Page 1 of 801
SUZUKI
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SQ 416-420-625
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M.Y 1998 - 2005
SERVICE MANUAL
VOLUME 1
- CHASSIS SECTIONS
- ELECTRICAL
- BODY SECTIONS
Page 3 of 801
YH4
GRAND
vol.1
0A
0B
1A
1B
3
3A
3B1
3C
3C1
3D
3E
3F
4A2
4B
5
6
7A5A
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
6-1ENGINE
General Information and
Diagnosis (G16 / J20)
General Information and
Diagnosis (H25)
Engine Mechanical (G16)
Engine Mechanical (H25)
Engine Mechanical (J20)
Engine Cooling
Engine Fuel
Engine and Emission Control
System (SFI for G16 / J20)
Engine and Emission Control
System (SFI for H25)
Ignition System (G16)
Ignition System (J20 / H25)
Cranking System
(Reduction Type)
Cranking System
(No-Reduction Type)
Charging System
Exhaust System
TRANSMISSION, CLUTCH
AND DIFFERENTIAL
Manual Transmission (Type 1)
Manual Transmission (Type 2)
Automatic Transmission
Clutch (Hydraulic Type)
Transfer
Differential (Front)
Differential (Rear)
BODY ELECTRICAL SYSTEM
Wiring Diagram
Lighting System
Instrumentation / Driver
Information
Windows, Mirrors, Security
and Lock
Immobilizer Control System
BODY SERVICE
RESTRAINT SYSTEM
Seat Belt
Air Bag System GENERAL INFORMATION
General Information
Maintenance and Lubrication
TABLE OF CONTENTS TABLE OF CONTENTS SECTIONSECTION
0B
HEATING AND AIR
CONDITIONING
Heater and Ventilation
Air Conditioning
STEERING, SUSPENSION,
WHEELS AND TIRES
Front End Alignment
Power Steering (P / S) System
Steering Wheel and Column
(Not Equipped with Air Bag)
Air Bag Steering Wheel
and Column
Front Suspension
Rear Suspension
Wheel and Tires
1A
3A 0A
1B
3B1
3C
3C1
3D
3E
3F36A16
6A2
6A4
6B
6C
6E1
6E2
6F1
DRIVE SHAFT / PROP. SHAFT
Front Drive Shaft / Shaft
Bearing, Oil Seal
Propeller Shaft
BRAKES
Brake Pipe / Hose / Master
Cylinder
Front Brakes
Parking and Rear Brakes
Antilock Brake System
4A2
4B
5
5A
5B
5C
5E1
6F2
6G
6G1
6H
6K
7A
7A1
7B1
7C1
7D
7E
7F
8
8A
8B
8C
8D
8G
9
10
10A
10B
6-1
NOTE:
The screen toned Sections 6 ± 6K are included in Volume 2 and Section 8A is in Wiring
Diagram Manual.
Page 80 of 801
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VITARA
AIR CONDITIONING (OPTIONAL) 1B-9
ABNORMAL NOISE FROM CRANKSHAFT PULLEY
ConditionPossible CauseCorrection
A large rattling noise is heard at
idle or sudden acceleration.Loosen pulley mounting bolt.
Worn or broken bearings.Retighten bolt.
Replace bearings.
ABNORMAL NOISE FROM TENSION PULLEY
ConditionPossible CauseCorrection
Clattering noise is heard from
pulley.
Pulley cranks upon contact.Worn or damaged bearings.
Cracked or loose bracket.Replace bearings.
Replace or retighten bracket.
ABNORMAL NOISE FROM EVAPORATOR
ConditionPossible CauseCorrection
Whistling sound is heard from
evaporator.Depending on the combination of
the interior / exterior
temperatures, engine rpm and
refrigerant pressure, the
refrigerant flowing out of the
expansion valve may, under
certain conditions, make a
whistling sound.At times, slightly decreasing
refrigerant volume may stop this
noise.
Inspect expansion valve and
replace if faulty.
ABNORMAL NOISE FROM BLOWER MOTOR
ConditionPossible CauseCorrection
Blower motor emits a chirping
sound in proportion to its speed of
rotation.
Fluttering noise or large droning
noise is heard from blower motor.Worn or damaged motor brushes
or commutator.
Leaves or other debris
introduced from fresh air inlet to
blower motor.Repair or replace blower motor.
Remove debris and make sure
that the screen at fresh air inlet is
intact.
Page 85 of 801
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1B-14 AIR CONDITIONING (OPTIONAL)
HIGH PRESSURE CAUGE LOW PRESSURE GAUGE THERMOMETER AT
CENTER DUCT
Insufficient
cooling of
condenser
PERFORMANCE DIAGNOSIS TABLE
TESTING RESULTSPOSSIBLE CAUSEREMEDY
Pressure high
(ªAº area of high side
graph)Refrigerant overcharged
Expansion valve frozen or clogged
Clogged refrigerant passage of high side
Condenser fan malfunction
Dirty or bent condenser fins
Compressor malfunction (Insufficient oil etc.)
Engine overheatRecharge
Check expansion valve
Clean or replace
Check condenser fan
Clean or repair
Check compressor
Check engine cooling
system
Pressure low
(ªBº area of high side
graph)Insufficient refrigerant (Insufficient charge or
leakage)
Expansion valve malfunction (Valve opens too
wide)
Compressor malfunction (Insufficient
compression)Check for leakage, repair if
necessary and recharge
Check expansion valve
Check compressor
Pressure high
(ªAº area of low side
graph)Expansion valve malfunction (Valve opens too
wide)
Compressor malfunction (Insufficient
compression)Check expansion valve
Check compressor
Pressure low
(ªBº area of low side
graph)Insufficient refrigerant (Insufficient charge or
leakage)
Expansion valve malfunction (Valve opens too
narrow)
Clogged refrigerant passage (Crashed pipe)Check for leakage, repair if
necessary and recharge
Check expansion valve
Repair or replace
Outlet air temperature
at center duct is high
(Crossing point is in
area ªAº)Insufficient or excessive charge of refrigerant
Dirty or bent evaporator fins
Air leakage from cooling (heater) unit or air
duct
Malfunctioning, switchover function of damper
in cooling (heater) unit
Compressor malfunctionCheck refrigerant
pressure
Clean or repair
Repair or replace
Repair or replace
Check compressor
Outlet air temperature
at center duct is low
(Crossing point is in
area ªBº)Insufficient air volume from center duct
(Heater blower malfunction)
Compressor malfunctionCheck blower motor and
fan
Check compressor
NOTE:
If ambient temperature is within 30 ± 35C (85 ± 95F), it is possible to do using next page table for more
detail diagnosis.
Page 265 of 801
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1. Boot
2. Boot band
1. Circlip1. Cage Wheel side
ªAº Fill grease 85g (3.0 oz)
4A2-6 FRONT DRIVE SHAFT / SHAFT BEARING, OIL SEAL
ASSEMBLY
CAUTION:
To prevent any problem caused by washing solution, do
not wash joint boots. Degreasing of those parts with cloth
is allowed.
For M / T vehicle with H25 engine
To ensure full performance of joint as designed, be sure
to distinguish between two types of grease in repair set
and apply specified volume to respective joint. i.e. yellow
grease to wheel side joint and black one to differential
side.
Bend each boot band against forward rotation.
Do not squeeze or distort boot when fastening it with
bands.
Distorted boot caused by squeezing air may reduce its du-
rability.
1) Fully apply joint grease to wheel side joint.
Use joint grease in the tube included in spare part.
2) Fit wheel side boot on shaft.
Fill up inside of boot with joint grease of about 90 gram.
Before fixing boot band, insert screwdriver into boot on joint side
and allow air to enter boot so that air pressure in boot becomes
the same as atmospheric pressure.
3) Fixing boot band.
4) Install boot onto drive shaft till its small diameter side fits to shaft
groove and fix there with boot band.
5) Install cage to shaft.
CAUTION:
Install cage directing smaller outside diameter side to
shaft end.
6) Install circlip by using snap ring plier.
