engine h25 SUZUKI GRAND VITARA 2001 2.G Service Workshop Manual

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.

YH4
GRAND
VITARA
G16 engine
J20 engine
H25 engine
M / T (Type1)
4-speed A / T M / T (Type2)
GENERAL INFORMATION 0A-17
IDENTIFICATION INFORMATION
BODY NUMBER
The vehicle body number is on the left side of instrument panel and
punched on the chassis inside the tire housing on the right front side.
It is possible to identify the country of origin (the production plant)
of the vehicle by the first three digits of the body number as shown
below.
JSAxxx Japan (Iwata) produced. . . . . . . . . . .
2S2xxx Canada (CAMI) produced. . . . . . . . . . .
ENGINE IDENTIFICATION NUMBER
The number is punched on the cylinder block.
TRANSMISSION IDENTIFICATION NUMBER
The number is located on the transmission case.

YH4
GRAND
VITARA
0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULE UNDER NORMAL DRIVING CONDITIONS
Interval:
This interval should be judged by
This table includes services as scheduled up to 90,000 km
(54,000 miles) mileage. Beyond 90,000 km (54,000 miles), carry
out the same services at the same intervals respectively.
This interval should be judged by
odometer reading or months,Km (x 1,000)153045607590g
whichever comes first.Miles (x 1,000)91827364554
Months122436486072
ENGINE
1-1. Drive beltV-beltIRIRIR
V-rib belt (Flat type)±±I±±R
1-2. Camshaft timing belt (G16 engine only)Replace every 100,000 km or
60,000 miles
1-3. Valve lash (clearance)G16 engine only±I±I±I
1-4. Engine oil and
oil filterJ20 / H25 engines
G16 engine with HO2S (SG, SH, SJ)RRRRRR
G16 engine with HO2S (SE, SF),
G16 engine without HO2SReplace every 10,000 km (6,000 miles)
or 8 months
1-5. Engine coolant±±R±±R
1-6. Exhaust system±I±I±I
IGNITION SYSTEM
2-1. Spark plugs
Wh
Vehicle without
HO2S
Nickel plug±R±R±R
When
unleaded
HO2SIridium plug±±±R±±unleaded
fuel isVehicle with
HO2S
Nickel plug±±R±±Rfuel is
usedHO2SIridium plugReplace every 105,000 km or 63,000
miles
When leaded fuel is used, refer to ªSevere Driving Conditionº schedule
FUEL SYSTEM
3-1. Air cleaner filterIIRIIR
3-2. Fuel lines and connections±I±I±I
3-3. Fuel filterReplace every 105,000 km or 63,000
miles
3-4. Fuel tank±±I±±I
EMISSION CONTROL SYSTEM
4-1. Crankcase ventilation hoses and connections
(Vehicle without HO2S)±±I±±I
4-2. PCV valveVehicle without HO2S±±I±±I
Vehicle with HO2S±±±±±I
4-3. Fuel evaporative emission
tl t
Vehicle without HO2S±I±I±I
control systemVehicle with HO2S±±±±±I
NOTES:

ªRº : Replace or change

ªIº : Inspect and correct, replace or lubricate if necessary

For Item 1-2. Camshaft timing belt: This belt may be replaced every 90,000 km (54,000 miles) according
to customer's maintenance convenience.

For Sweden, item 2-1, 4-2 and 4-3 should be performed by odometer reading only.

For Item 2-1. Spark plugs, replace every 50,000 km if the local law requires.

Nickel spark plug: BKR6E-11 or K20PR-U11

Iridium spark plug: IFR6E11 or SK20PR-A11 for G16 engine, IFR5J11 or SK16PR11 for J20 / H25 engines

YH4
GRAND
VITARA
1. Crankshaft pulley
2. Water pump pulley
3. 100 N, 10 kg or 22 lb
G16
H25
MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SERVICE
ENGINE
ITEM 1-1
Drive Belt Inspection and Replacement
WARNING:
All inspection and replacement are to be performed with
ENGINE NOT RUNNING.
Water pump and generator drive belt (G16 and H25 engines)
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any defect exists, replace.
Check belt for tension.
Water pump and generator belt tension
ªaº: 6 ± 8 mm (0.24 ± 0.32 in.) deflection for G16, 9 ± 11 mm
(0.35 ± 0.43 in.) deflection for H25 under 100 N, 10 kg or
22 lb pressure
NOTE:
When replacing belt with a new one, adjust belt tension to
5 ± 6 mm (0.20 ± 0.24 in.) for G16, 7 ± 9 mm (0.28 ± 0.35 in.)
for H25.
3) If belt is too tight or too loose, adjust it to specification by adjust-
ing alternator position.
4) Tighten alternator adjusting bolt and pivot bolts.
5) Connect negative cable to battery.
Replacement
Replace belt. Refer to Section 6B for replacement procedure of
pump belt.

YH4
GRAND
VITARA
G16 with P / S
G16 with P / S and A / C
H25 with P / S
H25 with P / S and A / C
1. Crankshaft pulley
2. P / S pump pulley
3. A / C compressor pulley
(if equipped)4. Tension pulley
5. Tension pulley bolts
MAINTENANCE AND LUBRICATION 0B-7
Power steering pump and / or A / C compressor drive belts (if
equipped) for G16 and H25 engines.
Inspection
1) Disconnect negative cable at battery.
2) Inspect belt for cracks, cuts, deformation, wear and cleanliness.
If any defect exists, replace.
Check belt for tension.
Power steering pump and / or A / C compressor drive belt
tension.
ªaº: 6 ± 9 mm (0.24 ± 0.35 in.) deflection under 100 N, 10 kg
or 22 lb pressure.
ªbº: 4 ± 7 mm (0.16 ± 0.28 in.) deflection under 100 N, 10 kg
or 22 lb pressure.
If belt tension is out of above specification, adjust it referring to
Section 1B or 3B1.
3) Connect negative cable to battery.
Replacement
Replace belt referring to Section 1B or 3B1 for replacement proce-
dure of belt.

YH4
GRAND
VITARA
2
1. Oil filter
2. Oil filter wrench
MAINTENANCE AND LUBRICATION 0B-9
3) Loosen oil filter by using oil filter wrench (special tool).
Special Tool
(A): 09915-47310 (H25 engine)
09915-47330 (G16 and J20 engines)
NOTE:
Before fitting new oil filter, be sure to oil its O-ring. Use engine
oil for this purpose.
4) Screw new filter on oil filter stand by hand until the filter O-ring
contacts the mounting surface.
CAUTION:
To tighten oil filter properly, it is important to accurately
identify the position at which at filter O-ring first contacts
the mounting surface.
5) Tighten the filter 3 / 4 turn from the point of contact with the
mounting surface using an oil filter wrench.
Tightening Torque (Reference)
(b): 14 N
.m (1.4 kg-m, 10.5 lb-ft)
6) Replenish oil until oil level is brought to FULL level mark on dip-
stick. (oil pan and oil filter capacity). The filler inlet is at the top
of the cylinder head cover.
It is recommended to use engine oil of SG, SH or SJ grade.
NOTE:
For temperature between ±20
C (±4
F) and 30
C (86
F), it
is highly recommended to use SAE 10W ± 30 oil.
G16 EngineJ20 EngineH25 Engine
Oil pan capacityAbout 4.0 liters
(10.6 / 8.8 US / Imp pt.)About 5.0 liters
(10.6 / 8.8 US / Imp pt.)

Oil filter capacityAbout 0.2 liters
(0.4 / 0.3 US / Imp pt.)
About 0.5 liters
(1.1 / 0.9 US / Imp pt.)
OthersAbout 0.3 liters
(0.6 / 0.5 US / Imp pt.)About 0.4 liters
(1.1 / 0.9 US / Imp pt.)About 0.7 liters
(1.5 / 1.2 US / Imp pt.)
TotalAbout 4.5 liters
(9.5 / 7.9 US / Imp pt.)About 5.6 liters
(11.8 / 9.8 US / Imp pt.)About 6.2 liters
(13.1 / 10.9 US / Imp pt.)

YH4
GRAND
VITARA
Fig. A
Fig. B
Fig. C
C51-3-6 For G16
and J20 engines
C51-3-25 For
H25 engine
1B-18 AIR CONDITIONING (OPTIONAL)
INSPECTION OF A / C CONTROLLER AND ITS
CIRCUITS
CAUTION:
A / C controller and ECM cannot be checked by itself.
It is strictly prohibited to connect voltmeter or ohmmeter to
A / C controller and ECM with couplers disconnected from it.
A / C controller (1) and its circuits can be checked at A / C controller
wiring couplers by measuring voltage.
Voltage Check
1) Remove A / C controller (1) from vehicle (refer to ªA / C CON-
TROLLER REMOVALº in this section).
2) Remove ECM (2) from vehicle.
3) Connect A / C controller couplers to A / C controller and connect
ECM couplers to ECM.
4) Check each terminal voltage with couplers connected by refer-
ing to the A / C CONTROLLER VOLTAGE VALUES TABLE the
later.

YH4
GRAND
VITARA
SYSTEM CIRCUIT
A. To heater fuse
B. To rear defogger fuse
C. To ignition / meter fuse
D. To A / C fuse
E. Only LH vehicle1. Blower motor relay
2. Blower motor
3. Blower motor switch
4. A / C switch
5. Deflloster position switch
6. Deflloster / foot position switch7. Dual pressure (refrigerant
pressure) switch
8. A / C thermistor (evaporator
temperature sensor)
9. Compressor relay
10. Compressor11. Condenser fan motor relay
12. Condenser fan motor
13. A / C controller
14. ECM
15. Compressor thermal switch
(only IWATA production vehicle)
TERMINAL ARRANGEMENT OF A / C CONTROLLER
TERMINAL ARRANGEMENT OF ECM FOR G16, J20 ENGINE
TERMINAL ARRANGEMENT OF ECM FOR H25 ENGINE
H25 engine
E61-27
G16, J20
engines
E61-8
H25 engine
E61-28
G16, J20
engines
E61-17
1919
19H25 engine
E61-5
G16, J20
engines
E61-22
AIR CONDITIONING (OPTIONAL) 1B-19

YH4
GRAND
VITARA
AIR CONDITIONING (OPTIONAL) 1B-21
TerminalWireCircuitMeasurement
groundNormal valueCondition
AC2-1L/YSensor groundGround to body
(Fig. A)± 0.4 ± 0 voltEngine running
1.5 volts
(3150
)Evaporator thermistor temperature at
approx. 15C (59F) with engine
running
AC2-2W/B
Evaporator
thermistor
temperature
(evaporator temp.
sensor) input
Ground to engine
(Fig. B)
2.62 volts
(6.311
)
Evaporator thermistor temperature at
approx. 1C (34F) with engine
running
* If the temperature is less than
approx. 1C, in this case
compressor and condenser fan
should be stop (come back at more
than approx. 2.5C (less than
5840
, 2.5 V))
H25
engine
E61-27 /
G16 J20Gr/W
Signal output to
A / C controller
(A / C ON
Ground to engine
(Fig C)
10 ± 14 volts
Required A / C ON (terminal AC-A13)
at engine running with normal
condition (refer to ªINSPECTION OF
ECM AND ITS CIRCUITº in Section
6E)
G16, J20
engines
E61-8
(
permission
signal)(Fig. C)
0 ± 1 volt
Except the above-mentioned with
engine running
In this case compressor should be
stop
H25
engine
E61-28 /
Y/B
Signal input from
A / C controller
Ground to engine
0 ± 1.5 voltsRequire A / C ON
G16, J20
engines
E61-17Y/B(A / C ON request
signal)
g
(Fig. C)
10 ± 14 voltsTurn off the A / C
H25
engine
E61-5 /
G16, J20
engines
E61-22
Y/L
A / C condenser
cooling fan relay
outputGround to engine
(Fig. C)0 ± 1 volt

Blower fan motor switch and A / C or
defroster position switch (see
NOTE) ON with engine running at
evaporator thermistor temperature
input more than approx. 2.5C (less
than 2.5 V (5840
)), refrigerant
pressure switch ON and signal
input from ECM ON

Engine coolant temperature sensor
more than 113C (236F) with
engine running
10 ± 14 voltsExcept the above-mentioned with
engine running
NOTE:
Defroster position switch circuit is equipped with LH vehicle only.

YH4
GRAND
VITARA
J20 engine
H25 engine G16 engine
1. Generator belt
2. Compressor drive belt3. Compressor pulley
4. Crankshaft pulley
1B-22 AIR CONDITIONING (OPTIONAL)
DRIVE BELT
INSPECTION
For G16 and H25 engines
Refer to Section 3B1 for details.
For J20 engine
Refer to Section 6H for details.