2002-2008 Suzuki Grand Vitara (SQ420WD) OEM Service & Repair Manual

WARNING: For vehicles equipped with a Supplemental Restraint (Air Bag) System: D 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 service on or near the air bag system components 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. D 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 system activation. D Do not modify the steering wheel, instru- ment panel or any other air bag system component (on or around air bag system components or wiring). Modifications can adverse- ly affect air bag system performance and lead to injury. D 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) module, sensing and diagnostic module (SDM), seat belt pretensioner (if equipped) before- hand to avoid component damage or unintended 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 special meanings. Pay special attention to the messages highlighted by these signal words. NOTE: Indicates special information to make maintenance 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 mechanics only. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the me- chanic and may render the vehicle unsafe for the driver and passengers.

( x ) ( x ) FOREWORD This manual is a supplement to SQ416/SQ420/SQ625 SERVICE MANUAL. It has been pre- pared exclusively for the following applicable model. Applicable model: SQ420WD (GRAND VITARA RHZ Diesel engine model) on and after the following VIN No. JSAFTD82V00100001 X It described only different servicing information of SQ420WD RHZ engine model as compared with SQ416/SQ420/ SQ625. Therefore, whenever servicing SQ420WD, consult this service manual first. And for any section, item or description not found in this service manual, refer to the related manuals below. When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials (lubricant, sealants, etc.) as specified in each description. All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice. RELATED MANUALS: Manual Name Manual No. SQ416/SQ420/SQ625 Service Manual (Volume 1 and 2) 99500-65D10-XXX GRAND VITARA SUPPLEMENTARY SERVICE MANUAL 99501-65D30-XXX SQ416/SQ420/SQ625 Unit Repair Manual (For Manual Transmission, Automatic Transmission, Transfer and Differential.) 99501-65D01-XXX SQ416/SQ420/SQ625 Wiring Diagram Manual 99512-65D11-015 SQ420WD Supplementary Wiring Diagram Manual 99512-68D10-015  COPYRIGHT SUZUKI MOTOR CORPORATION 2002

0A 0B 1A 3B1 3E 4A2 4B 6 6A3 6B 6C 6E3 6G 6H 6K 7A2 7B1 7C1 7E 7F 8C 8G 1B 6-1 ENGINE Engine General Information and Diagnosis (RHZ Engine With Single-connector ECM) Engine General Information and Diagnosis (RHZ Engine With Triple-connector ECM) Engine Mechanical (RHZ engine) Engine Cooling Engine Fuel Engine and Emission Control System (RHZ engine) Cranking System (2.0 kw Reduction Type) Charging System Exhaust System HEATING AND AIR CONDITIONING Heater and Ventilation Air Conditioning BODY ELECTRICAL SYSTEM Instrumentation/Driver Information Immobilizer Control System TABLE OF CONTENTS SECTION GENERAL INFORMATION General Information Maintenance and Lubrication STEERING, SUSPENSION, WHEELS AND TIRES Power Steering (P / S) System Rear Suspension DRIVE SHAFT / PROPELLER SHAFT Front Drive Shaft / Shaft Bearing, Oil Seal Propeller Shafts 0A 0B 1B 3B1 4A2 6 6A3 6B 6C 6E3 6G 6H 6K 7A2 7C1 7F 8C 8G TRANSMISSION, CLUTCH AND DIFFERENTIAL Manual Transmission Automatic Transmission Clutch (Hydraulic Type) Differential (Front) Differential (Rear) 3E 4B 7B1 7E 1A 6-1

0A GENERAL INFORMATION 0A-1 SECTION 0A GENERAL INFORMATION NOTE: For the descriptions (items) not found in this section, refer to the same section of the Service Manual men- tioned in FOREWORD of this manual. CONTENTS PRECAUTIONS 0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Precautions 0A- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IDENTIFICATION INFORMATION 0A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Number 0A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Identification Number 0A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Identification Number 0A- 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING, CAUTION AND INFORMATION LABELS 0A- 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FASTENER INFORMATION 0A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metric Fasteners 0A- 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0A-2 GENERAL INFORMATION PRECAUTIONS GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply. WARNING: D Whenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING POINTS” on SECTION 0A. D When it is necessary to do service work with the engine running, make sure that the parking brake is set fully and the transmission is in Neutral (for manual transmission vehicles) or Park (for automatic transmission vehicles). Keep hands, hair, clothing, tools, etc. away from the fan, belts and fuel line between high pressure fuel pump and injectors when the engine is running. D When it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors. D Do not perform service work in areas where combustible materials can come in contact with a hot exhaust system. When working with toxic or flammable materials (such as gasoline and refrigerant), make sure that the area you work in is well-ventilated. D To avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold, tail- pipe, muffler, etc. D New and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact with used engine oil has been found to cause [skin] cancer in laboratory animals. Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a long-sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing engine oil. If engine oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil, recycle or properly dispose of used oil and filters. D Make sure the bonnet is fully closed and latched before driving. If it is not, it can fly up unexpectedly during driving, obstructing your view and resulting in an accident. CAUTION: D Before starting any service work, cover fenders, seats and any other parts that are likely to get scratched or stained during servicing. Also, be aware that what you wear (e.g, but- tons) may cause damage to the vehicle’s finish. D When performing service to electrical parts that does not re- quire use of battery power, disconnect the negative cable of the battery.

GENERAL INFORMATION 0A-3 “A” D When removing the battery, be sure to disconnect the negative cable first and then the positive cable. When reconnect- ing the battery, connect the positive cable first and then the negative cable, and replace the terminal cover. D When removing parts that are to be reused, be sure to keep them arranged in an orderly manner so that they may be rein- stalled in the proper order and position. D Whenever you use oil seals, gaskets, packing, O-rings, locking washers, split pins, self-locking nuts, and certain other parts as specified, be sure to use new ones. Also, before installing new gaskets, packing, etc., be sure to remove any residual material from the mating surfaces. D Make sure that all parts used in reassembly are perfectly clean. D When use of a certain type of lubricant, bond or sealant is specified, be sure to use the specified type. “A”: Sealant 99000-31150 D Be sure to use special tools when instructed. Special Tool (A): 09917-98221 (B): 09916-58210

0A-4 GENERAL INFORMATION D When disconnecting vacuum hoses, attach a tag describing the correct installation positions so that the hoses can be re- installed correctly. D After servicing fuel, oil, coolant, vacuum, exhaust or brake systems, check all lines related to the system for leaks. D For vehicles equipped with fuel injection systems, never disconnect the fuel line between the fuel pump and injector within 30 sec. after engine stop, or fuel can be sprayed out under pressure.

4-speed A / T M/T GENERAL INFORMATION 0A-5 IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The number is punched on the chassis inside the tire housing on the right front side. ENGINE IDENTIFICATION NUMBER The number is punched on the cylinder block. TRANSMISSION IDENTIFICATION NUMBER The number is located on the transmission case.

NOTE: Air bag CAUTION / WARNING labels are attached on the vehicle equipped with air bag system only. 1. Air bag label 2. Smoke level label 3. Air bag label on sun visor 4. Radiator cooling fan label 5. Degassing tank cap (radiator cap) label 6. Transfer label 7. Air bag label on wire harness 8. Air bag label on passenger air bag (inflator) module 9. Seat belt pretensioner label on retractor 10. Air bag label on SDM 11. Air bag label on driver air bag (inflator) module 12. Air bag label on combination switch and contact coil assembly 13. Air bag label on steering column 0A-6 GENERAL INFORMATION WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handling parts, refer to WARNING/CAUTION instructions printed on labels. If any WARNING/CAUTION label is found stained or damaged, clean or replace it as necessary.

1. Diameter 2. Pitch GENERAL INFORMATION 0A-7 FASTENER INFORMATION METRIC FASTENERS Most of the fasteners used for this vehicle are metric fasteners. When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch and strength. CAUTION: Note that both ISO and JIS type bolts and nuts are used for the engine assembly and related parts. Even when the diameter of the thread is the same, its pitch may vary between these two types. Installing a mismatched bolt or nut will cause damage to the thread. As the first step, make sure to tighten it by hand temporarily and if it feels tight, check the thread pitch for correct matching.

2002-2008 Suzuki Grand Vitara (SQ420WD) OEM Service & Repair Manual

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