake air temperature: between – 14 c and 70 c (6.8 f and 158 f) atmospheric pressure: higher than 560 mmhg (altitud...
Page 231
Yh4 grand vitara 6-1-120 engine (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) dtc p1510 ecm back-up power supply malfunction wiring diagram circuit description battery voltage is translated to 5 v in ecm (pcm) back-up circuit. The voltage is supplied to keep dtc m...
Page 232
Yh4 grand vitara engine (h25 engine) 6-1-121 terminal arrangement of ecm (pcm) coupler viewed from harness side 1. Fuel pump 2. Fuel pump relay 3. Main relay table b-1 fuel pump circuit check wiring diagram circuit description fuel pump relay is turned on for 3 sec. After ignition switch is turned o...
Page 233
Yh4 grand vitara 6-1-122 engine (h25 engine) 1. Service wire left hand steering vehicle right hand steering vehicle troubleshooting step action yes no 1 fuel pump operation check: (1) remove fuel filler cap. (2) turn on ignition switch. Is fuel pump operation sound heard for 3 sec. After ignition sw...
Page 234
Yh4 grand vitara engine (h25 engine) 6-1-123 terminal arrangement of ecm (pcm) coupler viewed from harness side 1. Fuel injector 2. Main relay table b-2 fuel injector circuit check wiring diagram.
Page 235
Yh4 grand vitara 6-1-124 engine (h25 engine) 10 – 14 at 20 c 10 – 14 v troubleshooting step action yes no 1 fuel injector operation check: (1) using sound scope, check each injector for operating sound at engine cranking. Do all 6 injectors make operating sound? Go to step 2. Go to step 3. 2 fuel in...
Page 236
Yh4 grand vitara engine (h25 engine) 6-1-125 1. Injector 2. Delivery pipe 3. Fuel pressure regulator 4. Fuel filter 5. Fuel pump (a): gauge (b): hose (c): attachment table b-3 fuel pressure check system diagram system description fuel pressure regulator keeps the fuel pressure applied to injector 29...
Page 237
Yh4 grand vitara 6-1-126 engine (h25 engine) step action yes no 5 is there fuel leakage from fuel feed line hose, pipe or joint? Fuel leakage from fuel feed line hose, pipe or joint. Fuel leakage from injector, fuel pressure regulator or fuel pump. 6 was fuel pressure higher than specification in st...
Page 238
Yh4 grand vitara engine (h25 engine) 6-1-127 terminal arrangement of ecm (pcm) coupler viewed from harness side 1. A / c control module table b-4 a/c signal circuit check (if equipped) circuit diagram circuit description ecm (pcm) outputs a / c on signal (one of the signals for a / c control module ...
Page 239
Yh4 grand vitara 6-1-128 engine (h25 engine) step action yes no 2 a / c on signal check: (1) check voltage between e61-27 and ground under following conditions. Engine running and a / c switch and / or heater blower switch off 0 – 1.5 v ignition switch on and both a / c switch and heater blower swit...
Page 240
Yh4 grand vitara engine (h25 engine) 6-1-129 terminal arrangement of ecm (pcm) coupler viewed from harness side 1. Condenser fan 2. Condenser fan relay table b-5 a/c condenser fan motor relay control system check (if equipped) circuit diagram circuit description a / c condenser fan is turned on by e...
Page 241
Yh4 grand vitara 6-1-130 engine (h25 engine) step action yes no 2 a / c condenser fan control signal check: (1) remove ecm (pcm) cover. (2) check voltage between e61-5 and ground under following conditions. Other than conditions a and b in step 1: 10 – 14 v under condition a or b in step 1: 0 – 1 v ...
Page 242: Special Tools
Yh4 grand vitara engine (h25 engine) 6-1-131 1. Pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. 3-way joint & hose 09912-58490 4. Checking tool set 09912-58421 4-1. Tool body & washer 4-2. Body plug 4-3. Body attachment-1 4-4. Holder 4-5. Return hose & clamp 4-6. Body attachment-2 & washe...
Page 243: Section 6A1
Yh4 grand vitara 6a1 engine mechanical (g16 engine) 6a1-1 section 6a1 engine mechanical (g16 engine) 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. Ref...
Page 244: General Description
Yh4 grand vitara 6a1-2 engine mechanical (g16 engine) the engine is a water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit equipped with its s.O.H.C. (single overhead camshaft) valve mechanism ar- ranged for “v”-type valve configuration and 16 valves (in 2 and ex 2 / one cylinder). The si...
Page 245
Yh4 grand vitara engine mechanical (g16 engine) 6a1-3 the oil pump is of a trochoid type, and mounted on crankshaft at crankshaft pulley side. Oil is drawn up through oil pump strainer and passed through pump to oil filter. The filtered oil flows into two paths in cylinder block. In one path, oil re...
Page 246: On-Vehicle Service
Yh4 grand vitara 6a1-4 engine mechanical (g16 engine) on-vehicle service compression check check compression pressure on all four cylinders as follows: 1) warm up engine. 2) stop engine after warming up. Note: after warming up engine, place transmission gear shift le- ver in “neutral” (shift selecto...
Page 247
Yh4 grand vitara engine mechanical (g16 engine) 6a1-5 7) crank engine with fully charged battery, and read the highest pressure on compression gauge. Note: for measuring compression pressure, crank engine at least 250 r / min. By using fully charged battery. Compression pressure standard 1400 kpa (1...
Page 248
Yh4 grand vitara 6a1-6 engine mechanical (g16 engine) engine vacuum check the engine vacuum that develops in the intake line is a good indica- tor of the condition of the engine. The vacuum checking procedure is as follows: 1) warm up engine to normal operating temperature. Note: after warming up en...
Page 249
Yh4 grand vitara 1. Full level mark 2. Low level mark 1. Oil pressure switch 2. Oil filter engine mechanical (g16 engine) 6a1-7 oil pressure check note: prior to checking oil pressure, check following items. Oil level in oil pan. If oil level is low, add oil up to full level mark on oil level gauge....
Page 250
Yh4 grand vitara 1. Sealing tape 6a1-8 engine mechanical (g16 engine) 6) before reinstalling oil pressure switch, be sure to wrap its screw threads with sealing tape and tighten switch to specified torque. Note: if sealing tape edge is bulged out from screw threads of switch, cut it off. Tightening ...
Page 251
Yh4 grand vitara (1) (2) (3) (4) (5) (6) (7) (8) 1. Crankshaft pulley 2. V mark 1. Thickness gauge in ex in ex engine mechanical (g16 engine) 6a1-9 valve lash (clearance) 1) remove negative cable at battery. 2) remove cylinder head cover referring to item “cylinder head cover”. 3) using 17 mm socket...
Page 252
Yh4 grand vitara in ex (1) (2) (3) (4) (5) (6) (7) (8) 6a1-10 engine mechanical (g16 engine) 6) after checking and adjusting valve lashes at valves (1), (2), (5) and (7), (or (3), (4), (6) and (8)) rotate crankshaft exactly one full turn (360 _ ) and check the same at valves (3), (4), (6) and (8) (o...
Page 253
Yh4 grand vitara engine mechanical (g16 engine) 6a1-11 air cleaner element removal 1) remove air cleaner case clamps. 2) remove air cleaner element from case. Inspection check air cleaner element for dirt. Replace excessively dirty ele- ment. Clean blow off dust by compressed air from air outlet sid...
Page 254
Yh4 grand vitara 1. Cylinder head cover 2. Cylinder head cover gasket 3. O-rings 1 cylinder head cover gasket 2. O-rings 3. Cylinder head cover 6a1-12 engine mechanical (g16 engine) cylinder head cover removal 1) disconnect negative cable at battery. 2) remove ignition coil assemblies with high-tens...
Page 255
Yh4 grand vitara 1. Intake manifold 2. Gasket 3. Intake manifold no.2 stiffener 4. Intake manifold stiffener (front) 5. Engine hook 6. Fuel delivery pipe 7. Throttle body 8. Intake manifold stiffener (rear) 9. Egr valve 10. Manifold absolute pressure (map) sensor engine mechanical (g16 engine) 6a1-1...
Page 256
Yh4 grand vitara 6a1-14 engine mechanical (g16 engine) 6) disconnect accelerator cable and a / t throttle cable (for a / t) from throttle body. 7) disconnect following hoses: brake booster hose from intake manifold canister purge hose from evap canister purge valve engine cooling water (coolant) hos...
Page 257
Yh4 grand vitara engine mechanical (g16 engine) 6a1-15 installation reverse removal procedure for installation noting the followings. Use new intake manifold gasket. When installing intake manifold, install clamps at positions as shown in figure. Adjust accelerator cable play and a / t throttle cabl...
Page 258
Yh4 grand vitara 1. Exhaust manifold 2. Upper cover 3. Gasket 4. Heated oxygen sensor-1 5. Lower cover 6. Exhaust manifold stiffener 7. Engine hook 8. Heated oxygen sensor-2 connector 1. Exhaust pipe 3. Exhaust manifold stiffener (if equipped) 1. Exhaust manifold 2. Exhaust manifold gasket vehicle n...
Page 259
Yh4 grand vitara 1. Exhaust manifold gasket 1. Heated oxygen sensor-1 connector 2. Bracket 3. Engine hook (a) (a) engine mechanical (g16 engine) 6a1-17 installation 1) install new gasket to cylinder head. 2) install exhaust manifold and stiffener (if equipped). Tighten bolts and nuts to specified to...
Page 260
Yh4 grand vitara 6a1-18 engine mechanical (g16 engine) 1. Timing belt 2. Tensioner 3. Tensioner plate 4. Tensioner spring 5. Camshaft timing pulley 6. Tensioner bolt 7. Pulley bolt 8. Seal 9. Inside cover seal 10. Inside cover 11. Outside cover seal 12. Outside cover 13. Tensioner stud 1. Crankshaft...
Page 261
Yh4 grand vitara 1. “v” mark on cylinder head cover 2. Timing mark by “e” on camshaft timing belt pulley 3. Arrow mark on oil pump case 4. Punch mark on crankshaft timing belt pulley 1. Timing belt 2. Tensioner plate 3. Tensioner bolt 4. Tensioner stud 5. Spring 1. Camshaft allowable turning range -...
Page 262
Yh4 grand vitara 1. Lug 2. Hole 1. Tensioner bolt 2. Tensioner 1. “v” mark 2. Timing mark by “e” 3. Tensioner plate 1. Arrow mark 2. Punch mark 6a1-20 engine mechanical (g16 engine) inspect tensioner for smooth rotation. Installation 1) install tensioner plate to tensioner. Insert lug of tensioner p...
Page 263
Yh4 grand vitara 1. Drive side of belt 2. Tensioner spring 3. Tensioner stud 4. Damper 1. Pin 2. Crankshaft pulley 3. Pulley bolt engine mechanical (g16 engine) 6a1-21 5) install timing belt and tensioner spring. With two sets of marks aligned and tensioner plate pushed up, install timing belt on tw...
Page 264
Yh4 grand vitara 6a1-22 engine mechanical (g16 engine) 9) install radiator fan shroud, water pump pulley, cooling fan and water pump drive belt. Adjust water pump drive belt tension, referring to “engine cooling” section. 10) install power steering pump belt or a / c compressor belt, if equipped. Ad...
Page 265
Yh4 grand vitara 1. Oil pan 2. Oil pump strainer 3. Seal 4. Drain plug gasket 5. Drain plug 6. Ckp sensor 3. Oil pan 1. Oil pan engine mechanical (g16 engine) 6a1-23 oil pan and oil pump strainer removal 1) raise vehicle. 2) remove front differential housing (1) with differential (2), refer- ring to...
Page 266
Yh4 grand vitara 1. Cylinder block 2. Strainer 3. Oil pan 6a1-24 engine mechanical (g16 engine) 6) remove oil pan and then oil pump strainer. Cleaning clean mating surfaces of oil pan and cylinder block. Remove oil, old sealant, and dusts from mating surfaces and oil pan inside. Clean oil pump strai...
Page 267
Yh4 grand vitara engine mechanical (g16 engine) 6a1-25 installation 1) apply sealant to oil pan mating surface continuously as shown in figure. “a” sealant: 99000-31150 2) install oil pump strainer (1) and oil pan (3). Install seal (2) in the position as shown in figure. Tighten strainer bolt first ...
Page 268
Yh4 grand vitara 6a1-26 engine mechanical (g16 engine) 5) install ckp sensor (1) and connect its coupler. Tightening torque (a): 10 n . M (1.0 kg-m, 7.5 lb-ft) 6) install front differential housing with differential according to installation procedure described in “differential” section. 7) refill f...
Page 269
Yh4 grand vitara 1. Rotor plate 2. Inner rotor 3. Outer rotor 4. Gasket 5. Pin 6. Pin 7. Relief valve 8. Spring 9. Retainer 10. Retainer ring 1. Flywheel (drive plate for a / t) 2. Pulley bolt 3. Crank timing belt pulley 1. Cylinder block engine mechanical (g16 engine) 6a1-27 oil pump removal 1) dis...
Page 270
Yh4 grand vitara 2. Oil level gauge guide 4. Guide seal 6a1-28 engine mechanical (g16 engine) 6) remove oil pump assembly (1) after removing bolts (2). Disassembly 1) remove oil level gauge guide bolt (3) and pull out guide from oil pump (1). 2) remove rotor plate (1). 3) remove outer rotor (1) and ...
Page 271
Yh4 grand vitara 1. Oil seal 2. Oil pump case 1. Outer rotor 2. Inner rotor 1. Outer rotor 2. Inner rotor engine mechanical (g16 engine) 6a1-29 note: when installing oil seal, press-fit it till its end face is flush with oil pump case end face. Check outer and inner rotors, rotor plate, and oil pump...
Page 272
Yh4 grand vitara 1. Oil pump 2. Oil level gauge guide 3. Guide seal 1. No. 1 bolts (short) 2. No. 2 bolts (long) 6a1-30 engine mechanical (g16 engine) 4) install rotor plate. Tighten 5 screw securely. After installing plate, check to be sure that gears turn smoothly by hand. 5) apply engine oil to g...
Page 273
Yh4 grand vitara engine mechanical (g16 engine) 6a1-31 1. Key 2. Crank timing belt pulley 3. Pulley bolt 4. Dowel pin (crankshaft pulley pin) 5. Flywheel (drive plate for a / t) 5 5) install timing pulley key and crank timing belt pulley. Refer to figure for proper installation of these parts. With ...
Page 274
Yh4 grand vitara -1 1. Camshaft -1 2. Camshaft oil seal -1 3. Rocker arm shaft -1 4. O-ring -1 5. Rocker shaft bolt -1 6. Rocker arm (in) -1 7. Rocker arm no. 1 (ex) -1 8. Rocker arm no. 2 (ex) -1 9. Valve adjusting screw -1 10. Valve adjusting screw -1 11. Clip -1 12. Lock nut (without flange) 12-1...
Page 275
Yh4 grand vitara 1. Camshaft pulley 1. Cmp sensor 2. Cmp sensor case 1. Valve adjusting screw 2. Lock nut 3. Rocker arm 1. Oil plug 2. Timing belt inside cover engine mechanical (g16 engine) 6a1-33 5) remove camshaft timing belt pulley by using special tool. Special tool (a): 09917-68220 6) remove c...
Page 276
Yh4 grand vitara 1. Rocker arm (in) 2. Clip 3. Rocker arm shaft 1. Rocker arm shaft 2. O-ring 1. Rocker arm shaft bolt 2. Rocker arm shaft ex 1. Rocker arm (ex) 2. Rocker arm spring 1. Adjusting screw 2. Rocker arm 3. Cam-riding face in 6a1-34 engine mechanical (g16 engine) 11) remove intake rocker ...
Page 277
Yh4 grand vitara engine mechanical (g16 engine) 6a1-35 rocker arm shaft runout using “v” blocks and dial gauge, check runout. If runout exceeds its limit, replace rocker arm shaft. Runout limit: 0.20 mm (0.008 in.) rocker arm-to-rocker arm shaft clearance using a micrometer and a bore gauge, measure...
Page 278
Yh4 grand vitara 1. Gaging plastic 2. Scale 6a1-36 engine mechanical (g16 engine) camshaft journal wear check camshaft journals and camshaft housings for pitting, scratches, wear or damage. If any malcondition is found, replace camshaft or cylinder head with housing. Never replace cylinder head with...
Page 279
Yh4 grand vitara 1. Rocker arm spring 2. Rocker arm (ex) 1. Rocker arm shaft 2. O-ring 1. Parallel engine mechanical (g16 engine) 6a1-37 if measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head as...
Page 280
Yh4 grand vitara 1. Rocker arm 2. Clip 3. Pivot holding part 1. Timing belt side 2. Flywheel side 3. Camshaft housing no.6 indicates position from timing belt side. Install in numerical order starting from timing belt side. Indicates direction of housing. Install so that arrow is directed toward tim...
Page 281
Yh4 grand vitara 1. Camshaft oil seal 1. Camshaft timing belt pulley 2. Dwell pin 1. O-ring engine mechanical (g16 engine) 6a1-39 8) install camshaft oil seal. After applying engine oil to oil seal lip, press-fit camshaft oil seal till oil seal surface becomes flush with housing surface. 9) install ...
Page 282
Yh4 grand vitara 1. Engine hood lock 6a1-40 engine mechanical (g16 engine) 14) adjust valve clearance as previously outlined. 15) install cylinder head cover. 16) install radiator and refill cooling system referring to “engine cooling” section. 17) install hood lock to front upper member and adjust ...
Page 283
Yh4 grand vitara 1. Valve cotters 2. Valve spring retainer 3. Valve spring 4. Valve stem seal 5. Valve spring seat 6. Exhaust valve 7. Intake valve engine mechanical (g16 engine) 6a1-41 valves and cylinder head removal 1) relieve fuel pressure according to fuel pressure relief procedure described in...
Page 284
Yh4 grand vitara 6a1-42 engine mechanical (g16 engine) 5) remove air intake hose. 6) disconnect following electric wires: throttle position sensor manifold differential idle air control valve pressure sensor engine coolant temp. Sensor evap canister purge valve camshaft position sensor injector wire...
Page 285
Yh4 grand vitara “1”: camshaft pulley side “2”: distributor side engine mechanical (g16 engine) 6a1-43 13) disconnect exhaust pipe from exhaust manifold and remove exhaust manifold stiffener or exhaust pipe bracket bolt. 14) loosen cylinder head bolts in such order as indicated in figure and remove ...
Page 286
Yh4 grand vitara 1. Valve cotters 1. Valve stem oil seal 2. Valve spring seat 6a1-44 engine mechanical (g16 engine) disassembly 1) for ease in servicing cylinder head, remove intake manifold with throttle body and exhaust manifold from cylinder head. 2) remove intake rocker arm with clip from rocker...
Page 287
Yh4 grand vitara 1. Valve head thickness 2. 45 _ (1) (2) engine mechanical (g16 engine) 6a1-45 inspection valve guides using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length...
Page 288
Yh4 grand vitara 6a1-46 engine mechanical (g16 engine) inspect valve stem end face for pitting and wear. If pitting or wear is found there, valve stem end may be resurfaced, but not so much as to grind off its chamfer. When it is worn so much that its chamfer is gone, replace valve. Seating contact ...
Page 289
Yh4 grand vitara 1. Valve seat cutter 1. Valve seat engine mechanical (g16 engine) 6a1-47 d valve seat repair: a valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding an...
Page 290
Yh4 grand vitara 6a1-48 engine mechanical (g16 engine) flatness of gasketed surface: using a straightedge and thickness gauge, check surface at a to- tal of 6 locations. If distortion limit, given below, is exceeded, cor- rect gasketed surface with a surface plate and abrasive paper of about #400 (w...
Page 291
Yh4 grand vitara engine mechanical (g16 engine) 6a1-49 valve springs referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing pow...
Page 292
Yh4 grand vitara 1. Valve guide protrusion (11.5 mm) 6a1-50 engine mechanical (g16 engine) assembly 1) before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so remove burrs and make it truly round. Special tool (a): 09916-34542 (b): 09916-38210 2) install...
Page 293
Yh4 grand vitara 1. Valve stem seal 1. Large-pitch 2. Small-pitch 3. Valve spring retainer side 4. Valve spring seat side 1. Valve cotters engine mechanical (g16 engine) 6a1-51 5) install new valve stem seal to valve guide. After applying engine oil to seal and spindle of special tool (valve guide i...
Page 294
Yh4 grand vitara 6a1-52 engine mechanical (g16 engine) “” 1. Cylinder head gasket “2”. Crankshaft pulley side “3”. Flywheel side “1”: camshaft pulley side “1” 1 “2” “3” 9) install rocker arms, springs and rocker arm shaft as previously outlined. 10) install intake manifold and exhaust manifold. Inst...
Page 295
Yh4 grand vitara engine mechanical (g16 engine) 6a1-53 4) reverse removal procedure for installation. 5) adjust water pump drive belt tension, referring to “engine cooling” section. 6) adjust power steering pump belt tension or a / c compressor belt tension, if equipped. Refer to section 0b. 7) adju...
Page 296
Yh4 grand vitara 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 1. Guide hoses 6a1-54 engine mechanical (g16 engine) piston, piston rings, connecting rods and cylinders removal 1) remove cyli...
Page 297
Yh4 grand vitara 1. Piston pin circlip engine mechanical (g16 engine) 6a1-55 disassembly 1) using piston ring expander, remove two compression rings (top and 2nd) and oil ring from piston. 2) remove piston pin from connecting rod. Ease out piston pin circlips, as shown. Force piston pin out. Cleanin...
Page 298
Yh4 grand vitara 1. 50 mm (1.96 in.) 2. 95 mm (3.74 in.) 1. 23 mm (0.91 in.) 6a1-56 engine mechanical (g16 engine) inspection cylinders inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cyli...
Page 299
Yh4 grand vitara engine mechanical (g16 engine) 6a1-57 1. 23 mm (0.91 in.) 1. Piston ring 2. Thickness gauge piston clearance: measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If it ...
Page 300
Yh4 grand vitara 6a1-58 engine mechanical (g16 engine) 1. Cylinder block 2. Feeler gauge 3. Piston ring 4. 120 mm (4.72 in.) piston rings to measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge. If measured gap is out of specification, replace ring...
Page 301
Yh4 grand vitara 1. Gaging plastic 1. Rod bearing cap 2. Arrow mark 3. Crankshaft pulley side engine mechanical (g16 engine) 6a1-59 crank pin and connecting rod bearings inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is damage...
Page 302
Yh4 grand vitara 1. Gaging plastic 2. Scale 1 or 2 piston no. 1 cylinder no. 2 cylinder no. 3 cylinder no. 4 cylinder crank pulley side flywheel side finished crankpin dia. = measured big end bore dia. (including undersize bearing) 0.035 mm (0.0014 in.) – 6a1-60 engine mechanical (g16 engine) 5) rem...
Page 303
Yh4 grand vitara 1. Piston 2. Arrow mark 3. Connecting rod 4. Oil hole the oil hole should come on intake side 1. Arrow mark 2. 1st ring end gap 3. 2nd ring end gap and oil ring spacer gap 4. Oil ring upper rail gap 5. Oil ring lower rail gap 6. Intake side 7. Exhaust side 1. 1st ring 2. 2nd ring 3....
Page 304
Yh4 grand vitara 6a1-62 engine mechanical (g16 engine) 1. Crankshaft pulley side 2. Flywheel side 1. Rod bearing cap 2. Arrow mark 3. Crankshaft pulley side installation or connection 1) apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankpins. Note: do not apply oil...
Page 305
Yh4 grand vitara engine mechanical (g16 engine) 6a1-63 6) reverse removal procedure for installation, as previously out- lined. 7) adjust water pump drive belt tension, referring to section 0b. 8) adjust power steering pump belt tension or a / c compressor belt tension, if equipped. Refer to section...
Page 306: Unit Repair Overhaul
Yh4 grand vitara 6a1-64 engine mechanical (g16 engine) unit repair overhaul engine assembly removal 1) release fuel pressure in fuel feed line by referring to fuel pres- sure relief procedure in section 6. 2) disconnect negative cable from battery. 3) remove engine hood. 4) drain cooling system. 5) ...
Page 307
Yh4 grand vitara engine mechanical (g16 engine) 6a1-65 9) disconnect following hoses: canister purge hose from evap canister purge valve radiator outlet hose from inlet pipe brake booster hose from intake manifold vacuum hose from intake manifold heater inlet and outlet hose from pipe fuel feed hose...
Page 308
Yh4 grand vitara 6a1-66 engine mechanical (g16 engine) 16) remove right side transmission stiffener from transmission and cylinder block (a / t). 17) remove clutch housing (torque converter housing) lower plate. 18) remove torque converter bolts (a / t). Special tool (a): 09927-56010 19) remove nuts...
Page 309
Yh4 grand vitara engine mechanical (g16 engine) 6a1-67 installation 1) lower engine assembly into engine compartment and connect engine to transmission. Hand-tighten bolts and nuts fastening cylinder block and trans- mission. 2) tighten engine mounting bracket nuts (r & l). Tightening torque (a): 50...
Page 310
Yh4 grand vitara 6a1-68 engine mechanical (g16 engine) tighten bolts of exhaust pipes to specified torque. Tightening torque (a): 50 n . M (5.0 kg-m, 36.5 lb-ft) tighten transmission stiffener bolts (right side) to specified torque (a / t). Tightening torque (a): 50 n . M (5.0 kg-m, 36.5 lb-ft) 6) a...
Page 311
Yh4 grand vitara 1. Cylinder block 2. Front oil seal 3. Main bearing 4. Bearing cap 5. Cap bolt 6. Timing pulley key 7. Crankshaft 8. Thrust bearing 9. Rear oil seal 10. Pin 11. Oil seal housing gasket 12. Oil seal housing 13. Housing bolt 14. Input shaft bearing 15. Flywheel 16. Flywheel bolt engin...
Page 312
Yh4 grand vitara 1. Flywheel bolt 1. Oil pump 2. Bolt 6a1-70 engine mechanical (g16 engine) removal 1) remove engine assembly from body as previously outlined. 2) remove clutch cover, clutch disc and flywheel (drive plate for a / t). Special tool (a): 09924-17810 3) remove crankshaft pulley, timing ...
Page 313
Yh4 grand vitara 1. Thrust bearing engine mechanical (g16 engine) 6a1-71 inspection crankshaft crankshaft runout using a dial gauge, measure runout at center journal. Rotate crank- shaft slowly. If runout exceeds its limit, replace crankshaft. Limit on runout: 0.06 mm (0.0023 in.) crankshaft thrust ...
Page 314
Yh4 grand vitara 1. Cylinder block 2. Upper half of bearing 3. Oil groove 1. Gaging plastic 6a1-72 engine mechanical (g16 engine) main bearings general information service main bearings are available in standardsize and 0.25 mm (0.0098 in.) undersize, and each of them has 5 kinds of bearings differi...
Page 315
Yh4 grand vitara 1. Gaging plastic 2. Scale 1. Crank webs of no.2 and no.3 cylinders engine mechanical (g16 engine) 6a1-73 5) remove cap and using scale on gaging plastic envelope, mea- sure gaging plastic width at its widest point. If clearance exceeds its limit, replace bearing. Always replace bot...
Page 316
Yh4 grand vitara 1. Paint 6a1-74 engine mechanical (g16 engine) 2) next, check bearing cap bore diameter without bearing. On mat- ing surface of cylinder block, four alphabets are stamped as shown in figure. Three kinds of alphabets (“a”, “b” and “c”) represent following cap bore diameters. Alphabet...
Page 317
Yh4 grand vitara 1. Crank webs of no.2 and no.3 cylinders 1. Gaging plastic 2. Scale 1. Paint engine mechanical (g16 engine) 6a1-75 4) from numerals stamped on crank webs of no.2 and no.3 cylin- ders and the alphabets stamped on mating surface of cylinder block, determine new standard bearing to be ...
Page 318
Yh4 grand vitara 1. Rear oil seal 1. Oil seal 2. Oil seal housing 6a1-76 engine mechanical (g16 engine) if necessary, regrind crankshaft journal and select under-size bearing to use with it as follows. 1) regrind journal to following finished diameter. Finished diameter:51.732 – 51.750 mm (2.0367 – ...
Page 319
Yh4 grand vitara 1. 23 mm (0.91 in.) engine mechanical (g16 engine) 6a1-77 flywheel if ring gear is damaged, cracked or worn, replace flywheel. If the surface contacting clutch disc is damaged, or excessively worn, replace flywheel. Check flywheel for face runout with dial gauge. If runout exceeds i...
Page 320
Yh4 grand vitara 1. Cylinder block 2. Upper half of bearing 3. Oil groove 1. Thrust bearing 2. Oil groove 6a1-78 engine mechanical (g16 engine) 5) rebore and hone cylinder to calculated dimension. Note: before reboring, install all main bearing caps in place and tighten to specification to avoid dis...
Page 321
Yh4 grand vitara 1. Short bolts 2. Long bolts engine mechanical (g16 engine) 6a1-79 3) install crankshaft to cylinder block. 4) install bearing cap to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequen- tially in ascending order, 1, 2, 3, 4 and 5...
Page 322
Yh4 grand vitara 6a1-80 engine mechanical (g16 engine) 8) install pistons and connecting rods as previously outlined. 9) install oil pump strainer and oil pan as previously outlined. 10) install cylinder head assembly to cylinder block as previously outlined. 11) install camshaft, crankshaft timing ...
Page 323: Special Tools
Yh4 grand vitara 1. 09915-64510-001 compression gauge 2. 09915-64510-002 connector 3. 09915-64530 hose 4. 09915-67010 attachment 09915-67310 vacuum gauge 09918-08210 vacuum gauge hose joint 09915-77310 oil pressure gauge 09917-18210 tappet adjuster wrench 09927-56010 gear stopper 09926-18210 oil sea...
Page 324: Required Service Materials
Yh4 grand vitara 6a1-82 engine mechanical (g16 engine) 09917-98221 valve stem seal installer 09916-77310 piston ring compressor 09924-17810 flywheel holder 09915-47330 oil filter wrench required service materials materials recommended suzuki product use sealant suzuki bond no.1207c (99000-31150) mat...
Page 325: Section 6A2
Yh4 grand vitara 6a2 engine mechanical (h25 engine) 6a2-1 section 6a2 engine mechanical (h25 engine) 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. Ref...
Page 326: General Description
Yh4 grand vitara 6a2-2 engine mechanical (h25 engine) the engine is a water-cooled, 60 _ v6 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration. The double overhead camshaft is mounted over the cylinder head; it i...
Page 327
Yh4 grand vitara engine mechanical (h25 engine) 6a2-3 the oil pump is of a trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into 3 paths in cylinder block. In one path, oil reaches the...
Page 328: On-Vehicle Service
Yh4 grand vitara 1. Ignition coil 2. Spark plug 6a2-4 engine mechanical (h25 engine) on-vehicle service compression check check compression pressure on all 6 cylinders as follows: 1) warm up engine. 2) stop engine after warming up. 3) remove ignition coil covers and disconnect ignition coil har- nes...
Page 329
Yh4 grand vitara 2. Evap canister purge valve engine mechanical (h25 engine) 6a2-5 engine vacuum check the engine vacuum that develops in the intake line is a good indica- tor of the condition of the engine. The vacuum checking procedure is as follows: 1) warm up engine to normal operating temperatu...
Page 330
Yh4 grand vitara for rh steering vehicle for lh steering vehicle 6a2-6 engine mechanical (h25 engine) oil pressure check note: prior to checking oil pressure, check the followings. Oil level in oil pan if oil level is low, add oil up to full level hole on oil level gauge. Oil quality if oil is disco...
Page 331
Yh4 grand vitara engine mechanical (h25 engine) 6a2-7 air cleaner element this air cleaner element is of dry type. Note that it needs cleaning according to the following method. Removal 1) remove air cleaner upper case. 2) remove air cleaner element. Inspection check element for dirt. Clean blow off...
Page 332
Yh4 grand vitara 1. Air cleaner box 2. Intake air hose 3. Intake air pipe 4. Surge tank pipe 5. Intake manifold 6. Throttle body 7. Intake collector 8. Intake air temperature sensor 9. Manifold absolute pressure (map) sensor 1. Radiator 2. Radiator drain plug 9 6a2-8 engine mechanical (h25 engine) t...
Page 333
Yh4 grand vitara 2 1 1. Surge tank cover 1. Intake air pipe 2. Surge tank pipe 1. Accelerator cable 2. A / t throttle cable 3. Water hose 1. Injector wire 2. Brake booster hose 1. Tp sensor 2. Maf sensor 3. Iac valve coupler 4. Earth wires 5. Clamp bracket engine mechanical (h25 engine) 6a2-9 6) rem...
Page 334
Yh4 grand vitara 1 2 1. Evap canister purge valve 2. Egr valve 3. Egr pipe 4. Evap canister purge valve hose 5. Heater hose 6. Pcv hose 7. Water hose 8. Breather hose 1. Heater hose 2. Fuel feed hose 3. Fuel return hose 4. Evap canister hose 5. Vacuum hose 1. Throttle body 2. Intake collector 3. Int...
Page 335
Yh4 grand vitara 1 1. Gasket 1. Intake manifold 1. Intake collector 2. Throttle body 1. Iac valve 2. Egr valve 3. Evap canister purge valve 4. Evap canister purge valve hose 5. Iac valve hose 6. Clamp 1. Heater hose 2. Fuel feed hose 3. Fuel return hose 4. Evap canister hose 5. Vacuum hose engine me...
Page 336
Yh4 grand vitara 2 1 1. Evap canister purge valve 2. Egr valve 3. Egr pipe 4. Evap canister purge valve hose 5. Heater hose 6. Pcv hose 7. Water hose 8. Breather hose 1. Tp sensor coupler 2. Maf sensor coupler 3. Iac valve coupler 4. Earth wires 5. Clamp bracket 1. Injector wire 2. Brake booster hos...
Page 337
Yh4 grand vitara 1. Surge tank cover 1. Strut tower bar engine mechanical (h25 engine) 6a2-13 19) install surge tank cover. 20) install air cleaner upper case. 21) connect coupler to intake air temp. Sensor. 22) install strut tower bar. 23) check to ensure that all removed parts are back in place. R...
Page 338
Yh4 grand vitara 3 1. Exhaust manifold 2. Exhaust manifold cover 3. Oil level gauge guide 1. Ho2s-1 (colorless connector) 2. Ho2s-2 (black connector) type 1 type 2 1. Exhaust manifold 2. Exhaust manifold cover 3. Exhaust no.1 pipe 6a2-14 engine mechanical (h25 engine) exhaust manifold warning: to av...
Page 339
Yh4 grand vitara engine mechanical (h25 engine) 6a2-15 1. Stiffener 2. Exhaust no.1 pipe 1. Left (no.1) exhaust manifold 2. Right (no.2) exhaust manifold 1. Exhaust manifold stiffener 2. Exhaust no.1 pipe 3. Transmission 1. Match mark 7) hoist vehicle. 8) for 4wd vehicle, before disconnecting front ...
Page 340
Yh4 grand vitara 6a2-16 engine mechanical (h25 engine) 1. Exhaust no.1 pipe 2. Catalytic converter 3. Stiffener 1. Match mark type 1 type 2 1. Exhaust manifold 2. Exhaust no.1 pipe 4) install exhaust no.1 pipe and stiffener. Tighten exhaust no.1 pipe bolts and nuts to specified torque. Tightening to...
Page 341
Yh4 grand vitara 1. Exhaust manifold 2. Exhaust manifold cover 3. Oil level gauge guide 1. Ho2s-1 (colorless connector) 2. Ho2s-2 (black connector) engine mechanical (h25 engine) 6a2-17 6) connect egr pipe to left (no.1) bank exhaust manifold. 7) install exhaust manifold covers. 8) install oil level...
Page 342
Yh4 grand vitara 6a2-18 engine mechanical (h25 engine) 1. Cylinder head cover 2. Nut 3. Seal washer 4. Cylinder head cover gasket left (no.1) cylinder area to apply sealant “a” right (no.2) cylinder area to apply sealant “a” 1. Cylinder head cover 2. Nut 3. Seal washer 4. Cylinder head cover gasket ...
Page 343
Yh4 grand vitara engine mechanical (h25 engine) 6a2-19 1. Upper oil pan 2. Lower oil pan 3. Oil pump strainer 4. Bracket 5. O-ring 6. Drain plug 7. Gasket 1. Differential housing 2. Differential 3. Oil pan 1. Upper oil pan 2. Lower oil pan 3. Drain plug oil pan and oil pump strainer removal 1) remov...
Page 344
Yh4 grand vitara 6a2-20 engine mechanical (h25 engine) 1. Oil strainer 2. Screen 1. O-ring 1. Upper oil pan 1. Upper oil pan clean inside of oil pan and oil pump strainer screen. Clean sealing surface on upper oil pan, lower oil pan and lower crankcase. Remove oil, old sealant, and dust from sealing...
Page 345
Yh4 grand vitara engine mechanical (h25 engine) 6a2-21 (f) (d) 1. Upper oil pan 1. Upper oil pan 2. Oil pump strainer 3. Bracket 1. Gasket 2. Drain plug 5) install upper oil pan to lower crankcase. Tightening torque (b): 11.0 n . M (1.1 kg-m, 8.0 lb-ft) (c): 27.0 n . M (2.7 kg-m, 19.5 lb-ft) 6) inst...
Page 346
Yh4 grand vitara 6a2-22 engine mechanical (h25 engine) 1. Timing chain cover 2. Crankshaft pulley 3. Crankshaft pulley bolt 4. Oil seal 5. O-ring 6. Ckp sensor 1. Crankshaft pulley 2. Bolt 3. Wrench 1. Crankshaft pulley timing chain cover removal 1) disconnect negative cable at battery. 2) drain eng...
Page 347
Yh4 grand vitara engine mechanical (h25 engine) 6a2-23 1. Timing chain cover 2. Oil seal 1. Timing chain cover 2. Sealant “a” (d): all bolts 1. Crankshaft pulley 2. Bolt 3. Wrench 4. Ckp sensor 4 clean clean sealing surface on timing chain cover, crankcase, cylinder block and cylinder heads. Remove ...
Page 348
Yh4 grand vitara 6a2-24 engine mechanical (h25 engine) 1. Oil pump ass’y 2. Oil pump chain guide 3. Oil pump chain 4. Bolt 1. Oil pump 2. Crankcase 1. Oil pump case no.1 2. Oil pump case no.2 3. Relief valve 4. Relief spring 5. Retainer oil pump removal 1) disconnect negative cable at battery. 2) dr...
Page 349
Yh4 grand vitara engine mechanical (h25 engine) 6a2-25 1. Oil pump case no.1 2. Outer rotor 3. Inner rotor 4. Thickness gauge 1. Oil pump case no.1 2. Outer rotor 3. Inner rotor 4. Thickness gauge 5. Straightedge measure free length and tension of oil relief spring. Item standard spring free length ...
Page 350
Yh4 grand vitara 6a2-26 engine mechanical (h25 engine) (e) 1 (a) (d): long size 1. Oil pump chain guide 3) assemble oil pump. After assembling oil pump check to be sure that rotor turns smoothly by hand. Tightening torque (a): 12.0 n . M (1.2 kg-m, 8.5 lb-ft) installation 1) install oil pump to cran...
Page 351
Yh4 grand vitara engine mechanical (h25 engine) 6a2-27 1. Lh bank 2nd timing chain 2. Timing chain tensioner adjuster no.3 3. Lh bank intake camshaft sprocket 4. Lh bank exhaust camshaft sprocket 5. Camshaft sprocket bolt 6. Timing chain guide no.4 7. Timing chain guide no.5 8. Idler sprocket no.2 l...
Page 352
Yh4 grand vitara 6a2-28 engine mechanical (h25 engine) 1. Timing chain tensioner adjuster no.3 2. Lh bank intake camshaft 1. Lh bank intake camshaft sprocket 2. Lh bank exhaust camshaft sprocket 3. Hexagonal part of camshaft 1. Lh bank exhaust camshaft sprocket 2. Lh bank exhaust camshaft 6) remove ...
Page 353
Yh4 grand vitara engine mechanical (h25 engine) 6a2-29 1. Timing chain guide no.4 2. Timing chain guide no.5 3. Shoe 1. Shoe 1. Latch 2. Tooth surface inspection timing chain guide no.4 and no.5 check shoe for wear or damage. Camshaft sprocket check teeth of sprocket for wear or damage. Timing chain...
Page 354
Yh4 grand vitara 6a2-30 engine mechanical (h25 engine) 2, (a) 1. Crank timing pulley key 2. Oil jet 1. Idler sprocket no.2 2. Mark 3. Crankshaft 1. Timing chain guide no.4 2. Bolts 1. Knock pin of lh bank intake camshaft 2. Knock pin of lh bank exhaust camshaft 3. Match mark of intake side 4. Match ...
Page 355
Yh4 grand vitara engine mechanical (h25 engine) 6a2-31 4, (b) 1. Silver plate 2. Arrow mark on intake camshaft timing sprocket 3. Arrow mark on exhaust camshaft timing sprocket 4. Sprocket bolt 1. Timing drain tensioner adjuster no.3 2. Stopper 1. Plunger 2. Latch 3. Set hole 4. Stopper (pin) 6) ins...
Page 356
Yh4 grand vitara 6a2-32 engine mechanical (h25 engine) 1. Crank timing pulley key 2. Oil jet 3. Timing mark of rh bank 1st timing chain sprocket 4. Timing mark of rh bank 1st timing chain 5. Timing mark or lh bank 2nd timing chain intake sprocket 6. Timing mark of lh bank 2nd timing chain 7. Timing ...
Page 357
Yh4 grand vitara engine mechanical (h25 engine) 6a2-33 1. 1st timing chain 2. Timing chain tensioner adjuster no.1 3. Rh bank 1st timing chain intake camshaft sprocket 4. 1st timing chain crankshaft sprocket 5. Idler sprocket no.2 6. Shaft 7. Idler sprocket no.1 8. Shaft 9. Washer 10. Timing chain t...
Page 358
Yh4 grand vitara 6a2-34 engine mechanical (h25 engine) 1. Rh bank 1st timing chain intake camshaft sprocket 2. Rh bank intake camshaft 3. Hexagonal part of camshaft 5) for reinstallation of timing chain, align 8 timing marks as shown in figure by turning crankshaft. 6) remove lh bank 2nd timing chai...
Page 359
Yh4 grand vitara engine mechanical (h25 engine) 6a2-35 1. Timing chain guide no.1 2. Timing chain guide no.2 1. Shoe 1. Bearing inspection timing chain guides no.1 and no.2 check shoe for wear or damage. Timing chain tensioner check shoe for wear or damage. 1st timing chain crankshaft sprocket check...
Page 360
Yh4 grand vitara 6a2-36 engine mechanical (h25 engine) 1. Bush 1. Latch 2. Tooth surface 1. Crank timing pulley key 1. Crankshaft 2. Crankshaft timing sprocket 3. Lower crankcase 2. Oil jet idler sprocket no.2 check teeth of sprocket for wear or damage. 1st timing chain check timing chain for wear o...
Page 361
Yh4 grand vitara engine mechanical (h25 engine) 6a2-37 5, (a) (b) 1. Knock pin of intake camshaft 2. Match mark 1. Rh bank 1st timing chain intake camshaft sprocket 2. Rh bank intake camshaft 3. Hexagonal part of camshaft 4. Rh mark 5. Bolt 1. Timing chain tensioner 2. Spacer 3. Rh bank cylinder hea...
Page 362
Yh4 grand vitara 6a2-38 engine mechanical (h25 engine) (d) 1. Silver plate 2. Match mark on intake sprocket 3. Rh bank cylinder head 1. Gold or yellow plate 2. Match mark on crankshaft timing sprocket 3. Crankshaft 1. Plunger 2. Latch 3. Stopper 1. Timing chain tensioner adjuster no.1 2. Timing chai...
Page 363
Yh4 grand vitara engine mechanical (h25 engine) 6a2-39 (e) (e) (e) 1. Timing chain guide no.2 2. Timing chain guide no.1 3. Guide bolts 3. Match mark of rh bank 1st timing chain sprocket 4. Silver plate (lh) of 1st timing chain 1. Crank timing pulley key 2. Oil jet 5. Match mark of idler sprocket no...
Page 364
Yh4 grand vitara 6a2-40 engine mechanical (h25 engine) 18) install lh bank 2nd timing chain. Refer to item “lh (no.1) bank 2nd timing chain and tensioner” in this section for installation. 19) install timing chain cover. Refer to item “timing chain cover” in this section for instal- lation. 20) inst...
Page 365
Yh4 grand vitara engine mechanical (h25 engine) 6a2-41 1. Rh bank 2nd timing chain 2. Timing chain tensioner adjuster no.2 3. Rh bank exhaust camshaft sprocket 4. Rh bank 2nd timing chain intake camshaft sprocket 5. Rh bank exhaust camshaft 6. Rh bank intake camshaft 7. Rh bank exhaust camshaft hold...
Page 366
Yh4 grand vitara 6a2-42 engine mechanical (h25 engine) 1. Shoe 2) remove lh bank 2nd timing chain. Refer to item “lh (no.1) bank 2nd timing chain and chain tensioner” in this section for removal. 3) remove 1st timing chain. Refer to item “1st timing chain and chain tensioner” in this section for rem...
Page 367
Yh4 grand vitara engine mechanical (h25 engine) 6a2-43 (a) (a) 1. Shoe 1. Crank timing pulley key 2. Oil jet 1. Timing chain tensioner adjuster no.2 2. Engine front side 3. Water pump side rh bank 2nd timing chain sprockets check teeth of sprocket for wear or damage. Rh bank 2nd timing chain check t...
Page 368
Yh4 grand vitara 6a2-44 engine mechanical (h25 engine) 1. Yellow or silver plate 2. Match mark of rh bank 2nd timing chain exhaust camshaft sprocket 3. Match mark of rh bank 2nd timing chain intake camshaft sprocket 1. Rh bank intake camshaft 2. Rh bank exhaust camshaft 3. Pin i: intake side e: exha...
Page 369
Yh4 grand vitara engine mechanical (h25 engine) 6a2-45 (c) (c) 1. Timing chain guide no.3 9) install timing chain guide no.3. Tightening torque (c): 11 n . M (1.1 kg-m, 7.5 lb-ft) 10) install 1st timing chain. Refer to item “1st timing chain and chain tensioner” in this section for installation. 11)...
Page 370
Yh4 grand vitara 6a2-46 engine mechanical (h25 engine) 1. Oil pump chain 2. Oil pump drive sprocket 3. Oil pump chain tensioner (oil pump guide) 3 2 oil pump chain removal 1) disconnect negative cable at battery. 2) drain engine oil. 3) drain coolant. 4) remove timing chain cover. Refer to item “tim...
Page 371
Yh4 grand vitara engine mechanical (h25 engine) 6a2-47 1. Oil pump drive chain 2. Oil pump sprocket 3. Match mark 7) put match marks to oil pump chain and oil pump sprocket. 8) remove oil pump chain guide. 9) remove oil pump chain. 10) remove oil pump drive sprocket..
Page 372
Yh4 grand vitara 6a2-48 engine mechanical (h25 engine) 1. Shoe 1. Crankshaft 2. Oil pump drive sprocket 3. Crankcase inspection oil pump chain guide check shoe for wear or damage. Oil pump drive sprocket check teeth of sprocket for wear or damage. Oil pump sprocket check teeth of sprocket for wear o...
Page 373
Yh4 grand vitara engine mechanical (h25 engine) 6a2-49 (c) 1, (c) 1. Oil pump drive chain 2. Oil pump sprocket 3. Match mark 1. Oil pump chain guide 2) install oil pump chain by aligning match marks on oil pump chain and oil pump sprocket. 3) install oil pump chain guide and hand-tighten oil pump ch...
Page 374
Yh4 grand vitara 6a2-50 engine mechanical (h25 engine) 1. Rh bank 2nd timing chain 2. Rh bank exhaust camshaft 3. Rh bank intake camshaft 4. Rh bank exhaust camshaft holder 5. Rh bank intake camshaft holder 6. Lh bank intake camshaft 7. Lh bank exhaust camshaft 8. Lh bank intake camshaft holder 9. L...
Page 375
Yh4 grand vitara engine mechanical (h25 engine) 6a2-51 lh bank don’t apply force 1. Engine oil 2. Valve lash adjuster removal 1) disconnect negative cable at battery. 2) drain engine oil. 3) drain coolant. 4) remove timing chain cover. Refer to item “timing chain cover” in this section for re- moval...
Page 376
Yh4 grand vitara 6a2-52 engine mechanical (h25 engine) rh bank lh bank 1. Gaging plastic 2. Scale “a” camshaft runout set camshaft between two “v” blocks, and measure its runout by using a dial gauge. If measured runout exceeds below specified limit, replace cam- shaft. Runout limit 0.10 mm (0.0039 ...
Page 377
Yh4 grand vitara engine mechanical (h25 engine) 6a2-53 if measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the differ- ence from specification is greater. Standard camshaft...
Page 378
Yh4 grand vitara 6a2-54 engine mechanical (h25 engine) 1. Cylinder head 2. Oil hole 1. Crank timing pulley key 2. Oil jet 1. Lh bank intake camshaft 2. Lh bank exhaust camshaft 3. Lh bank cylinder head 4. Match mark lh bank installation 1) before installing valve lash adjuster to cylinder head, fill...
Page 379
Yh4 grand vitara engine mechanical (h25 engine) 6a2-55 1. Lh bank intake camshaft 2. Lh bank exhaust camshaft 3. Pin installation position 4. Area to apply sealant “a” i: intake side e: exhaust side position from timing chain side timing chain side lh bank 6) install lh bank camshaft housing pins as...
Page 380
Yh4 grand vitara 6a2-56 engine mechanical (h25 engine) 10) install 1st timing chain. Refer to item “1st timing chain and chain tensioner” in this section for installation. 11) install lh bank 2nd timing chain. Refer to item “lh (no.1) bank 2nd timing chain and chain tensioner” in this section for in...
Page 381
Yh4 grand vitara engine mechanical (h25 engine) 6a2-57 valve lash adjuster noise diagnosis in case of the followings, valve lash adjuster noise may be caused by air trapped into valve lash adjusters. Vehicle is left for 24 hours or more. Engine oil is changed. Hydraulic lash adjuster is replaced or ...
Page 382
Yh4 grand vitara 6a2-58 engine mechanical (h25 engine) 1. Cylinder block 2. Rh bank cylinder head 3. Lh bank cylinder head 4. Rh bank cylinder head gasket 5. Lh bank cylinder head gasket 6. Exhaust valve 7. Intake valve 8. Valve spring seat 9. Outer valve spring 10. Inner valve spring 11. Valve stem...
Page 383
Yh4 grand vitara engine mechanical (h25 engine) 6a2-59 1. Hex hole bolt 2. Timing chain side 3. Flywheel side rh bank lh bank removal 1) relieve fuel pressure according to procedure described in sec- tion 6. 2) disconnect negative cable at battery. 3) drain engine oil. 4) drain coolant. 5) remove cm...
Page 384
Yh4 grand vitara 6a2-60 engine mechanical (h25 engine) (e) 1. Valve cotter 1. Valve stem seal 2. Valve spring seat disassembly 1) using special tools (a), (b) & (c), compress valve springs and then remove valve cotters by using special tool (d). Special tool (a): 09916-14510 (b): 09916-14910 (c): 09...
Page 385
Yh4 grand vitara engine mechanical (h25 engine) 6a2-61 1. Valve head thickness 2. 45 inspection valve guides using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each s...
Page 386
Yh4 grand vitara 6a2-62 engine mechanical (h25 engine) 1. Valve seat cutter intake exhaust d seating contact width: create contact pattern one each valve in the usual manner, i.E., by giving uniform coat of marking compound to valve seat and by rotatingly tapping seat with valve head. Valve lapper (...
Page 387
Yh4 grand vitara engine mechanical (h25 engine) 6a2-63 cylinder head remove all carbon from combustion chambers. Note: do not use any sharp-edged tool to scrape off carbon. Be careful not to scuff or nick metal surfaces when decarbon- ing. The same applies to valves and valve seats, too. Check cylin...
Page 388
Yh4 grand vitara 6a2-64 engine mechanical (h25 engine) valve springs referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing pow...
Page 389
Yh4 grand vitara engine mechanical (h25 engine) 6a2-65 1. Valve guide protrusion (13.5 mm) assembly 1) before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round. Special tool (e): 09916-34542 (f): 09916-38210 2) i...
Page 390
Yh4 grand vitara 6a2-66 engine mechanical (h25 engine) 1. Valve stem seal 1. Large-pitch 2. Small-pitch 3. Valve spring retainer side 4. Valve spring seat side 1. Valve cotters 5) install new valve stem seal to valve guide. After applying engine oil to seal and spindle of special tool (valve guide i...
Page 391
Yh4 grand vitara engine mechanical (h25 engine) 6a2-67 1. Cylinder head gasket 2. Crankshaft pulley side 3. Flywheel side 4. Knock pin 5. “86fa” mark rh (no.2) bank lh (no.1) bank 1. Hex hole bolt 2. Crankshaft pulley side 3. Flywheel side rh (no.2) bank lh (no.1) bank 1. Crank timing pulley key 2. ...
Page 392
Yh4 grand vitara 6a2-68 engine mechanical (h25 engine) 8) install valve lash adjuster, camshaft, cmp sensor and rh bank 2nd timing chain. Refer to item “camshaft and valve lash adjuster” and “rh (no.2) bank 2nd timing chain and chain ten- sioner” in this section. For cmp sensor, refer to section 6f2...
Page 393
Yh4 grand vitara engine mechanical (h25 engine) 6a2-69 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10. Cylinder block piston, piston rings, connecting rods and cylinders removal 1) disconn...
Page 394
Yh4 grand vitara 6a2-70 engine mechanical (h25 engine) 1. Guide hose 1. Piston pin circlip 6) mark cylinder number on all pistons, connecting rods and con- necting rod caps. 7) remove rod bearing caps. 8) install guide hose over threads of rod bolts. This prevents damage to bearing journal and rod b...
Page 395
Yh4 grand vitara engine mechanical (h25 engine) 6a2-71 1. 50 mm (1.96 in.) 2. 95 mm (3.74 in.) 1. 26.5 mm (1.04 in.) inspection cylinders inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cy...
Page 396
Yh4 grand vitara 6a2-72 engine mechanical (h25 engine) 1. 26.5 mm (1.04 in.) 1. Piston ring 2. Thickness gauge piston clearance: measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If i...
Page 397
Yh4 grand vitara engine mechanical (h25 engine) 6a2-73 1. Cylinder block 2. Feeler gauge 3. Piston ring 4. 120 mm (4.72 in.) piston rings to measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge. If measure gap is out of specification, replace ring....
Page 398
Yh4 grand vitara 6a2-74 engine mechanical (h25 engine) (a) (a) (a) 1. Red paint 1. Gaging plastic 1 crank pin and connecting rod bearings inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is dam- aged, or out-of-round or taper is...
Page 399
Yh4 grand vitara engine mechanical (h25 engine) 6a2-75 1. Gaging plastic 2. Scale finished crank pin dia. = measured big end bore dia. (including under- size bearing) 0.054 mm (0.0021 in.) – 5) remove cap and using a scale on gaging plastic envelope, measure gaging plastic width at the widest point ...
Page 400
Yh4 grand vitara 6a2-76 engine mechanical (h25 engine) front no. 2 cylinder no. 5 cylinder no. 4 cylinder no. 6 cylinder no. 1 cylinder no. 3 cylinder assembly note: two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a s...
Page 401
Yh4 grand vitara engine mechanical (h25 engine) 6a2-77 1. Piston 2. Arrow mark 3. Connecting rod 86f 1. Piston 2. Arrow mark 3. Connecting rod 4. Oil hole circlip install so that circlip end gap comes within such range as indicated by arrow. 1. Arrow mark 2. 1st ring end gap 3. 2nd ring end gap and ...
Page 402
Yh4 grand vitara 6a2-78 engine mechanical (h25 engine) (a) (a) (a) installation 1) apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. Note: do not apply oil between connecting rod and bearing or be- tween bearing cap and bearing. 2) install guide hoses over c...
Page 403
Yh4 grand vitara engine mechanical (h25 engine) 6a2-79 6) install cylinder heads and oil pump to cylinder block. Refer to item “valves and cylinder heads” and “oil pump” in this section. 7) install valve lash adjusters, camshafts and rh bank 2nd timing chain. Refer to item “camshaft and valve lash a...
Page 404: Unit Repair Overhaul
Yh4 grand vitara 6a2-80 engine mechanical (h25 engine) 1. Accelerator cable 2. A / t throttle cable 4. Earth wires 5. Clamp bracket 1. Evap canister purge valve 2. Iac valve 3. Egr valve 4. Heater hose 1. Tp sensor coupler 2. Maf sensor coupler 3. Iac valve coupler unit repair overhaul engine assemb...
Page 405
Yh4 grand vitara engine mechanical (h25 engine) 6a2-81 1. Fuel feed hose 2. Fuel return hose front 16) disconnect following hoses at the location shown in figure: fuel feed hose from fuel feed pipe fuel return hose from fuel return pipe 17) remove evap canister. 18) remove p/s pump ass’y. Refer to s...
Page 406
Yh4 grand vitara 6a2-82 engine mechanical (h25 engine) 2, (b) 1, (b) 2, (b) 1, (b) (b) 1. Engine side mount bracket 1. Bolt (short) 2. Bolt (long) (c) 32) install lifting device. 33) disconnect engine side mounting brackets to engine mount- ings. 34) before lifting engine, check to ensure all hoses,...
Page 407
Yh4 grand vitara engine mechanical (h25 engine) 6a2-83 type 1 type 2 1. Exhaust no.1 pipe 6) tighten bolts and nuts of exhaust no.1 pipe to specified torque. Tightening torque (d): 50 n . M (5.0 kg-m, 36.5 lb-ft) 7) install front differential housing with differential to chassis if re- moved. Refer ...
Page 408
Yh4 grand vitara 6a2-84 engine mechanical (h25 engine) 1. Cylinder block 2. Lower crankcase 3. Crankshaft 4. Main bearing 5. Thrust bearing 6. Rear oil seal 7. Flywheel (m / t) drive plate (a / t) 8. Water pump 9. O-ring 10. Timing chain oil jet 11. O-ring 12. Clutch housing plate main bearings, cra...
Page 409
Yh4 grand vitara engine mechanical (h25 engine) 6a2-85 (a) 1. Flywheel bolt 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) 2, (a) 3, (b) 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) 4. Long bolt (8 mm thread diameter) 4, (b) rem...
Page 410
Yh4 grand vitara 6a2-86 engine mechanical (h25 engine) 1. Thrust bearing 2. Oil groove 1. Upper half of bearing 2. Oil groove thrust bearing item use a dial gauge to read displacement in axial (thrust) direction of crankshaft. If its limit is exceeded, replace thrust bearing with new standard one or...
Page 411
Yh4 grand vitara engine mechanical (h25 engine) 6a2-87 2, (a) 3, (b) 4, (b) 1. Gaging plastic 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) 4. Long bolt (8 mm thread diameter) 1. Gaging plastic 2. Scale inspect check bearings for pitting, scratches, wear or damage...
Page 412
Yh4 grand vitara 6a2-88 engine mechanical (h25 engine) 1. Crankshaft 2. Crank web 1. Crankshaft pulley side 2. Stamped alphabets no. 1 bearing no. 2 bearing no. 3 bearing no. 4 bearing selection of main bearings standard bearing: if bearing is in malcondition, or bearing clearance is out of specific...
Page 413
Yh4 grand vitara engine mechanical (h25 engine) 6a2-89 1. Paint 3) there are five kinds of standard bearings differing in thickness. To distinguish them, they are painted in following colors at the position as indicated in figure. Each color indicates following thickness at the center of bearing. Co...
Page 414
Yh4 grand vitara 6a2-90 engine mechanical (h25 engine) 1. Paint undersize bearing (0.25 mm): 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in following colors at such position as indicated in figure. Each color represents fol...
Page 415
Yh4 grand vitara engine mechanical (h25 engine) 6a2-91 rear oil seal carefully inspect oil seal for wear or damage. If lip portion is worn or damaged, replace oil seal. Flywheel if ring gear is damaged, cracked or worn, replace flywheel. If the surface contacting clutch disc is damaged, or excessive...
Page 416
Yh4 grand vitara 6a2-92 engine mechanical (h25 engine) 1. Cylinder block 2. O-ring 3. Oil groove 4. Bearing 5. Knock pin 1. Thrust bearing 2. Oil groove 1. Lower crankcase 2. Bearing 5) rebore and hone cylinder to calculated dimension. Note: before reboring, install all main bearing caps in place an...
Page 417
Yh4 grand vitara engine mechanical (h25 engine) 6a2-93 2, (a) 3, (b) 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) 4. Long bolt (8 mm thread diameter) 1. Rear oil seal 1. Fly wheel bolt 6) install crankcase to cylinder block. Apply oil to crankcase bolts be- fore ...
Page 418: Special Tools
Yh4 grand vitara 6a2-94 engine mechanical (h25 engine) 09911-97810 oil seal installer 09913-75510 bearing installer 09915-47310 oil filter wrench 09915-64510 compression gauge 09915-64530 compression gauge hose 09915-67010 compression gauge attachment (c) 09915-67310 vacuum gauge 09915-77310 oil pre...
Page 419: Required Service Material
Yh4 grand vitara engine mechanical (h25 engine) 6a2-95 09917-68221 camshaft lock holder 09917-87810 valve guide installer 09917-98221 valve stem seal installer 09918-08210 vacuum gauge hose joint 09919-28610 protective sleeve 09924-17810 flywheel holder 09926-58010 bearing puller attachment 09944-36...
Page 420: Section 6A4
Yh4 grand vitara 6a4 engine mechanical (j20 engine) 6a4-1 section 6a4 engine mechanical (j20 engine) 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. Ref...
Page 421: General Description
Yh4 grand vitara 6a4-2 engine mechanical (j20 engine) the engine is water-cooled, in line 4 cylinders, 4 stroke cycle gasoline unit with its dohc (double overhead camshaft) valve mechanism arranged for “v” type valve configuration and 16 valves (4 valves / one cylinder). The double overhead camshaft...
Page 422
Yh4 grand vitara engine mechanical (j20 engine) 6a4-3 the oil pump is of a trochoid type, and mounted under the crankshaft. Oil is drawn up through the oil pump strainer and passed through the pump to the oil filter. The filtered oil flows into 2 paths in cylinder block. In one path, oil reaches the...
Page 423: On-Vehicle Service
Yh4 grand vitara 1. Ignition coil 2. Spark plug 3. Accelerator cable 4. Clamp 5. Coupler for injectors 5 6a4-4 engine mechanical (j20 engine) on-vehicle service compression check check compression pressure on all 4 cylinders as follows: 1) warm up engine. 2) stop engine after warming up. Note: after...
Page 424
Yh4 grand vitara 1. Ignition coil 2. Spark plug 3. Accelerator cable 4. Clamp engine mechanical (j20 engine) 6a4-5 10) crank engine with fully charged battery, and read the highest pressure on compression gauge. Note: for measuring compression pressure, crank engine at least 250 r / min. By using fu...
Page 425
Yh4 grand vitara 6a4-6 engine mechanical (j20 engine) engine vacuum check the engine vacuum that develops in the intake line is a good indica- tor of the condition of the engine. The vacuum checking procedure is as follows: 1) warm up engine to normal operating temperature and make sure that engine ...
Page 426
Yh4 grand vitara 1. Oil pressure switch 2. Exhaust manifold 1. Sealing tape engine mechanical (j20 engine) 6a4-7 oil pressure check warning: to avoid danger of being burned, do not touch exhaust man- ifold when exhaust system is hot. When servicing, be sure to perform it after exhaust system has coo...
Page 427
Yh4 grand vitara 6a4-8 engine mechanical (j20 engine) air cleaner element removal 1) remove air cleaner case clamps. 2) remove air cleaner element from case. Inspect check air cleaner element for dirt. Replace excessively dirty ele- ment. Clean blow off dust by compressed air from air outlet side of...
Page 428
Yh4 grand vitara engine mechanical (j20 engine) 6a4-9 1. Intake manifold 2. Intake manifold gasket 3. Throttle body 4. Fuel delivery pipe 5. Egr valve 6. Intake manifold rear stiffener 7. Intake manifold front stiffener 8. Manifold differential pressure sensor throttle body and intake manifold remov...
Page 429
Yh4 grand vitara 1. Gasket 6a4-10 engine mechanical (j20 engine) 6) disconnect accelerator cable and a / t throttle cable (for a / t vehicle) from throttle body. 7) disconnect following hoses: brake booster hose from intake manifold pcv hose from intake manifold fuel pressure regulator vacuum hose f...
Page 430
Yh4 grand vitara engine mechanical (j20 engine) 6a4-11 check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled. Refill cooling system, referring to section 6b. Upon completion of installation, turn ignition switch on but en- gine off an...
Page 431
Yh4 grand vitara 1. Exhaust manifold 2. Exhaust manifold gasket 3. Heated oxygen sensor-1 4. Exhaust manifold upper cover 5. Exhaust manifold stiffener 6. Heated oxygen sensor-2 connector 2. Exhaust manifold upper cover 1. Heated oxygen sensor coupler 1. Exhaust manifold stiffener vehicle not equipp...
Page 432
Yh4 grand vitara 1. Exhaust no.1 pipe 1. Exhaust manifold 2. Exhaust manifold gasket 1. Exhaust manifold gasket 1. Exhaust no.1 pipe engine mechanical (j20 engine) 6a4-13 5) remove exhaust pipe bolts or nuts and exhaust pipe bracket bolt (if equipped). 6) remove exhaust manifold and its gasket from ...
Page 433
Yh4 grand vitara 2. Exhaust manifold upper cover 1. Heated oxygen sensor-1 coupler 1. Exhaust manifold stiffener (if equipped) 6a4-14 engine mechanical (j20 engine) 4) install exhaust manifold stiffener if equipped. Tighten exhaust manifold stiffener nut and bolt to specified torque. 5) install uppe...
Page 434
Yh4 grand vitara 1. Oil level gauge 2. Breather hose 3. Pcv hose : area to apply sealant “a” 1. Cylinder head cover 2. Cylinder head cover gasket 3. O-ring 4. Cylinder head side seal 1. Seal washer 2. Oil level gauge 3. Accelerator cable engine mechanical (j20 engine) 6a4-15 cylinder head cover remo...
Page 435
Yh4 grand vitara 1. Oil pan 2. Strainer 3. O-ring 4. Gasket 5. Drain plug 1. Differential housing 2. Differential 3. Oil pan 4. Steering gear box 1. Oil pump 2. Oil pump strainer 6a4-16 engine mechanical (j20 engine) oil pan and oil pump strainer removal 1) remove oil level gauge. 2) raise vehicle a...
Page 436
Yh4 grand vitara 1. Oil pan engine mechanical (j20 engine) 6a4-17 clean 1) inside of oil pan and oil pump strainer screen. 2) clean sealing surface on oil pan and crankcase. Remove oil, old sealant, and dust from sealing surface. Installation 1) to facilitate and ensure installation of oil pan, incr...
Page 437
Yh4 grand vitara 6a4-18 engine mechanical (j20 engine) 1. Oil pump 2. O-ring 3. Oil pump strainer 4. Oil pan 1. Oil pan 2. Drain plug 3) install o-rings in the position as shown in figure and install oil pump strainer to oil pump. Tighten strainer bolts first and then bracket bolt to specified torqu...
Page 438
Yh4 grand vitara 1. Cylinder block 2. Oil pump 3. Oil pump sprocket 4. Oil pump sprocket cover 1. Oil pump sprocket cover 1. Lower crankcase 2. Oil pump 4. Relief valve 5. Relief spring 6. Retainer 1. Oil pump case no.1 2. Oil pump case no.2 3. Outer rotor engine mechanical (j20 engine) 6a4-19 oil p...
Page 439
Yh4 grand vitara 1. Oil pump case no.1 2. Outer rotor 3. Inner rotor 4. Thickness gauge 1. Oil pump case no.1 2. Outer rotor 3. Inner rotor 4. Thickness gauge 5. Straightedge 6a4-20 engine mechanical (j20 engine) measure free length and tension of oil relief spring. Item standard spring free length ...
Page 440
Yh4 grand vitara 1. Retainer 2. Relief spring 3. Relief valve 4. Oil pump case no.2 5. Oil pump case pin 1. Lower crankcase 2. Oil pump 1. Oil pump sprocket cover engine mechanical (j20 engine) 6a4-21 4) install relief valve, relief spring and retainer to oil pump case no.2. Tighten retainer to spec...
Page 441
Yh4 grand vitara 1. Cylinder head cover 2. Cylinder head cover gasket 3. Cylinder head side seal 4. O-ring 5. Oil pan 6. Oil pump strainer 7. Timing chain cover 8. Crankshaft pulley 9. Crankshaft pulley bolt 10. Oil seal 1. Water bypass pipe 2. Water bypass hose no.2 3. Cooling fan pulley 4. Water p...
Page 442
Yh4 grand vitara 1. Generator belt idler pulley 2. A / c compressor bracket 3. Radiator outlet hose 1. Crankshaft pulley 2. Bolt 3. Wrench 1. Crankshaft pulley 1. Timing chain cover 2. Oil seal engine mechanical (j20 engine) 6a4-23 11) remove generator belt idler pulley. 12) disconnect radiator outl...
Page 443
Yh4 grand vitara 1. Timing chain cover 2. Cylinder head 3. Cylinder block 4. Dowel pin position 1. Timing chain cover 2. Nut 3. Bolt 1. Crankshaft pulley 2. Bolt 3. Wrench 6a4-24 engine mechanical (j20 engine) installation reverse removal sequence to install timing chain cover noting fol- lowing poi...
Page 444
Yh4 grand vitara 1. Generator belt idler pulley 2. A / c compressor bracket 3. Radiator outlet hose 1. Water bypass pipe 2. Water bypass hose no.2 3. Water pump pulley 4. Generator belt tensioner engine mechanical (j20 engine) 6a4-25 4) install a / c compressor bracket if equipped. Tighten bracket b...
Page 445
Yh4 grand vitara 1. 2nd timing chain 2. Timing chain tensioner adjuster no.2 3. Intake camshaft timing sprocket 4. Exhaust camshaft timing sprocket 5. Idler sprocket 6. Timing chain guide no.2 7. Tensioner adjuster no.2 gasket 1. Timing marks of intake camshaft timing sprocket 2. Timing marks of exh...
Page 446
Yh4 grand vitara 1. Timing chain tensioner adjuster no.2 1. Intake camshaft timing sprocket 2. Exhaust camshaft timing sprocket 3. Hexagonal part of camshaft 1. Camshafts (in & ex) allowable turning range . . . . . By knock pin on camshaft within 15 _ from mark on cylinder head on both right and lef...
Page 447
Yh4 grand vitara 1. Timing chain guide no.2 2. Shoe 1. Shoe 6a4-28 engine mechanical (j20 engine) inspection timing chain guide no.2 check shoe for wear or damage. Camshaft sprocket check teeth of sprocket for wear or damage. Timing chain check timing chain for wear or damage. Tensioner adjuster no....
Page 448
Yh4 grand vitara 1. Crank timing sprocket key 2. Timing mark 1. Arrow mark on idler sprocket 2. Knock pin of intake camshaft 3. Knock pin of exhaust camshaft 4. Timing mark of intake side 5. Timing mark of exhaust side 1. Yellow plate 2. Match mark of 2nd timing chain (arrow mark) 1. Dark blue 2. Ar...
Page 449
Yh4 grand vitara 1. Intake camshaft timing sprocket 2. Exhaust camshaft timing sprocket 1. Plunger 2. Body 3. Stopper push 1. Timing chain tensioner adjuster no.2 2. Stopper 6a4-30 engine mechanical (j20 engine) 6) install intake and exhaust camshaft timing sprocket bolts. To install it, fit a spann...
Page 450
Yh4 grand vitara 1. Crank timing sprocket key 2. Timing mark for crank timing sprocket key 3. Timing mark on intake camshaft timing sprocket 4. Timing mark for intake camshaft timing sprocket 5. Timing mark on exhaust camshaft timing sprocket 6. Timing mark for exhaust camshaft timing sprocket engin...
Page 451
Yh4 grand vitara 1. 1st timing chain 2. Idler sprocket 3. Idler sprocket shaft 4. Crankshaft timing sprocket 5. Timing chain tensioner 6. Timing chain tensioner adjuster no.1 7. Timing chain guide no.1 6a4-32 engine mechanical (j20 engine) 1st timing chain and chain tensioner removal 1) disconnect n...
Page 452
Yh4 grand vitara 1. Timing chain guide no.1 2. Timing chain tensioner adjuster no.1 3. Timing chain tensioner 1. Timing chain guide no.1 1. Shoe engine mechanical (j20 engine) 6a4-33 7) for reinstallation of timing chain, turn crankshaft so that timing marks on cylinder head and cylinder block match...
Page 453
Yh4 grand vitara 1. Bush 1. Latch 2. Tooth surface 6a4-34 engine mechanical (j20 engine) crankshaft timing sprocket check teeth of sprocket for wear or damage. Idler sprocket check teeth and bush of sprocket for wear or damage. 1st timing chain check timing chain for wear or damage. Timing chain ten...
Page 454
Yh4 grand vitara 1. Crank timing sprocket key 2. Timing mark 1. Crankshaft 2. Crankshaft timing sprocket 1. Idler sprocket 2. Match mark on idler sprocket 3. 1st timing chain 4. Dark blue plate 1. Crankshaft timing sprocket 2. Match mark 3. 1st timing chain 4. Yellow plate 1. Timing chain tensioner ...
Page 455
Yh4 grand vitara 1. Plunger 2. Latch 3. Body 4. Stopper 1. Timing chain tensioner adjuster no.1 2. Timing chain tensioner 3. Stopper 1. Timing chain guide no.1 2. Guide bolts 1. Match mark on idler sprocket 2. Dark blue plate 3. Match mark on crank timing sprocket 4. Yellow plate 6a4-36 engine mecha...
Page 456
Yh4 grand vitara engine mechanical (j20 engine) 6a4-37 13) install 2nd timing chain. Refer to item “2nd timing chain and chain tensioner” in this section for installation. 14) install timing chain cover. Refer to item “timing chain cover” in this section for instal- lation. 15) install cylinder head...
Page 457
Yh4 grand vitara 1. Intake camshaft 2. Exhaust camshaft 3. Camshaft housing 4. Intake camshaft housing 5. Exhaust camshaft housing 6. Valve lash adjuster 7. Cmp sensor 8. Oil relief valve 9. Timing chain guide no.2 6a4-38 engine mechanical (j20 engine) camshafts and valve lash adjusters removal 1) d...
Page 458
Yh4 grand vitara 1. Engine oil 2. Valve lash adjuster don’t apply force engine mechanical (j20 engine) 6a4-39 9) after removing 2nd timing chain, set key on crankshaft in posi- tion as shown by turning crankshaft. This is to prevent interfer- ence between valves and piston. 10) loosen camshaft housi...
Page 459
Yh4 grand vitara 1. Gaging plastic 2. Scale 6a4-40 engine mechanical (j20 engine) camshaft runout set camshaft between two “v” blocks, and measure its runout by using a dial gauge. If measured runout exceed below specified limit, replace camshaft. Runout limit 0.10 mm (0.0039 in.) camshaft journal w...
Page 460
Yh4 grand vitara engine mechanical (j20 engine) 6a4-41 if measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the differ- ence from specification is greater. Item standard cam...
Page 461
Yh4 grand vitara 1. Cylinder head 2. Oil hole 1. Crank timing sprocket key 2. Timing mark 1. Knock pin of intake camshaft 2. Knock pin of exhaust camshaft 3. Match mark for intake camshaft 4. Match mark for exhaust camshaft 6a4-42 engine mechanical (j20 engine) oil relief valve check oil relief valv...
Page 462
Yh4 grand vitara 1. Intake camshaft 2. Exhaust camshaft 3. Pin installation position i: intake side e: exhaust side position from timing chain side timing chain side 1. Stud bolt 2. Timing chain guide engine mechanical (j20 engine) 6a4-43 5) install camshaft housing pins as shown in figure. 6) apply...
Page 463
Yh4 grand vitara 6a4-44 engine mechanical (j20 engine) caution: don’t turn camshafts or start engine (i.E., valves should not be operated) for about half an hour after reinstalling hydraulic valve lash adjusters and camshafts. As it takes time for valves to settle in place, operating engine within h...
Page 464
Yh4 grand vitara 1. Cylinder block 2. Cylinder head 3. Cylinder head gasket 4. Intake valve 5. Exhaust valve 6. Valve spring seat 7. Valve stem seal 8. Valve spring (outer) 9. Valve spring (inner) 10. Valve spring retainer 11. Valve cotter 12. Hydraulic valve lash adjuster 13. Valve guide 14. Water ...
Page 465
Yh4 grand vitara 6a4-46 engine mechanical (j20 engine) 7) disconnect following electric lead wires: egr valve coupler iac valve coupler tp sensor coupler evap canister purge valve coupler ground terminal from intake manifold heated oxygen sensor-1 and / or -2 coupler cmp sensor coupler ect sensor co...
Page 466
Yh4 grand vitara 1. Exhaust manifold stiffener 1. Crankshaft pulley side 2. Flywheel side 3. Bolt (m6) 1. Exhaust no.1 pipe engine mechanical (j20 engine) 6a4-47 13) disconnect exhaust no. 1 pipe from exhaust manifold. 14) remove exhaust manifold stiffener (if equipped). 15) loosen cylinder head bol...
Page 467
Yh4 grand vitara 1. Valve cotter (b) (a) (c) (d) (c) 1 1 1. Valve stem seal 2. Valve spring seat 6a4-48 engine mechanical (j20 engine) disassembly 1) when servicing cylinder head, remove intake manifold, injec- tors, exhaust manifold, water outlet pipe and water outlet cap from cylinder head. 2) usi...
Page 468
Yh4 grand vitara 1. Valve head thickness 2. 45 _ engine mechanical (j20 engine) 6a4-49 inspection valve guides using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance. Be sure to take reading at more than one place along the length of each...
Page 469
Yh4 grand vitara 1. Valve seat cutter in ex 6a4-50 engine mechanical (j20 engine) d seating contact width: create contact pattern on each valve in the usual manner, i.E. By giving uniform coat of marking compound to valve seat and by ro- tatingly tapping seat with valve head. Valve lapper (tool used...
Page 470
Yh4 grand vitara engine mechanical (j20 engine) 6a4-51 cylinder head remove all carbon deposits from combustion chambers. Note: do not use any sharp-edged tool to scrape off carbon depos- its. Be careful not to scuff or nick metal surfaces when decar- boning. The same applies to valves and valve sea...
Page 471
Yh4 grand vitara 6a4-52 engine mechanical (j20 engine) valve springs referring to data given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weak- ening. Remember, weakened valve springs can cause chatter, not to mention possibility of reducing pow...
Page 472
Yh4 grand vitara engine mechanical (j20 engine) 6a4-53 1. Valve guide protrusion (13.5 mm) assembly 1) before installing valve guide into cylinder head, ream guide hole with special tool (11 mm reamer) so as to remove burrs and make it truly round. Special tool (a): 09916-34542 (b): 09916-38210 2) i...
Page 473
Yh4 grand vitara (d) (a) (b) (c) 1 1. Valve stem seal 1. Large-pitch 2. Small-pitch 3. Valve spring retainer side 4. Valve spring seat side 1. Valve cotter 1 6a4-54 engine mechanical (j20 engine) 5) install new valve stem seal to valve guide. After applying engine oil to seal and spindle of special ...
Page 474
Yh4 grand vitara 1. Cylinder head 2. Water outlet pipe 1. Cylinder head gasket 2. Cylinder block 3. Knock pin 4. Crankshaft pulley side 5. Flywheel side 1. Crankshaft pulley side 2. Flywheel side 1. Crankshaft pulley side 2. Flywheel side 1. Crankshaft pulley side 2. Flywheel side 3. Bolt (m6) “top”...
Page 475
Yh4 grand vitara 1. Timing mark 2. Crank timing sprocket key 6a4-56 engine mechanical (j20 engine) 5) check that key on crankshaft aligns with timing mark as shown in figure. 6) reverse removal procedure for installation. 7) adjust cooling fan belt tension. Refer to section 6b for adjusting procedur...
Page 476
Yh4 grand vitara 1. Top ring 2. 2nd ring 3. Oil ring 4. Piston 5. Connecting rod 6. Connecting rod bearing cap 7. Connecting rod bearing 8. Piston pin 9. Piston pin circlip 10. Cylinder block 11. Oil pump 12. Oil pump sprocket cover 13. Knock sensor 1. Guide hose engine mechanical (j20 engine) 6a4-5...
Page 477
Yh4 grand vitara 1. Piston pin circlip 6a4-58 engine mechanical (j20 engine) disassembly 1) using piston ring expander, remove two compression rings (top and 2nd) and oil ring from piston. 2) remove piston pin from connecting rod. Ease out piston pin circlips, as shown. Force piston pin out. Cleanin...
Page 478
Yh4 grand vitara 1. 50 mm (1.96 in.) 2. 95 mm (3.74 in.) 1. 26.5 mm (1.04 in.) engine mechanical (j20 engine) 6a4-59 inspection cylinder inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cyl...
Page 479
Yh4 grand vitara 1. 26.5 mm (1.04 in.) 1. Piston ring 2. Thickness gauge 6a4-60 engine mechanical (j20 engine) piston clearance: measure cylinder bore diameter and piston diameter to find their difference which is piston clearance. Piston clearance should be within specification as given below. If i...
Page 480
Yh4 grand vitara 1. Cylinder block 2. Feeler gauge 3. Piston ring 4. 120 mm (4.72 in.) engine mechanical (j20 engine) 6a4-61 piston rings to measure end gap, insert piston ring into cylinder bore and then measure the gap by using thickness gauge. If measured gap is out of specification, replace ring...
Page 481
Yh4 grand vitara 1. Red paint 1. Gaging plastic 1. Arrow mark 6a4-62 engine mechanical (j20 engine) crank pin and connecting rod bearings inspect crank pin for uneven wear or damage. Measure crank pin for out-of-round or taper with a micrometer. If crank pin is dam- aged, or out-of round or taper is...
Page 482
Yh4 grand vitara 1. Gaging plastic 2. Scale finished crank pin dia. = measured big-end bore dia. (including under- size bearing) 0.048 mm (0.0018 in.) – engine mechanical (j20 engine) 6a4-63 5) remove cap and using a scale on gaging plastic envelope, mea- sure gaging plastic width at the widest poin...
Page 483
Yh4 grand vitara no. 2 cylinder 1. Piston 2. Cylinder block 3. Paint 4. Crankshaft pulley side 5. Flywheel side 1 or 2 no. 1 cylinder no. 1 cylinder no. 1 cylinder no. 1 cylinder 1. Crankshaft pulley side 2. Flywheel side red red blue blue no. 1 cylinder no. 3 cylinder no. 4 cylinder 6a4-64 engine m...
Page 484
Yh4 grand vitara 1. Piston 2. Arrow mark 3. Connecting rod 1. Piston 2. Arrow mark 3. Connecting rod 4. Oil hole circlip crankshaft pulley side install so that circlip end gap comes within such range as indicated by arrow. 1. 1st ring 2. 2nd ring 3. Oil ring “rn” “r” 1. Arrow mark 2. 1st ring end ga...
Page 485
Yh4 grand vitara 1. Crankshaft pulley side 2. Flywheel side 1. Arrow mark 6a4-66 engine mechanical (j20 engine) installation 1) apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crank pins. Note: do not apply oil between connecting rod and bearing or be- tween bearing c...
Page 486
Yh4 grand vitara tightening torque (a): 50 n . M 5.0kg . M 36.5 lb-ft (b): 85 n . M 8.5 kg . M 61.5 lb-ft engine mechanical (j20 engine) 6a4-67 6) reverse removal procedure for installation, as previously out- lined. 7) adjust cooling fan belt tension. Refer to section 6b for adjusting procedure. 8)...
Page 487: Unit Repair Overhaul
Yh4 grand vitara 6a4-68 engine mechanical (j20 engine) unit repair overhaul engine assembly removal 1) release fuel pressure in fuel feed line. Refer to section 6. 2) disconnect negative cable at battery. 3) remove engine hood. 4) remove strut tower bar. 5) drain coolant. 6) remove radiator, radiato...
Page 488
Yh4 grand vitara 1. Exhaust no.1 pipe 1. Right side transmission stiffener engine mechanical (j20 engine) 6a4-69 12) with hoses connected, detach power steering pump and a / c compressor from cylinder block if equipped. 13) raise vehicle. 14) drain engine oil if necessary. 15) remove front different...
Page 489
Yh4 grand vitara 6a4-70 engine mechanical (j20 engine) 23) remove bolt and nuts fastening cylinder block and transmis- sion. 24) install lifting device. 25) remove engine side mounting bracket nuts from engine mountings. 26) before lifting engine, check to ensure all hoses, wires and cables are disc...
Page 490
Yh4 grand vitara 1. Right side transmission stiffener 1. Exhaust no.1 pipe engine mechanical (j20 engine) 6a4-71 5) tighten torque converter bolts to specified torque (for a / t ve- hicle). Tightening torque (a): 65 n . M (6.5 kg-m, 47.0 lb-ft) 6) tighten transmission stiffener bolts to specified to...
Page 491
Yh4 grand vitara 6a4-72 engine mechanical (j20 engine) 1. Cylinder block 2. Lower crankcase 3. Crankshaft 4. O-ring 5. Oil pump drive chain 6. Main bearing 7. Thrust bearing 8. Rear oil seal 9. Check valve 10. Flywheel (m / t) drive plate (a / t) 11. Clutch housing plate 12. Blank 13. Engine side mo...
Page 492
Yh4 grand vitara engine mechanical (j20 engine) 6a4-73 1. Flywheel bolt 1. Water pump 2. Engine side mounting bracket 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) 1. Ckp sensor 2. Cylinder block 3. Crankshaft removal 1) remove engine assembly from vehicle as prev...
Page 493
Yh4 grand vitara 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) 1. Thrust bearing 2. Oil groove 6a4-74 engine mechanical (j20 engine) inspection crankshaft crankshaft runout using a dial gauge, measure runout at center journal. Rotate crank- shaft slowly. If runout...
Page 494
Yh4 grand vitara engine mechanical (j20 engine) 6a4-75 1. Upper half of bearing 2. Oil groove 1. Gaging plastic 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) main bearings general information service main bearings are available in standard size and 0.25 mm (0.0098...
Page 495
Yh4 grand vitara 6a4-76 engine mechanical (j20 engine) 1. Gaging plastic 2. Scale 1. Crankshaft pulley side 2. Flywheel side 3. Crankshaft web no.2 5) remove lower crankcase and using scale on gaging plastic en- velop, measure gaging plastic width at its widest point. If clear- ance exceeds its limi...
Page 496
Yh4 grand vitara engine mechanical (j20 engine) 6a4-77 1. Bearing cap no.1 2. Bearing cap no.2 3. Bearing cap no.3 4. Bearing cap no.4 5. Bearing cap no.5 6. Crankshaft pulley side 7. Flywheel side 1. Paint 2) next, check crankcase (bearing cap) bore diameter without bearing. On lower crankcase five...
Page 497
Yh4 grand vitara 6a4-78 engine mechanical (j20 engine) 1. Gaging plastic 2. Scale 4) from number stamped on crank web no.2 and alphabets stamped on lower crankcase, determine new standard bearing to be installed to journal, by referring to table shown below. For example, if number stamped on crank w...
Page 498
Yh4 grand vitara 1. Paint engine mechanical (j20 engine) 6a4-79 undersize bearing (0.25 mm): 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in following colors at such position as indicated in figure. Each color represents fol...
Page 499
Yh4 grand vitara 6a4-80 engine mechanical (j20 engine) 1. Crankshaft 2. Oil pump sprocket oil pump sprocket check teeth of sprocket for wear or damage. If any damage or wear is found, replace crankshaft. Oil pump drive chain check oil pump drive chain for wear or damage. Rear oil seal carefully insp...
Page 500
Yh4 grand vitara engine mechanical (j20 engine) 6a4-81 1. 26.5mm (1.04 in.) cylinder block distortion of gasketed surface using straightedge and thickness gauge, check gasketed sur- face for distortion and, if flatness exceeds its limit, correct it. Flatness limit: 0.06 mm (0.0024 in.) honing or reb...
Page 501
Yh4 grand vitara 6a4-82 engine mechanical (j20 engine) 1. Cylinder block 2. O-ring 3. Oil groove 4. Bearing 5. Knock pin 1. Thrust bearing 2. Oil groove 1. Crankshaft 2. Crankshaft position sensor plate 1. Lower crankcase 2. Bearing 3. Lower crankcase installation note: all parts to be installed mus...
Page 502
Yh4 grand vitara engine mechanical (j20 engine) 6a4-83 1. Lower crankcase 2. Bolt (10 mm thread diameter) 3. Bolt (8 mm thread diameter) 1. Flywheel bolt 1. Rear oil seal 1, (c), “a” (a) 1. Ckp sensor 2. Cylinder block 3. Crankshaft (a) 6) install lower crankcase to cylinder block. Apply oil to cran...
Page 503
Yh4 grand vitara 6a4-84 engine mechanical (j20 engine) 1. Engine side mounting bracket 2. Water pump 3. Heater outlet pipe (d) 1. Oil pump chain guide 2. Oil pump chain guide nuts 3. Thickness gauge 9) install engine side mounting brackets (right and left). Tighten bracket bolts to specified torque....
Page 504: Special Tools
Yh4 grand vitara engine mechanical (j20 engine) 6a4-85 09911-97710 oil seal guide 09911-97810 oil seal installer 09913-75510 bearing installer 09915-47330 oil filter wrench 1. 09915-64510-001 compression gauge 2. 09915-64510-002 connector 3. 09915-64530 hose 4. 09915-67010 attachment 09915-67310 vac...
Page 505: Required Service Materials
Yh4 grand vitara 6a4-86 engine mechanical (j20 engine) 09917-87810 valve guide installer 09917-98221 valve stem seal installer 09918-08210 vacuum gauge hose joint 09919-28610 protective sleeve 09924-17810 flywheel holder 09926-58010 bearing puller attachment 09944-36011 steering wheel remover 09927-...
Page 506: Section 6B
Yh4 grand vitara 6b engine cooling 6b-1 section 6b engine cooling contents general description 6b- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling system circulation 6b- 2 . . . . . . . . . . . . . . . . . ...
Page 507: General Description
Yh4 grand vitara 6b-2 engine cooling bypass (h25 engine only) water pump cylinder cylinder head heater unit throttle body thermostat thermostat closed bypass general description the cooling system consists of the radiator cap, radiator, coolant reservoir, hoses, water pump, cooling fan, and thermost...
Page 508
Yh4 grand vitara engine cooling 6b-3 [a] [b] [c] [a]: g16 engine [b]: j20 engine [c]: h25 engine 1. Radiator 2. Cooling fan 3. Thermostat 4. Water pump 5. Radiator inlet way 6. Radiator outlet way 7. Outlet pipe 8. Outlet cap 9. Throttle body 10. Heater outlet way 11. Heater inlet way 12. Bypass 13....
Page 509
Yh4 grand vitara 1. Air bleed valve 2. Thermostat seal 3. Bypass valve [g16 & j20 engines] [h25 engine] 1. Cooling fan 2. Fan clutch 3. Bimetal 6b-4 engine cooling thermostat temp. At which valve begins to open j20 and h25 engines : 82 2 _ c (179 3.6 _ f) g16 engine : 88 2 _ c (190 3.6 _ f) temp. At...
Page 510
Yh4 grand vitara engine cooling 6b-5 coolant the coolant recovery system is standard. The coolant in the radiator expands with heat, and the overflow is col- lected in the reservoir. When the system cools down, the coolant is drawn back into the radiator. The cooling system has been filled at the fa...
Page 511: Diagnosis
Yh4 grand vitara 6b-6 engine cooling 1. Reservoir 2. Full level mark 3. Low level mark 4. Arrow mark diagnosis diagnosis table condition possible cause correction engine overheats loose or broken water pump belt not enough coolant faulty thermostat faulty water pump dirty or bent radiator fins coola...
Page 512
Yh4 grand vitara engine cooling 6b-7 cooling system service warning: to help avoid danger of being burned, do not remove radia- tor cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if cap is taken off too soon. Cooling system should be serviced as...
Page 513
Yh4 grand vitara 6b-8 engine cooling 1. Reservoir 2. Full level mark 3. Low level mark 4. Arrow mark 3) stop engine and open radiator drain plug to drain coolant. 4) close drain plug (1). Add water until system is filled and run en- gine until upper radiator hose is hot again. 5) repeat steps 3) and...
Page 514
Yh4 grand vitara engine cooling 6b-9 1. 10 kg (22 lbs) 2. Adjusting bolt 3. Pivot bolt “a”: belt tension [g16 engine] [h25 engine] cooling fan belt tension check and adjustment warning: disconnect negative cable at battery before checking and adjusting belt tension. For g16 and h25 engines 1) inspec...
Page 515
Yh4 grand vitara 6b-10 engine cooling “a” 2. Pivot bolt 1. Adjusting bolt 3. Tension bolt 4. Fan pulley 5. Pivot bolt “a”: belt tension 1. 10 kg (22 lbs) 2. Adjusting bolt 3. Crankshaft pulley [j20 engine] for j20 engine 1) inspect belt for cracks, cuts, deformation, wear and cleanliness. If so, rep...
Page 516: On-Vehicle Service
Yh4 grand vitara engine cooling 6b-11 1. Thermostat case 2. Water outlet pipe on-vehicle service warning: check to make sure that engine coolant temperature is cold before removing any part of cooling system. Also be sure to disconnect negative cable from battery terminal before removing any part. C...
Page 517
Yh4 grand vitara 6b-12 engine cooling 4. O-ring 5. Heater hose 6. Water hose (to throttle body) 4. O-ring 5. Heater hose 6. Water hose (to throttle body) 1. Thermostat case 2. Water outlet pipe 1. Water outlet pipe (j20 engine) 7) remove water outlet cap (3) from cylinder heads. 8) remove water outl...
Page 518
Yh4 grand vitara engine cooling 6b-13 [g16 engine] [j20 engine] [h25 engine] 6) install throttle body and intake manifold. Refer to section 6a2 for installation. 7) install radiator outlet pipe (3) to thermostat case with new o-ring. 8) install radiator inlet and outlet hoses (1), (2). 9) refill coo...
Page 519
Yh4 grand vitara 6b-14 engine cooling 1. Thermostat 2. Thermometer 3. Heater [g16 engine] [j20 engine] [h25 engine] 1. Thermostat 2. Air bleed valve 3. Match mark _ check thermostatic movement of wax pellet as follows: a) immerse thermostat in water, and heat water gradually. B) check that valve sta...
Page 520
Yh4 grand vitara engine cooling 6b-15 cooling fan belt removal for g16 and h25 engines 1) disconnect negative (–) cable at battery. 2) loosen p / s pump drive belt adjusting bolt and then remove p / s pump belt. 3) loosen adjusting bolt (1) and pivot bolt. 4) slacken belt by displacing generator and...
Page 521
Yh4 grand vitara 6b-16 engine cooling 1. Cooling fan 2. Fan clutch 3. Bimetal cooling fan belt tension inspection inspect belt and check belt tension. Refer to “cooling fan belt tension check and adjustment” in this section. Cooling fan and fan clutch removal 1) disconnect negative (–) cable at batt...
Page 522
Yh4 grand vitara engine cooling 6b-17 1. Cooling fan / clutch nut 1. Radiator 2. Inlet hose (outlet from oil cooler) 3. Outlet hose (inlet to oil cooler) installation install removed parts in reverse order of removal procedure. After installation, adjust belt tension for specification and tighten ea...
Page 523
Yh4 grand vitara 6b-18 engine cooling 6) remove p / s oil tank stay bolts (1) from radiator stay. 7) remove radiator shroud securing clips. 8) then remove cooling fan / clutch and radiator shroud. 9) disconnect water inlet and outlet hose (1), (2) and reservoir tank hose (3) from radiator. 10) remov...
Page 524
Yh4 grand vitara engine cooling 6b-19 water pump removal for g16 engine 1) disconnect negative (–) cable at battery. 2) drain cooling system. 3) remove timing belt and tensioner referring to “timing belt and belt tensioner” in section 6a1. 4) remove rubber seal (1) between oil pump and water pump. 5...
Page 525
Yh4 grand vitara 6b-20 engine cooling 3. Exhaust manifold cover 3. Thermostat cap for j20 engine 1) disconnect negative (–) cable at battery. 2) drain coolant. 3) remove radiator outlet hose from thermostat cap (2). 4) remove heater outlet pipe bolt (1). 5) remove generator belt by loosening tension...
Page 526
Yh4 grand vitara engine cooling 6b-21 1. Water pump 2. Impeller 3. O-ring inspection for g16 engine rotate water pump by hand to check for smooth operation. If pump does not rotate smoothly or makes abnormal noise, replace it. For j20 engine caution: do not disassemble water pump. If any repair is r...
Page 527
Yh4 grand vitara 6b-22 engine cooling installation for g16 engine 1) install new pump gasket (2) to cylinder block. 2) install water pump (1) to cylinder block. Tightening torque water pump bolt (g16 engine) (a): 12 n . M (1.2 kg-m, 8.5 lb-ft) 3) after installing water pump, install rubber seal (1) ...
Page 528
Yh4 grand vitara engine cooling 6b-23 2, (a) 3. Thermostat cap 3. Exhaust manifold cover (a) (a) 1 2. Impeller for j20 engine 1) install new o-ring (1) to water pump (2). Note: do not forget to install dowel pins on water pump side be- fore mounting water pump to engine block. 2) install water pump ...
Page 529: Required Service Material
Yh4 grand vitara 6b-24 engine cooling engine coolant temperature (ect) sensor refer to section 6e1 (for g16 and j20 engine) or 6e2 (for h25 en- gine). Required service material material recommended suzuki product use ethylene glycol base coolant (anti-freeze / anti-corrosion coolant) ——— additive to...
Page 530: Section 6C
Yh4 grand vitara 6c engine fuel 6c-1 1. Fuel tank 2. Fuel pump (with fuel level gauge) 3. Fuel filter 4. Fuel filler cap 5. Breather hose 6. Fuel feed line (to delivery pipe) 7. Fuel return line (from delivery pipe) 8. Fuel vapor line (to evap canister) 9. Fuel tank protector 10. Belt 11. Fuel tank ...
Page 531: Diagnosis
Yh4 grand vitara with following type pipe, fit hose as far as its peripheral projection as shown. 6c-2 engine fuel diagnosis diagnosis table refer to engine diagnosis in section 6. On-vehicle service precautions warning: before attempting service of any type on fuel system, fol- lowing cautions shou...
Page 532
Yh4 grand vitara 1. Fuel pump assembly 2. Gasket 3. To fuel filter 4. From delivery pipe engine fuel 6c-3 fuel pump removal 1) remove fuel tank. Refer to “fuel tank” in this section. 2) remove fuel pump assembly from fuel tank. Inspection check fuel pump filter for evidence of dirt and contamination...
Page 533
Yh4 grand vitara 1. Fuel filter 2. Fuel filter outlet hose 3. Fuel filter inlet hose 1. To delivery pipe 2. Fuel tank 3. Fuel filter 1. Fuel feed hose (if equipped) 2. Fuel return hose 3. Fuel vapor hose 4. Clamp 6c-4 engine fuel installation reverse removal procedure noting the following. Upon comp...
Page 534
Yh4 grand vitara 1. Fuel filler cap 2. Gasket 1. Fuel filler hose 2. Fuel tank inlet (check) valve 1. Tank 2. Breather hose 3. Filler hose 4. Inlet valve engine fuel 6c-5 fuel filler cap inspection remove cap, and check gasket for even filler neck imprint, and de- terioration or any damage. If gaske...
Page 535
Yh4 grand vitara 1. Fuel filter 2. Fuel filter outlet hose 3. Fuel filter inlet hose 6c-6 engine fuel 8) disconnect fuel filter inlet hose from filter. 9) disconnect fuel vapor hose (1) and return hose (2) from pipes. 10) remove fuel tank protector from vehicle. 11) lower fuel tank gradually while h...
Page 536
Yh4 grand vitara rear side rear side 1. Fuel tank 2. Fuel pump (with fuel level gauge) 3. Fuel filter 4. Fuel filler cap 5. Breather hose 6. Fuel feed line (to delivery pipe) 7. Fuel return line (from delivery pipe) 8. Fuel vapor line (to evap canister) 9. Fuel tank protector 10. Belt 11. Filler nec...
Page 537
Yh4 grand vitara 6c-8 engine fuel 9) connect coupler to fuel pump assembly and tank pressure sensor respectively. 10) connect negative (–) cable to battery. 11) upon completion of installation, check fuel system for leakage. Fuel tank purging procedure caution: this purging procedure will not remove...
Page 538: Section 6E1
Yh4 grand vitara 6e1 engine and emission control system (g16 / j20 engines) 6e1-1 general description 6e1- 3 . . . . . . . . . . . . . . Air intake system 6e1- 8 . . . . . . . . . . . . . . . . . . Fuel delivery system 6e1- 9 . . . . . . . . . . . . . . Electronic control system 6e1-10 . . . . . . E...
Page 539
Yh4 grand vitara ho2s -1 and -2 6e1-37 . . . . . . . . . . . . . . . . . . . . . . Vehicle speed sensor 6e1-39 . . . . . . . . . . . . . . . . . Camshaft position sensor 6e1-39 . . . . . . . . . . . . . Crankshaft position sensor 6e1-40 . . . . . . . . . . . . Manifold absolute pressure sensor 6e1-4...
Page 540: General Description
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-3 the engine and emission control system has 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control sys- tem. Air intake system includes air cleaner, mass air flow sensor...
Page 541
Yh4 grand vitara 6e1-4 engine and emission control system (g16 / j20 engines) g16 engine.
Page 542
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-5.
Page 543
Yh4 grand vitara 6e1-6 engine and emission control system (g16 / j20 engines) j20 engine.
Page 544
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-7.
Page 545
Yh4 grand vitara 6e1-8 engine and emission control system (g16 / j20 engines) 1. Air cleaner 2. Mass air flow sensor (maf sensor) 3. Air cleaner outlet hose 4. Throttle body 5. Throttle valve 6. Idle air control valve (iac valve) 7. Intake manifold 8. Cylinder head 9. Exhaust manifold 10. Bypass air...
Page 546
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-9 1. Fuel tank 2. Fuel pump 3. Fuel feed line 4. Fuel filter 5. Fuel delivery pipe 6. Fuel injectors 7. Fuel pressure regulator 8. Fuel return line 9. Intake manifold 10. Evap canister purge valve 11. Evap canister 12. Tank ...
Page 547
Yh4 grand vitara 6e1-10 engine and emission control system (g16 / j20 engines) information sensors - 1. Maf sensor - 2. Vss - 3. Heated oxygen sensor-1 3-1. Heated oxygen sensor-2 (if equipped) - 4. Power steering pressure switch - 5. Ect sensor - 6. Battery - 7. Tp sensor - 8. Transmission range sw...
Page 548
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-11 j20 engine information sensors - 1. Iat sensor - 2. Maf sensor - 3. Power steering pressure switch (if equipped) - 4. Heated oxygen sensor-1 4-1. Heated oxygen sensor-2 (if equipped) - 5. Blank - 6. Abs control module (if...
Page 549
Yh4 grand vitara or w bl / g bl / y c51-1-22 c51-1-23 c51-1-10 c51-1-11 6e1-12 engine and emission control system (g16 / j20 engines).
Page 550
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-13 6- 1. Fuel injector no.1 - 2. Fuel injector no.2 - 3. Fuel injector no.3 - 4. Fuel injector no.4 - 5. Egr valve (if equipped) - 6. Idle air control (iac) valve - 7. Evap canister purge valve - 8. Ignition coil assembly fo...
Page 551
Yh4 grand vitara 6e1-14 engine and emission control system (g16 / j20 engines) 16 heater blower switch 17 a / c signal (if equipped) 18 —— 19 “4wd” lamp (4wd) 20 “o / d off” lamp (a / t) 21 “power” lamp (a / t) 22 a / c fan motor relay (if equipped) 23 fuel pump relay ground for ho2s–2 ground for co...
Page 552
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-15.
Page 553
Yh4 grand vitara 6e1-16 engine and emission control system (g16 / j20 engines) input output cmp sensor maf sensor tp sensor ect sensor ia t sensor ho2s vss blower fan switch rear defogger switch (if equipped) psp switch dlc ignition switch starter switch abs control module (if equipped) a/c amplifie...
Page 554: On-Vehicle Service
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-17 g16 engine j20 engine 1. Brake booster hose 2. Engine ground 3. Vacuum hose for fuel pressure regulator 4. A / t throttle cable (a / t) 5. Throttle cable 6. Pcv hose 7. Breather hose 8. Fuel pressure regulator 9. Evap can...
Page 555
Yh4 grand vitara 6e1-18 engine and emission control system (g16 / j20 engines) 1. Accelerator cable 2. Adjusting nut 3. Lock nut 3. Pedal stopper bolt 1. Lever stopper 2. Throttle lever 1. A / t throttle cable 2. Adjusting nut 3. Lock nut general when hoses are disconnected and system components are...
Page 556
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-19 1. Dlc idle speed/idle air control (iac) duty inspection before idle speed and iac duty check, make sure of the following. Lead wires and hoses of engine / emission control systems are connected securely. Accelerator cabl...
Page 557
Yh4 grand vitara 1. Co adjusting resistor knob 6e1-20 engine and emission control system (g16 / j20 engine) idle mixture inspection/adjustment (vehicle without heated oxygen sensor) all vehicles not equipped with heated oxygen sensor are shipped with their co% factory adjusted as follows. Engine idl...
Page 558
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-21 1. Cable bracket 2. Throttle body 3 tp sensor 4. Idle air control valve 5. O-ring air intake system throttle body on-vehicle inspection check that throttle valve lever moves smoothly. Removal 1) disconnect negative cable ...
Page 559
Yh4 grand vitara 6e1-22 engine and emission control system (g16 / j20 engines) 1. Bypass air passage cleaning 1) remove iac valve from throttle body. 2) clean throttle body bore and bypass air passages by blowing compressed air. Caution: do not blow compressed air through bypass air pas- sage with i...
Page 560
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-23 1. Plunger idle air control valve (iac valve) inspection 1) disconnect connector from iac valve. 2) check each coil of iac valve for resistance. Terminals resistance between “1” and “2” “3” and “2” “4” and “5” “6” and “5”...
Page 561
Yh4 grand vitara 6e1-24 engine and emission control system (g16 / j20 engines) at specified idle speed 210 – 260 kpa 2.1 – 2.6 kg / cm 2 29.8 – 37.0 psi with 1 min. After engine (fuel pump) stopped (pressure re- duces as time passes.) over 180 kpa 1.8 kg / cm 2 25.6 psi condition fuel pressure with ...
Page 562
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-25 1. Fuel filler 2. Ignition switch 8) install plug bolt to fuel delivery pipe. Use new gasket. Tighten it to specified torque, using backup wrench. Tightening torque (a): 30 n . M (3.0 kg-m, 22.0 lb-ft) 9) with engine “off...
Page 563
Yh4 grand vitara 6e1-26 engine and emission control system (g16 / j20 engines) installation 1) install fuel pump to its bracket. 2) install fuel pump to fuel tank and then install fuel tank to body ac- cording to procedure described in “fuel system” section. Fuel pressure regulator removal 1) reliev...
Page 564
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-27 1. Sound scope 1 fuel injector on-vehicle inspection 1) using sound scope or such, check operating sound of injector when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If n...
Page 565
Yh4 grand vitara 6e1-28 engine and emission control system (g16 / j20 engines) 1. Injectors 2. Delivery pipe (for g16) 1. Fuel feed pipe and hose 2. Fuel injector 3. Fuel pressure regulator 4. Fuel return pipe 6) remove fuel delivery pipe bolts. 7) remove fuel injector(s) from delivery pipe and inta...
Page 566
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-29 when using suzuki scan tool: when not using suzuki scan tool: 1. Fuel pump relay connector 2. Service wire 3. Junction (fuse) box 1. Injector 2. Battery 3. Keep as far apart as possible 1. Injector 2. Vinyl tube 3. Less t...
Page 567
Yh4 grand vitara 6e1-30 engine and emission control system (g16 / j20 engines) 5 1. Insulator 2. Grommet 3. O-ring 4. Cushion 5. Delivery pipe (for j20) 1. O-ring 2. Grommet j20 engine g16 engine installation 1) replace injector o-ring with new one using care not to damage it. Install grommet to inj...
Page 568
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-31 1. Cover 2. Clip 1 2 electronic control system engine control module (ecm)/powertrain control module (pcm) caution: as ecm / pcm consists of precision parts, be careful not to expose it to excessive shock. Removal 1) disc...
Page 569
Yh4 grand vitara 6e1-32 engine and emission control system (g16 / j20 engines) c51-3-10 mass air flow sensor (maf sensor) inspection note: use voltmeter with high-impedance (10 k / v minimum) or digital type voltmeter. 1) connect voltmeter to “b +” terminal of maf sensor coupler dis- connected and g...
Page 570
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-33 removal 1) disconnect negative cable at battery and coupler from maf sen- sor. 2) remove air cleaner outlet hose from throttle body and maf sen- sor. 3) remove maf sensor from air cleaner case. Note: don’t disassemble maf...
Page 571
Yh4 grand vitara 6e1-34 engine and emission control system (g16 / j20 engines) temperature resist ance 1. Iat sensor 2. Seal intake air temperature (iat) sensor removal 1) disconnect negative cable from battery. 2) disconnect iat sensor coupler. 3) remove iat sensor from air cleaner case. Inspection...
Page 572
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-35 1. Ground terminal 2. Output voltage terminal 3. Reference voltage terminal throttle position sensor (tp sensor) inspection 1) disconnect negative cable at battery and coupler from tp sen- sor. 2) using ohmmeter, check re...
Page 573
Yh4 grand vitara 6e1-36 engine and emission control system (g16 / j20 engines) g16 engine j20 engine 1. Ect sensor 2. O-ring 3. Water outlet pipe ( ) for reference temperature resist ance engine coolant temperature sensor (ect sensor) removal 1) disconnect negative cable from battery. 2) drain cooli...
Page 574
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-37 g16 engine j20 engine installation reverse removal procedure noting the following. D clean mating surfaces of sensor and intake manifold. D check o-ring for damage and replace if necessary. D tighten ect sensor to specifi...
Page 575
Yh4 grand vitara 6e1-38 engine and emission control system (g16 / j20 engines) sensor-1 sensor-2 5. Remove while releasing lock 6. Ho2s-2 7. Exhaust no. 1 pipe 1. Ho2s-1 2. Exhaust manifold upper cover 3. Bracket 4. Connector lock for clamp 1, (a) 6, (a) removal warning: to avoid danger of being bur...
Page 576
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-39 “vss, c51-2-25” vehicle speed sensor (vss) on-vehicle inspection 1) hoist vehicle. 2) release parking brake lever, set transmission in neutral and transfer in “2h”. 3) remove ecm / pcm cover. 4) connector voltmeter betwee...
Page 577
Yh4 grand vitara 6e1-40 engine and emission control system (g16 / j20 engines) 1. Crankshaft position sensor 2. Cylinder block (a) crankshaft position sensor (g16 engine) inspection check crankshaft position sensor referring to steps 2 and 3 of dtc p0335 diag. Flow table in “engine diagnosis” sectio...
Page 578
Yh4 grand vitara engine and emission control system (g16 / j20 engine) 6e1-41 1 1. O-ring 1. Map sensor 2. 1.5 v battery (4.5 – 5.5 v in total) 3. Vacuum pump manifold absolute pressure (map) sensor removal 1) disconnect negative cable at battery. 2) disconnect connector from map sensor. 3) remove m...
Page 579
Yh4 grand vitara 6e1-42 engine and emission control system (g16 / j20 engines) installation 1) confirm that vacuum passage on intake manifold is free from clog. 2) apply engine oil to o-ring of sensor. 3) install sensor to intake manifold. 4) connect connector to sensor securely. Fuel level sensor (...
Page 580
Yh4 grand vitara 1. Main relay 2. Junction (fuse) box [a-1]: left-hand steering hard top model [a-2]: right-hand steering hard top model [b-1]: left-hand steering canvas top model [b-2]: right-hand steering canvas top model [a-1] [a-2] [b-1] [b-2] engine and emission control system (g16 / j20 engine...
Page 581
Yh4 grand vitara 6e1-44 engine and emission control system (g16 / j20 engines) [a-1]: left-hand steering hard top model [a-2]: right-hand steering hard top model [b-1]: left-hand steering canvas top model [b-2]: right-hand steering canvas top model 1. Fuel pump relay 2. Junction (fuse) box [a-1] [a-...
Page 582
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-45 1 1. Sound scope fuel cut operation inspection note: before inspection, check to make sure that gear shift lever is in neutral position (with a / t model, selector lever in “p” range) and that parking brake lever is pulle...
Page 583
Yh4 grand vitara 6e1-46 engine and emission control system (g16 / j20 engines) 1 2 1. Data link connector 1. Tech 1 display 2. Egr valve opening (0: close, 100: full open) 1. Egr valve 2. Egr valve coupler 3. Intake manifold 3 emission control system egr system system inspection [using suzuki scan t...
Page 584
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-47 1. Egr valve 2. Connector 1. Egr valve 2. Valve 3. Valve seat g16 engine j20 engine 1. Egr valve 2. Gasket 3. Intake manifold 2 3 inspection 1) check resistance between following terminals of egr valve in each pair. Termi...
Page 585
Yh4 grand vitara 6e1-48 engine and emission control system (g16 / j20 engines) 1. Purge hose 1. Vacuum nozzle evaporative emission control system evap canister purge system check 1) warm up engine to normal operating temperature. 2) stop engine and hoist vehicle so that all wheels rotate freely. 3) ...
Page 586
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-49 1. Hose “a” 2. Hose “b” 3. Evap canister purge valve 1. Hose “a” 2. Hose “b” 3. Evap canister purge valve 1. Tank pipe 2. Purge pipe 3. Air pipe 4. Blow air 3) disconnect vacuum hoses from intake manifold and its evap can...
Page 587
Yh4 grand vitara 6e1-50 engine and emission control system (g16 / j20 engines) 1. Tank pressure control valve 2. Orange side 3. Black side 4. To canister 5. From fuel tank 1. Pcv valve 1. Pcv valve 1 tank pressure control valve inspection 1) remove tank pressure control valve installed around evap c...
Page 588: Special Tools
Yh4 grand vitara engine and emission control system (g16 / j20 engines) 6e1-51 1. Pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. Attachment 09919-46010 4. Checking tool set 09912-58421 4-1. Tool body & washer 4-2. Body plug 4-3. Body attachment 4-4. Holder 4-5. Return hose & clamp 4-6. B...
Page 589: Section 6E2
Yh4 grand vitara 6e2 engine and emission control system (h25 engine) 6e2-1 general description 6e2- 3 . . . . . . . . . . . . . . Air intake system 6e2- 6 . . . . . . . . . . . . . . . . . . Fuel delivery system 6e2- 7 . . . . . . . . . . . . . . Electronic control system 6e2- 8 . . . . . . Engine &...
Page 590
Yh4 grand vitara vss 6e2-40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Map sensor 6e2-41 . . . . . . . . . . . . . . . . . . . . . . . . . Ckp sensor 6e2-41 . . . . . . . . . . . . . . . . . . . . . . . . . Main relay 6e2-42 . . . . . . . . . . . . . . . . . . . . . . . . Fuel p...
Page 591: General Description
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-3 the engine and emission control system has 4 major sub-systems: air intake system, fuel delivery system, electronic control system and emission control sys- tem. Air intake system includes air cleaner, mass air flow sensor, throt...
Page 592
Yh4 grand vitara 6e2-4 engine and emission control system (h25 engine).
Page 593
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-5.
Page 594
Yh4 grand vitara 1. Air cleaner 2. Iat sensor 3. Resonator 4. Intake manifold 5. Intake collector 6. Pcv hose 7. Brake booster 8. Fuel pressure regulator hose 9. Intake air pipe 10. Throttle body 11. Breather hose 12. Fast idle up thermo wax 13. Egr valve 14. Tp sensor 15. Iac hose 16. Maf sensor 17...
Page 595
Yh4 grand vitara 1. Fuel tank 2. Fuel pump 3. Fuel filter 4. Fuel feed line 5. Fuel return line 6. Fuel pressure regulator 7. Vacuum hose for fuel pressure regulator 8. Intake manifold surge tank 9. Fuel injector 10. Fuel delivery pipe 11. Throttle valve fuel air engine and emission control system (...
Page 596
Yh4 grand vitara 6e2-8 engine and emission control system (h25 engine) information sensors 1. Iat sensor 2. Map sensor (if equipped) 3. Heated oxygen sensor (sensor 1) (if equipped) 4. Ect sensor 5. Tp sensor 6. Maf sensor 7. Camshaft position sensor (cmp sensor) 8. Abs control module (if equipped) ...
Page 597
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-9.
Page 598
Yh4 grand vitara 6e2-10 engine and emission control system (h25 engine) terminal arrangement of ecm (pcm) connector (viewed from harness side) e61 c51-3 c51-1 c51-2.
Page 599
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-11 c51-3-17 heater of ho2s (bank 1 sensor 2) (if equipped) e61-18 abs control module (if equipped) e61-19 co adjusting resistor (if equipped) terminal circuit 1. Fuel injector no.1 2. Fuel injector no.2 3. Fuel injector no.3 4. Fue...
Page 600
Yh4 grand vitara 6e2-12 engine and emission control system (h25 engine) input output cmp sensor maf sensor tp sensor ect sensor ia t sensor ho2s (sensor 1) vss blower fan switch rear defogger switch psp switch ignition switch starter switch a/c amplifier (if equipped) tr switch (a/t vehicle) light s...
Page 601: On-Vehicle Service
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-13 1. Brake booster hose pipe 2. Vacuum hose for fuel pressure regulator 3. Fuel pressure regulator 4. Map sensor 5. Engine coolant hose 6. Evap canister purge valve 7. Breather hose 8. Egr pipe 9. Exhaust manifold 10. Heated oxyge...
Page 602
Yh4 grand vitara 6e2-14 engine and emission control system (h25 engine) 1. Accelerator cable 3. Lock nut 1. A / t throttle cable 3. Lock nut general when hoses are disconnected and system components are re- moved for service, reinstall components properly, and route and connect hoses correctly after...
Page 603
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-15 idle speed / idle air control (iac) duty inspection before idle speed / iac duty check, make sure of the following. Lead wires and hoses of engine / emission control systems are connected securely. Accelerator cable is adjusted....
Page 604
Yh4 grand vitara 6e2-16 engine and emission control system (h25 engine) a: output duty select switch terminal b: diagnosis switch terminal c: blank d: ground terminal e: test switch terminal f: duty output terminal [not using suzuki scan tool] (vehicle with monitor connector) note: if ecm (pcm) part...
Page 605
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-17 idle mixture inspection / adjustment (vehicle without heated oxygen sensor) all vehicles not equipped with heated oxygen sensor are shipped with their co% factory adjusted as follows. Engine idle mixture (co%) 0.8 – 1.3% at spec...
Page 606
Yh4 grand vitara 6e2-18 engine and emission control system (h25 engine) 2. Fast idle control cam 1. Throttle body 2. Intake collector 3. Breather hose 4. Water hose 5. Maf sensor 6. Tp sensor 7. Fast idle up thermo wax air intake system throttle body on-vehicle inspection 1) check that throttle valv...
Page 607
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-19 removal 1) disconnect negative cable at battery. 2) drain cooling system. 3) remove strut tower bar. 4) disconnect accelerator cable (1) and or a / t throttle cable (2) from throttle body. 5) disconnect water hose (3) from throt...
Page 608
Yh4 grand vitara 6e2-20 engine and emission control system (h25 engine) 15) remove throttle body (3) and intake collector (2) from intake manifold (1). 15) disconnect hoses of iac valve and pcv from throttle body. 16) remove throttle body from intake collector. Note: maf sensor (4), tp sensor (5), o...
Page 609
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-21 idle air control valve (iac valve) removal 1) disconnect battery negative cable at battery. 2) disconnect iac valve connector. 3) remove iac valve (1) from intake collector (2). On-vehicle inspection 1) disconnect connector from...
Page 610
Yh4 grand vitara 6e2-22 engine and emission control system (h25 engine) installation for installation, reverse removal procedure and note following pre- cautions. Use new gaskets (1)..
Page 611
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-23 2. Fuel return pipe 3. Fuel pressure regulator 4. Engine at specified idle speed 210 – 260 kpa 2.1 – 2.6 kg / cm 2 29.8 – 37.0 psi with 1 min. After engine (fuel pump) stopped (pressure re- duces as time passes) over 200 kpa 2.0...
Page 612
Yh4 grand vitara 6e2-24 engine and emission control system (h25 engine) fuel pump on-vehicle inspection caution: when fuel filler cap is removed in any procedure, work must be done in a well-ventilated area, keep away from any open flames and without smoking. 1) remove filler cap and turn on ignitio...
Page 613
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-25 fuel pressure regulator removal 1) relieve fuel pressure in fuel feed line referring to “fuel pressure relief procedure” in “engine” section. 2) disconnect battery negative cable from battery. 3) disconnect vacuum hose (1) from ...
Page 614
Yh4 grand vitara 6e2-26 engine and emission control system (h25 engine) fuel injector on-vehicle inspection 1) using sound scope (1) or such, check operating sound of injec- tor when engine is running or cranking. Cycle of operating sound should vary according to engine speed. If no sound or an unus...
Page 615
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-27 7) remove delivery pipes (1) (right and left) from intake manifold. 8) remove fuel injector(s). Inspection warning: as fuel is injected in this inspection, perform in a well venti- lated area and away from open flames. Use speci...
Page 616
Yh4 grand vitara 6e2-28 engine and emission control system (h25 engine) left hand steering vehicle right hand steering vehicle 1. Fuel pump relay connector 2. Service wire 3. Fuse box 4) install suitable vinyl tube onto injector (4) nozzle to prevent fuel from splashing out when injecting. 5) put gr...
Page 617
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-29 5 4 4 2) check if insulator (1) is scored or damaged. If it is, replace with new one. Install insulators and cushions (2) to intake manifold. 3) apply thin coat of fuel to o-rings (1) and then install injectors into delivery pip...
Page 618
Yh4 grand vitara 6e2-30 engine and emission control system (h25 engine) 8) connect fuel feed hose (1) and fuel return hose (2). 9) connect connectors (3) to injectors. 10) install throttle body and intake collector, refer to “throttle body installation” in this section. 11) with engine “off” and ign...
Page 619
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-31 1 electronic control system engine control module (ecm)/powertrain control module (pcm) caution: as ecm (pcm) consists of precision parts, be careful not to expose it to excessive shock. Removal 1) disconnect battery negative ca...
Page 620
Yh4 grand vitara terminal arrangement of ecm (pcm) coupler (viewed from harness side) c51-3-20 c51-3-23 6e2-32 engine and emission control system (h25 engine) mass air flow sensor (maf sensor) inspection note: use voltmeter with high-impedance (10 k / v minimum) or dig- ital type voltmeter. 1) remov...
Page 621
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-33 removal 1) disconnect negative cable at battery and coupler from maf sen- sor (2). 2) remove throttle body (1), referring to “throttle body re- moval” in this section. Note: don’t remove maf sensor. Caution: do not expose maf se...
Page 622
Yh4 grand vitara 6e2-34 engine and emission control system (h25 engine) ( ) for reference temperature resist ance intake air temperature (iat) sensor removal 1) disconnect negative cable from battery. 2) disconnect iat sensor coupler. 3) remove iat sensor from air cleaner case. Inspection immerse te...
Page 623
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-35 1. Reference voltage terminal 2. Output voltage terminal 3. Ground terminal throttle position sensor (tp sensor) inspection 1) warm up engine and stop it when its temperature has reached normal operating temperature (check to ma...
Page 624
Yh4 grand vitara 6e2-36 engine and emission control system (h25 engine) terminal arrangement of ecm (pcm) coupler (viewed from harness side) c51-3-12 adjustment 1) warm up engine to normal operating temperature. 2) check to make sure that fast idle cam and cam follower lever are not in contact with ...
Page 625
Yh4 grand vitara ( ) for reference temperature resist ance engine and emission control system (h25 engine) 6e2-37 engine coolant temperature sensor (ect sensor) removal 1) disconnect negative cable from battery. 2) drain cooling system. 3) disconnect coupler from ect sensor (1). 4) remove ect sensor...
Page 626
Yh4 grand vitara 6e2-38 engine and emission control system (h25 engine) heated oxygen sensor (sensor 1) removal warning: to avoid danger of being burned, do not touch exhaust sys- tem when system is hot. Oxygen sensor removal should be performed when system is cool. 1) disconnect negative cable from...
Page 627
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-39 heated oxygen sensor (sensor 2) removal warning: to avoid danger of being burned, do not touch exhaust sys- tem when system is hot. Oxygen sensor removal should be performed when system is cool. 1) disconnect negative cable from...
Page 628
Yh4 grand vitara 6e2-40 engine and emission control system (h25 engine) vehicle speed sensor (vss) on-vehicle inspection 1) hoist vehicle. 2) release parking brake lever, set transmission in neutral and transfer in “2h”. 3) remove ecm (pcm) cover. 4) connector voltmeter between vss terminal c51-3-1 ...
Page 629
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-41 manifold absolute pressure sensor inspection 1) disconnect coupler from map sensor (1). 2) remove map sensor (1). 3) arrange 3 new 1.5 v batteries (2) in series (check that total volt- age is 4.5 – 5.0 v) and connect its positiv...
Page 630
Yh4 grand vitara 6e2-42 engine and emission control system (h25 engine) left-hand steering vehicle right-hand steering vehicle main relay inspection 1) disconnect negative cable at battery. 2) remove main relay (1) from relay box (2). 3) check resistance between each two terminals as in table below....
Page 631
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-43 1 2. Fuse box 3. Instrument panel left-hand steering vehicle right-hand steering vehicle 1 1 fuel pump relay inspection 1) disconnect negative cable at battery. 2) remove fuel pump relay (1) from relay box. 3) structure of fuel ...
Page 632
Yh4 grand vitara 6e2-44 engine and emission control system (h25 engine) 1 2 1. Tech 1 display 2. Egr valve opening (0: close, 100: full open) emission control system egr system (if equipped) system inspection [using suzuki scan tool (tech 1)] 1) connect tech 1 to data link connector (dlc) with ignit...
Page 633
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-45 1. Egr valve 2. Connector inspection 1) check resistance between following terminals of egr valve in each pair. Terminals standard resistance a – b c – b f – e d – e 20 – 24 at 20 _ c, 68f b – valve body e – valve body infinity ...
Page 634
Yh4 grand vitara 6e2-46 engine and emission control system (h25 engine) 1. Purge hose evaporative emission control system evap canister purge inspection 1) warm up engine to normal operating temperature and keep id- ling 5 min. Or more. 2) disconnect purge hose from evap canister when engine is run-...
Page 635
Yh4 grand vitara engine and emission control system (h25 engine) 6e2-47 1 pcv valve 1) disconnect pcv valve (1) from cylinder head cover and plug head cover hole. 2) run engine at idle. 3) place your finger over end of pcv valve to check for vacuum. If there is no vacuum, check for clogged valve. Re...
Page 636: Special Tools
Yh4 grand vitara 6e2-48 engine and emission control system (h25 engine) 1. Pressure gauge 09912-58441 2. Pressure hose 09912-58431 3. 3-way joint & hose 09912-58490 4. Checking tool set 09912-58421 4-1. Tool body & washer 4-2. Body plug 4-3. Body attachment-1 4-4. Holder 4-5. Return hose & clamp 4-6...
Page 637: Section 6F1
Yh4 grand vitara 6f1 ignition system (for g16 engine) 6f1-1 section 6f1 ignition system (for g16 engine) 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....
Page 638: General Description
Yh4 grand vitara 1. To ignition switch 2. “ig.Coil meter” fuse 3. Ecm (or pcm) 4. Noise suppressor 5. Ignition coil assembly (igniter and ignition coil) for no.1 and no.4 cylinders 6. Ignition coil assembly (igniter and ignition coil) for no.2 and no.3 cylinders 7. High-tension cord – engine start s...
Page 639: Diagnosis
Yh4 grand vitara 1. Ignition coil assembly for no.1 and no.4 cylinders 2. Ignition coil assembly for no.2 and no.3 cylinders 3. Monitor coupler ( * ) 4. Cmp sensor 5. Ecm (or pcm) ( * ) 6. High-tension cord 7. Spark plug 8. Noise suppressor 9. Ignition timing adjusting resistor ( * ) (if equipped) 1...
Page 640
Yh4 grand vitara 6f1-4 ignition system (for g16 engine) diagnostic flow table step action yes no 1 was “engine diagnostic flow table” in section 6 performed ? Go to step 2. Go to “engine diag- nostic flow table” in section 6. 2 ignition spark test 1) check all spark plug for condition and type, refe...
Page 641
Yh4 grand vitara ignition system (for g16 engine) 6f1-5 1. Injector coupler cmp sensor signal ignition trigger signal primary coil current flow time waveforms at specified idle speed oscilloscope waveforms step action yes no 10 ignition timing check 1) check initial ignition timing and ignition timi...
Page 642
Yh4 grand vitara 1. Monitor connector 2. Service wire 3. Ground terminal 4. Test switch terminal 1. “v” mark on crankshaft pulley 2. 5 _ btdc 1 (a) 6f1-6 ignition system (for g16 engine) ignition timing check note: before starting engine, place transmission gear shift lever in “neutral” (shift selec...
Page 643
Yh4 grand vitara 1. Noise suppressor 4. Timing belt cover 5. Ignition label 2. Ignition timing adjusting resistor 3. Character on resistor ignition system (for g16 engine) 6f1-7 7) if ignition timing is out of specification, check as follows. For vehicle equipped with ignition timing adjusting resis...
Page 644: On-Vehicle Service
Yh4 grand vitara 6f1-8 ignition system (for g16 engine) 1. Ignition coil assembly 2. High-tension cord 1. Ignition coil assembly 2. High-tension cord on-vehicle service high-tension cord removal 1) remove high-tension cord from ignition coil assembly while gripping its cap. 2) pull out high-tension ...
Page 645
Yh4 grand vitara ignition system (for g16 engine) 6f1-9 1. Ignition coil assembly 1. Ignition coil bolt 2. Ignition coil assembly 3. High-tension cord 1. Ignition coil bolt 2. Ignition coil assembly 3. High-tension cord ignition coil assembly (igniter and ignition coil) removal 1) disconnect ignitio...
Page 646
Yh4 grand vitara 6f1-10 ignition system (for g16 engine) 1. Spark plug for no.1 cylinder 1. Spark plug for no.1 cylinder 1. Noise suppressor 2. Ignition timing adjusting resistor spark plug removal 1) pull out high-tension cord while gripping its cap. 2) remove ignition coil assembly, referring to “...
Page 647
Yh4 grand vitara ignition system (for g16 engine) 6f1-11 1. Noise suppressor 2. Engine harness 1. Cmp sensor inspection measure resistance of ignition timing adjusting resistor by using ohmmeter. Note: depending on number marked on ignition timing adjusting re- sistor, resistor value varies as follo...
Page 648: Special Tools
Yh4 grand vitara 6f1-12 ignition system (for g16 engine) 09930-76420 timing light (dry cell type) 09931-76011 suzuki scan tool (tech 1a) kit 09931-76030 16 / 14 pin dlc cable mass storage cartridge 1. Storage case 2. Operator’s manual 3. Tech 1a 4. Dlc cable 5. Test lead / probe 6. Power source cabl...
Page 649: Section 6F2
Yh4 grand vitara 6f2 ignition system (for j20 / h25 engines) 6f2-1 section 6f2 ignition system (for j20/h25 engines) 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 su...
Page 650: General Description
Yh4 grand vitara 1. To ignition switch 2. “ig.Coil meter” fuse 3. Ecm (or pcm) 4. Cmp sensor 5. Noise suppressor 6. Ignition coil assembly (for no.1 cylinder) 7. Ignition coil assembly (for no.2 cylinder) 8. Ignition coil assembly (for no.3 cylinder) 9. Ignition coil assembly (for no.4 cylinder) 10....
Page 651
Yh4 grand vitara note: above figure shows left hand steering vehicle. For right hand steering vehicle, parts with (*) are installed at the other side. 1. Ignition coil assembly (igniter and ignition coil) 2. Monitor coupler (*) (if equipped) 3. Cmp sensor 4. Noise suppressor 5. Ecm (or pcm) (*) 6. S...
Page 652: Diagnosis
Yh4 grand vitara 6f2-4 ignition system (for j20 / h25 engines) diagnosis condition possible cause correction engine cranks, but will not start or hard to start no spark blown fuse for ignition coil assembly loose connection or disconnection of lead wire faulty spark plug(s) faulty ignition coil asse...
Page 653
Yh4 grand vitara ignition system (for j20 / h25 engines) 6f2-5 no.1 ignition trigger signal oscilloscope waveforms ref signal of cmp sensor 2v / div. 1v/div. No.1 ignition trigger signal primary coil current flow time waveforms at specified idle speed 10ms / div. H25 engine j20 engine cmp sensor 2v ...
Page 654
Yh4 grand vitara 6f2-6 ignition system (for j20 / h25 engines) 1. Injector coupler j20 engine h25 engine 1. Dlc 1. Monitor coupler 2. Service wire 3. Ground terminal 4. Test switch terminal ignition spark check 1) for h25 engine, remove surge tank cover. 2) disconnect injector coupler. Warning: with...
Page 655
Yh4 grand vitara 1 3 (a) (a) 1 2 3 1. Cmp sensor 2. Bolt 1. Viewpoint 2. Timing mark on chain cover 3. Timing mark on crankshaft pulley j20 engine h25 engine j20 engine h25 engine ignition system (for j20 / h25 engines) 6f2-7 5) set timing light to ignition harness for no.1 cylinder. 6) using timing...
Page 656
Yh4 grand vitara 6f2-8 ignition system (for j20 / h25 engines) 1. Viewpoint 2. Timing mark on chain cover 3. Timing mark on crankshaft pulley h25 engine j20 engine 1 3 2 1 3 9) after checking and / or adjusting, end fixed spark mode of su- zuki scan tool or disconnect service wire from monitor cou- ...
Page 657: On-Vehicle Service
Yh4 grand vitara ignition system (for j20 / h25 engines) 6f2-9 1. Ignition coil bolt 2. Ignition coil assembly 1. Ignition coil bolt 2. Ignition coil 3. Spark plug j20 engine h25 engine j20 engine h25 engine on-vehicle service ignition coil assembly (igniter and ignition coil) removal 1) for h25 eng...
Page 658
Yh4 grand vitara 1. Ignition coil bolt 2. Ignition coil assembly 3. Spark plug h25 engine j20 engine 6f2-10 ignition system (for j20 / h25 engines) inspection caution: when servicing the iridium / platinum sparkplugs (slender center electrode type plugs), do not touch the center elec- trode to avoid...
Page 659
Yh4 grand vitara 1. Cmp sensor 2. Cmp sensor coupler 3. Bolt j20 engine h25 engine 2 3 1. Cmp sensor 2. O-ring j20 engine 1 2 1 2 1. Cmp sensor 2. Cmp sensor coupling 3. Camshaft a: slot offset h25 engine ignition system (for j20 / h25 engines) 6f2-11 cmp sensor caution: disassembly is prohibited. I...
Page 660
Yh4 grand vitara 2 3, (a) 1. Cmp sensor 2. Cmp sensor coupler 3. Bolt j20 engine h25 engine 1. Noise suppressor 2. Engine harness j20 engine h25 engine 6f2-12 ignition system (for j20 / h25 engines) 3) tighten cmp sensor bolts. Tightening torque (a): 15 n . M (1.5 kg-m, 11.0 lb-ft) 4) connect cmp se...
Page 661
Yh4 grand vitara ignition system (for j20 / h25 engines) 6f2-13 installation for installation, reverse removal procedure..
Page 662: Special Tools
Yh4 grand vitara 6f2-14 ignition system (for j20 / h25 engines) 09930-76420 timing light (dry cell type) 09931-76011 suzuki scan tool (tech 1a) kit 09931-76030 16 / 14 pin dlc cable mass storage cartridge 1. Storage case 2. Operator’s manual 3. Tech 1a 4. Dlc cable 5. Test lead / probe 6. Power sour...
Page 663: Section 6G
Yh4 grand vitara 6g cranking system 6g-1 section 6g cranking system (0.9 kw, 1.2 kw and 1.4 kw reduction type) note: starting motor vary depending on specifications, etc. Therefore, be sure to check model and specification of the vehicle being serviced before replacing parts. Contents general descri...
Page 664: General Description
Yh4 grand vitara ignition & starting motor switch pull-in coil pinion drive lever pinion & over-running clutch magnetic switch hold-in coil plunger starting motor magnetic switch contacts to distributor m / t: nothing a / t: park / neutral position switch in transmission range switch (shift lever sw...
Page 665
Yh4 grand vitara 1. Front housing 2. Bush 3. Snap ring 4. Pinion stop ring 5. Pinion gear 6. Over-running clutch 7. Lever 8. Plunger 9. Plate 10. Seal rubber 11. Magnetic switch 12. Ball 13. Internal gear 14. Planetary carrier shaft 15. Planetary gear 16. Packing 17. Yoke 18. Armature 19. Brush 20. ...
Page 666: Diagnosis
Yh4 grand vitara 6g-4 cranking system diagnosis possible symptoms due to starting system trouble would be as follows: starting motor does not run (or runs slowly) starting motor runs but fails to crank engine abnormal noise is heard proper diagnosis must be made to determine exactly where the cause ...
Page 667
Yh4 grand vitara cranking system 6g-5 condition possible cause correction motor not running burnt commutator layer short-circuit of armature crankshaft rotation obstructed replace armature. Replace. Repair. Starting motor running but too slow (small torque) if battery and wiring are satisfactory, in...
Page 668: Unit Repair Overhaul
Yh4 grand vitara 1. Magnetic switch 2. Front housing 3. Yoke 1. Magnetic switch 2. Protector 1. Magnetic switch 2. Spring 3. Plunger 6g-6 cranking system unit repair overhaul dismounting and remounting use following procedure to remove starter: 1) disconnect negative battery lead at battery. 2) disc...
Page 669
Yh4 grand vitara 1. Bolts 2. Reduction gear assembly 1. Planetary gear 2. Packing 1. Seal rubber 2. Plate 1. Shaft ass’y 2. Lever 1. Snap ring 2. Pinion stop ring 3. Over-running clutch assembly cranking system 6g-7 2) remove bolts shown in left figure, then separate reduction gear assembly from sta...
Page 670
Yh4 grand vitara 1. Internal gear 2. Snap ring 3. Pinion stop ring 4. Over-running clutch 1. Rear bracket 2. Armature 3. Yoke 1. Armature 2. Yoke 3. Ball 1. Rear bracket 2. Brush holder 6g-8 cranking system 7) remove snap ring, then pull out pinion stop ring and over-run- ning clutch and internal ge...
Page 671
Yh4 grand vitara 1. Rear bush 2. Rear bracket cap 3. Rear bracket cranking system 6g-9 11) remove brush springs and brushes. 12) remove rear bracket cap, and then remove rear bush, as re- quired..
Page 672
Yh4 grand vitara 1. Brush 2. Brush spring 3. Brush holder 1. Rear bracket 2. Brush holder screws 1. Over-running clutch 2. Pinion stop ring 3. Snap ring 4. Gear shaft 1. Shaft ass’y 2. Lever 6g-10 cranking system reassembly caution: washing, adjusting and disassembling of shock absorber (clutch plat...
Page 673
Yh4 grand vitara 1. Packing 2. Planetary gear 3. Bolt hole 4. Seal rubber 1. Ball 1. Bolts 2. Reduction gear assembly 1. Magnetic switch 2. Protector cranking system 6g-11 11) install packing so that cuts in packing align with holes for through bolts in front housing. 12) install plate and seal rubb...
Page 674
Yh4 grand vitara 6g-12 cranking system inspection 1. Plunger inspect plunger for wear. Replace if necessary. 2. Magnetic switch push in plunger and release it. The plunger should return quickly to its original position. Replace if necessary. Pull-in coil open circuit test check for continuity across...
Page 675
Yh4 grand vitara cranking system 6g-13 4. Brush check brushes for wear. Measure length of brushes and if below limit, replace brush. Brush length 0.9 kw and 1.2 kw types 1.4 kw type standard 12.3 mm (0.44 in.) 16.5 mm (0.65 in.) limit 7 mm (0.28 in.) install brushes to each brush holder and check fo...
Page 676
Yh4 grand vitara 1. Armature 2. V-block 3. Magnetic stand 4. Dial gauge 1. Commutator segment 2. Insulator “a” 6g-14 cranking system check commutator for uneven wear with armature supported on v-blocks. If deflection of dial gauge pointer exceeds limit, repair or replace. Note: below specification p...
Page 677
Yh4 grand vitara cranking system 6g-15 open circuit test check for continuity between segments. If there is no continuity at any test point, there is an open circuit and armature must be replaced. 8. Gears inspect internal gear and planetary gears for wear, damage or other abnormal conditions. Repla...
Page 678
Yh4 grand vitara 6g-16 cranking system 1. Terminal ‘s’ 2. Terminal ‘m’ 3. Lead wire (switch to motor) performance test caution: each test must be performed within 3 – 5 seconds to avoid coil from burning. 1) pull-in test connect battery to magnetic switch as shown. Check that plunger and pinion move...
Page 679: Specifications
Yh4 grand vitara cranking system 6g-17 specifications 1.2 kw type (1.4 kw type) voltage 12 volts output 1.2 kw (1.4 kw) rating 30 seconds direction of rotation clockwise as viewed from pinion side brush length 12.3 mm (0.44 in.) (16.5 mm (0.65 in.)) number of pinion teeth 8 performance condition gua...
Page 680: Required Service Material
Yh4 grand vitara 6g-18 cranking system 09900-06107 snap ring pliers (opening type) required service material material recommended suzuki product use lithium grease suzuki super grease a (99000-25010) front and rear bush. Plunger. Pinion drive lever. Internal gear. Planetary carrier shaft. Planetary ...
Page 681: Section 6G1
Yh4 grand vitara 6g1 cranking system 6g1-1 general description 6g1-2 . . . . . . . . . . . . . . Cranking circuit 6g1-2 . . . . . . . . . . . . . . . . . . . . . . Starting motor 6g1-2 . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis 6g1-4 . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 682: General Description
Yh4 grand vitara pinion drive lever plunger hold in coil pull in coil magnetic switch to distributor magnetic switch contacts starting motor pinion & over running clutch ignition & starter switch ig st bat. Battery 6g1-2 cranking system general description cranking circuit the cranking circuit consi...
Page 683
Yh4 grand vitara cranking system 6g1-3 8 “a” 7 3 6 15 “a” “a” 5 4 “a” 2 16 12 12 13 14 9 “a” 1. Drive housing cover 2. Drive bush 3. Drive housing 4. Armature ring 5. Armature stop ring 6. Over running clutch 7. Pinion drive lever 8. Magnetic switch 9. Commutator end cover 10. Brush spring 11. Brush...
Page 684: Diagnosis
Yh4 grand vitara 6g1-4 cranking system diagnosis possible symptoms due to starting system trouble would be as follows: starting motor does not run (or runs slowly) starting motor runs but fails to crank engine abnormal noise is heard proper diagnosis must be made to determine exactly where the cause...
Page 685
Yh4 grand vitara cranking system 6g1-5 condition possible cause correction starting motor running but too slow (small torque) if battery and wiring are satisfactory, inspect starting motor insufficient contact of magnetic switch main contacts layer short-circuit of armature disconnected, burnt or wo...
Page 686: Unit Repair Overhaul
Yh4 grand vitara 7 (a) 7 6 1 2 3 5 4 1. Starting motor 2. Clutch housing upper plate 3. Transmission case 4. Starting motor mounting bolt 5. Starting motor mounting nut 6. Magnetic switch lead wire 7. Battery cable 6g1-6 cranking system unit repair overhaul dismounting 1) disconnect negative battery...
Page 687
Yh4 grand vitara 1. Magnetic switch 2. Commutator end cover 3. Yoke 4. Drive housing 1. Magnetic switch 1 4 3 2 a b 1 cranking system 6g1-7 disassembly note: before disassembling starting motor, be sure to put match marks at two locations (a and b) as shown in the left figure so that any possible mi...
Page 688
Yh4 grand vitara 4 3 1 2 1. Stop ring 2. Snap ring 3. Pinion gear 4. Clutch #300 400 6g1-8 cranking system 6) draw off over running clutch, as follows: (1) draw stop ring toward clutch side. (2) remove armature ring and side off clutch. Reassembly assemble in reverse order of disassembly, noting the...
Page 689
Yh4 grand vitara insulator correct 0.4 – 0.8 mm (0.015 – 0.023 in.) commutator segments incorrect cranking system 6g1-9 inspect commutator for insulator depth. Correct or replace if be- low limit. Commutator mica depth standard: 0.4 – 0.6 mm (0.015 – 0.023 in.) limit: 0.2 mm (0.0078 in.) ground test...
Page 690
Yh4 grand vitara reverse drive 6g1-10 cranking system 4. Brush holder check movement of brush in brush holder. If brush movement within brush holder is sluggish, check brush holder for distortion and sliding faces for correct contamination. Clean or correct as necessary. Clean for continuity across ...
Page 691
Yh4 grand vitara ‘m’ ‘s’ ‘s’ cranking system 6g1-11 inspect spline teeth for wear or damage. Replace if necessary. Inspect pinion for smooth movement. 8. Armature shaft bush inspect bushes for wear or damage. Replace if necessary. 9. Magnetic switch push in plunger and release it. Plunger should ret...
Page 692
Yh4 grand vitara ‘bat’ ‘s’ ‘m’ ‘s’ ‘m’ ‘s’ ‘s’ ‘bat’ 6g1-12 cranking system performance test caution: these tests must be performed within 3 - 5 seconds to avoid coil from burning. Pull-in test connect battery to magnetic switch as shown. Check that pinion moves outward. If pinion does not move, rep...
Page 693: Specifications
Yh4 grand vitara cranking system 6g1-13 09900-06107 snap ring pliers (opening type) specifications voltage 12 volts output 0.9 kw rating 30 seconds direction of rotation clockwise as viewed from pinion side brush length 17.0 mm (0.67 in.) number of pinion teeth 8 performance condition guarantee no l...
Page 694: Section 6H
Yh4 grand vitara 6h charging system 6h-1 section 6h charging system 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 a...
Page 695: General Description
Yh4 grand vitara 6h-2 charging system general description battery the battery has three major functions in the electrical system. It is a source of electrical energy for cranking the engine. It acts as a voltage stabilizer for the electrical system. It can, for a limited time, provide energy when th...
Page 696
Yh4 grand vitara charging system 6h-3 care of battery warning: never expose battery to open flame or electric spark be- cause of battery generate gas which is flammable and ex- plosive. Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces as fluid is a corrosive acid. Flush...
Page 697
Yh4 grand vitara [60 a type] [70 a and 85 a types] 1. Generator with regulator ass’y 2. I.C. Regulator 3. Stator coil 4. Diode 5. Field coil (rotor coil) 6. Charge indicator light 7. Main switch 8. Battery 6h-4 charging system generator the generator is a small and high performance type with an ic r...
Page 698
Yh4 grand vitara charging system 6h-5 [60 a type] [70 a type] [85 a type] 1. Pulley 2. Pulley nut 3. Rotor fan 4. Stator coil 5. Stator core 6. Field coil 7. Regulator 8. Brush 9. Rear end frame 10. Drive end frame 11. Front housing 12. Rear housing b : generator output (battery terminal) d : dummy ...
Page 699: Diagnosis
Yh4 grand vitara 6h-6 charging system diagnosis battery common causes of failure a battery is not designed to last indefinitely; however, with proper care, it will provide many years of service. If the battery performs satisfactorily during test but fails to operate properly for no apparent reason, ...
Page 700
Yh4 grand vitara charging system 6h-7 hydrometer test the direct method of checking the battery for state of charge is to carry out a high rate discharge test, which involves a special pre- cise voltmeter and an expensive instrument used in the service shops, but not recommendable to the user of the...
Page 701
Yh4 grand vitara [60 a type] [70 a type] [85 a type] b : generator output : (battery terminal) d : dummy terminal e : ground f : field coil terminal ig : ignition terminal l : lamp terminal 6h-8 charging system generator caution: do not mistake polarities of ig terminal and l terminal. Do not create...
Page 702
Yh4 grand vitara ammeter between generator (b) terminal and battery (+) terminal voltmeter between generator (b) terminal and ground. 1. Generator 2. Ammeter 3. Voltmeter 4. Battery 5. Load 6. Switch [60 a type] [70 a and 85 a types] heatsink temperature ( _ c) regula ted vol t age (v) volt temperat...
Page 703
Yh4 grand vitara [60 a type] [70 a and 85 a types] heatsink temperature ( _ c) regula ted vol t age (v) volt temperature 6h-10 charging system higher voltage if voltage is higher than standard value, check ground of brushes. If brushes are not grounded, replace ic regulator. Lower voltage [60 a type...
Page 704: On-Vehicle Service
Yh4 grand vitara charging system 6h-11 on-vehicle service battery jump starting in case of emergency with auxiliary (booster) battery caution: if vehicle is manual transmission model and has a catalytic converter, do not push or tow it to start. Damage to its emis- sion system and / or to other part...
Page 705
Yh4 grand vitara 1. Battery 2. Positive cable 3. Negative cable 4. Body ground bolt 5. Retainer 6. Nut 6h-12 charging system with charging equipment caution: when jump starting engine with charging equipment, be sure equipment used is 12-volt and negative ground. Do not use 24-volt charging equipmen...
Page 706
Yh4 grand vitara 1. Generator belt 2. Crankshaft pulley 3. Radiator fan pulley 4. Tension pulley 5. Tensioner 1. Generator belt 2. Tensioner 3. Tensioner bolt charging system 6h-13 generator generator belt [g16 and h25 engines] refer to “cooling fan belt” in section 6b “engine cool- ing”. [j20 engin...
Page 707: Unit Repair Overhaul
Yh4 grand vitara 1. Battery 2. Negative (–) battery cable 1. Generator 2. Coupler 3. “b” terminal 1. Air cleaner outlet hose 2. Canister 1. Upper generator bolt (short) 2. Lower generator bolt (long) 3. “b” terminal 6h-14 charging system unit repair overhaul generator dismounting 1) disconnect negat...
Page 708
Yh4 grand vitara 1. Upper generator bolt (short) 2. Lower generator bolt (long) 3. “b” terminal charging system 6h-15 remounting 1) mount generator on the generator bracket. 2) tighten generator bolts. T ightening torque (a): 23 n . M (2.3 kg-m, 16.5 lb-ft) 3) install generator (cooling fan) belt. R...
Page 709
Yh4 grand vitara 1. Pulley 2. Front housing 3. Bearing 4. Retainer 5. Rotor 6. Stator 7. Ic regulator 8. Rectifier 9. Rear housing 10. Brush 1. Front housing 2. Rear housing 3. Match marks 6h-16 charging system disassembly [60 a type] 1) for easier reinstallation, provide match marks on both front a...
Page 710
Yh4 grand vitara 1. Rear housing 2. Stator core 3. Front housing 4. Lever 1. Pulley nut 2. Rotor 3. Cloth 4. Vise 1. Front housing 2. Retainer screw 4 2 3 3 2 charging system 6h-17 3) with lever inserted between stator core and front housing, sepa- rate generator into front and rear sides. 4) loosen...
Page 711
Yh4 grand vitara 1. Rear bearing 2. Oil hydraulic press 3. General rod 4. General tool 1. Screw 2. Generator “b” terminal nut 3. “b” terminal 1. Brush holder 2. Solder 3. Brush spring 1. Stator lead (solder) 6h-18 charging system 7) when removing rear bearing, use oil hydraulic press. 8) remove thre...
Page 712
Yh4 grand vitara 1. Pulley nut 2. Pulley 3. Drive end frame 4. Stator 5. Stud bolt 6. Drive end bearing 7. Bearing retainer 8. Rotor 9. End housing bearing 10. Bearing cover 11. Rear end frame 12. Rectifier 13. Insulator 14. Regulator 15. Brush 16. Brush holder 17. Rear end cover [70a type] [85 a ty...
Page 713
Yh4 grand vitara 1. Rear end cover 2. Insulator 3. “b” terminal inner nut 1. Ic regulator screws 2. Ic regulator 1. Rectifier 1. Rubber insulator 1. Pulley 2. Hexagonal box wrench 3. Offset wrench 3. Brush holder screws 4. Brush holder assembly 6h-20 charging system 1) remove “b” terminal inner nut ...
Page 714
Yh4 grand vitara 1. Rear end frame 2. Rotor shaft 3. Rear end frame nut 1. End housing bearing 2. Bearing puller 3. Bearing cover 1. Stud bolt 2. Retaining plate 3. Drive end bearing 4. Stator charging system 6h-21 9) remove 4 rear end frame nuts. 10) drive out rear end frame with rotor tapping shaf...
Page 715
Yh4 grand vitara 1. Rotor 1. Rotor 1. Stator 1. Stator 2. Stator lead 6h-22 charging system inspection [60 a type] rotor 1) using ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace rotor. Standard resistance: 2.5 – 2.9 2) using ohmmeter, check that there i...
Page 716
Yh4 grand vitara 1. Rectifier 2. Diode lead 1. Rectifier 2. Condenser charging system 6h-23 rectifier 1) using ohmmeter, check continuity between each of upper and lower rectifier bodies and each diode lead. Check both directions by reversing probes of ohmmeter and there should be only one-way conti...
Page 717
Yh4 grand vitara 6h-24 charging system inspection [70 a and 85 a types] rotor using ohmmeter, check for continuity between slip rings of rotor. If there is no continuity, replace rotor. Standard resistance: about 2.9 using ohmmeter, check that there is no continuity between slip ring and rotor. If t...
Page 718
Yh4 grand vitara “a” 1. “b” terminal 2. Rectifier terminal 1. Negative terminal 2. Rectifier terminal charging system 6h-25 brush and brush holder check each brush for wear by measuring its length as shown. If brush is found worn down to service limit, replace brush. Refer to “replace brush” in this...
Page 719
Yh4 grand vitara “a” 6h-26 charging system replace brush [60 a type] refer to “disassembly” and “reassembly” of 60 a type. [70 a and 85 a types] 1) remove rear end cover and then brush holder. 2) unsolder and remove the brush and spring. 3) run the wire of a new brush through the spring and the hole...
Page 720
Yh4 grand vitara 1. Stator 2. Brush 3. Brush holder 4. Solder 5. Brush spring 1. Pulley nut 2. Rotor 3. Cloth 4. Vise 1. Rear housing 2. Wire charging system 6h-27 reassembly [60 a type] assemble in reverse order of disassembly, noting the following. 1) be sure to install brushes in the proper direc...
Page 721
Yh4 grand vitara 1. End housing bearing 2. Rotor 3. Bearing cover 3. Drive end bearing 4. Stator 1. Stud bolt 2. Retaining plate 1. Rotor 2. Drive end frame 1. Rear end frame 2. Drive end frame 1. Pulley 2. Hexagonal box wrench 3. Offset wrench 1, (a) 6h-28 charging system reassembly [70 a and 85 a ...
Page 722
Yh4 grand vitara 1. Rectifier upward approx. 1 mm 1. Ic regulator 2. Brush holder 3. Rear end frame 1. Rear end cover 2. Insulator 3. “b” terminal inner nut 4. Terminal plate (85 a type only) 1. Rectifier insulators charging system 6h-29 10) install 4 rubber insulators. 11) install rectifier. Cautio...
Page 723
Yh4 grand vitara 6h-30 charging system 17) make sure that rotor turns smoothly..
Page 724: Specifications
Yh4 grand vitara charging system 6h-31 specifications battery note: the battery used in each vehicle is one of the following four types, depending on specification. Battery type 38b20l 55b24l (s) 55d23l 75d23l rated capacity ah / 5hr, 12 volts 28 36 48 54 electrolyte l (us / imp. Pt) 2.8 (5.92 / 4.9...
Page 725: Section 6K
Yh4 grand vitara 6k exhaust system 6k-1 section 6k exhaust system caution: be sure to use unleaded fuel for the catalytic converter equipped vehicle. Use of leaded fuel will affect performance of the catalytic converter adversely to a great extent. Contents general description 6k-1 . . . . . . . . ....
Page 726
Yh4 grand vitara 1-1. Exhaust manifold (j20 engine without wu-twc) 1-2. Exhaust manifold (g16 engine without wu-twc) 1-3. Exhaust manifold (g16 engine with wu-twc) 1-4. Exhaust manifold (j20 engine with wu-twc) 1-5. Exhaust manifold (h25 engine) 1- 2. Gasket 3-1. Exhaust no.1 pipe (g16 / j20 engines...
Page 727: Maintenance
Yh4 grand vitara exhaust system 6k-3 maintenance warning: to avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the ex- haust system should be performed when the system is cool. At every interval of periodic maintenance service, and when vehicl...
Page 728: On-Vehicle Service
Yh4 grand vitara 6k-4 exhaust system on-vehicle service warning: to avoid the danger of being burned, do not touch the ex- haust system when the system is hot. Any service on the ex- haust system should be performed when the system is cool. Exhaust manifold refer to section 6a1, 6a2 or 6a4 for remov...
Page 729
Yh4 grand vol.2 prepared by overseas service department 1st ed. April, 2000 printed in japan printing: april, 2000 736.