Suzuki SQ416 2001 Manuals

Manuals and User Guides for Suzuki SQ416 2001. We have 1 Suzuki SQ416 2001 manual available for free PDF download: Owner's Manual

Suzuki SQ416 2001 Owner's Manual (656 pages)

Brand: Suzuki | Category: Automobile | Size: 15 MB

General Information

6
Maintenance and Lubrication

14
- Maintenance Schedule
  
  15
- Maintenance Service
  
  18
  - Engine and Emission Control
    18
    
    Drive Belt Inspection and Replacement
    18
    
    Engine Oil and Filter Replacement
    19
    
    Heater and Ventilation 1A
    24
Section 1B Air Conditioning (Optional)

26
- General Description
  
  28
- Diagnosis
  
  31
  - General
    31
    
    Main A/C System (Front A/C System)
    31
    
    Rear A/C System
    33
  - Quickly Checking of Refrigerant Charge (if Equipped with Sight Glass)
    34
  - Performance Diagnosis
    35
    
    Performance Diagnosis Table
    37
    
    Detail Diagnosis Table
    38
  - Wiring Circuit
    39
  - Inspection of A/C Controller and Its Circuits
    40
    
    Voltage Check
    40
- Refrigerant Recovery, Evacuation and Charging
  
  44
  - Operation Procedure for Charging A/C with Refrigerant
    44
  - Recovery
    45
  - Evacuating
    46
    
    Evacuating Procedure
    46
    
    Checking System for Pressure Leaks
    47
  - Charging
    47
- On-Vehicle Service
  
  50
  - Precaution
    50
    
    Piping
    50
    
    Handling Refrigerant HFC-134A
    51
    
    Refrigerant Charge
    51
    
    Refrigerant Recovery
    51
    
    Replenishing Compressor Oil
    52
  - Rear A/C Unit (Rear A/C Evaporator)
    53
  - Rear Expansion Valve
    54
  - Rear A/C Evaporator Temperature Controller
    55
  - Refrigerant Pipes and Hoses
    56
  - Solenoid Valve
    57
  - Rear Blower Motor Assembly
    58
    
    Rear A/C Main Switch
    59
    
    Rear Blower Motor Relay and Solenoid Valve Relay
    59
    
    Rear Blower Motor Resistor
    60
    
    Rear Blower Motor Switch
    61
    
    Rear A/C No.1 and No.2 Duct
    62
    
    Rear A/C No.1 Duct
    62
    
    Rear A/C No.2 Duct
    62
    
    Compressor Assembly
    63
    
    Magnet Clutch
    66
- Required Service Materials
  
  69
- Tightening Torque Specification
  
  69
- Special Tools
  
  69
  - Steering Column
    79
  - Front Suspension
    88
Section 3E Rear Suspension

90
- Rear Suspension
  90
- On-Vehicle Service
  94
  - Rear Axle Housing
    94
  - Rear Axle Shaft Inner Oil Seal
    94
  - Required Service Material
    95
  - Tightening Torque Specification
    95
  - Special Tool
    96
    
    Wheels and Tires
    98
    
    Oil Seal
    100
  - On-Vehicle Service
    101
    
    Drive Shaft
    101
    
    Propeller Shafts
    104
    
    Propeller Shaft
    105
Section 5A Brakes Pipe/Hose/Master Cylinder

108
- General Description
  
  109
  - Master Cylinder Assembly
    109
- On-Vehicle Service
  
  110
  - Front Brake Hose/Pipe
    110
  - Master Cylinder Reservoir
    113
  - Master Cylinder Assembly
    114
  - Brake Booster
    115
- Special Tool
  
  117
- Tightening Torque Specification
  
  117
Section 5C Parking and Rear Brake

118
- General Description
  
  119
  - Drum Brake Assembly
    119
- On-Vehicle Service
  
  120
  - Parking Brake Cable
    120
  - Brake Drum
    120
  - Wheel Cylinder
    122
  - Brake Back Plate
    122
- Tightening Torque Specification
  
  124
Section 5E2 Antilock Brake System (Abs)

126
- General Description
  
  128
  - Components/Parts Location
    128
  - ABS Hydraulic Unit/Control Module Assembly
    129
    
    Fail-Safe Function
    129
    
    Self-Diagnosis Function
    129
- Diagnosis
  
  130
- On-Vehicle Service
  
  154
- Tightening Torque Specification
  
  159
- Special Tool
  
  159
Section 6-1 Engine General Information and Diagnosis (H27 Engine)

162
Section 6A2 Engine Mechanical (H27 Engine)

288
- On-Vehicle Service
  
  289
  - Throttle Body and Intake Manifold
    289
  - Exhaust Manifold
    296
  - LH (No.1) Bank 2Nd Timing Chain and Chain Tensioner
    300
  - Camshaft and Valve Lash Adjuster
    301
  - Valves and Cylinder Heads
    304
- Unit Repair Overhaul
  
  313
  - Engine Assembly
    313
  - Main Bearings, Crankshaft and Cylinder Block
    317
- Special Tool
  
  323
  - Engine Cooling
    326
  - Engine Fuel
    328
  - Fuel System
    328
  - Fuel Tank
    329
  - Fuel Lines
    332
Section 6E2 Engine and Emission Control System (Sequential Multiport Fuel Injection for H27 Engine)

334
- System Flow
  336
- System Diagram
  337
- Air Intake System
  339
- Fuel Delivery System
  340
- Electronic Control System
  341
- Diagnosis
  
  345
  - Engine and Emission Control Input/Output Table
    345
- On-Vehicle Service
  
  346
  - General
    346
  - Accelerator Cable Adjustment
    347
  - A/T Throttle Cable Adjustment (A/T Vehicle)
    347
  - Idle Speed/Idle Air Control (IAC) Duty Inspection
    348
    
    [Using SUZUKI Scan Tool]
    348
    
    [Not Using SUZUKI Scan Tool] (Vehicle with Monitor Connector)
    349
    
    Idle Mixture Inspection/Adjustment
    350
  - Air Intake System
    351
    
    Throttle Body
    351
    
    Idle Air Control Valve (IAC Valve)
    354
    
    Fast Idle Air Valve
    355
  - Fuel Delivery System
    356
    
    Fuel Pressure Inspection
    356
    
    Fuel Pump
    357
    
    Fuel Pressure Regulator
    358
  - Fuel Injector
    359
  - Electronic Control System
    364
  - Engine Control Module (Ecm)/Powertrain Control Module (PCM)
    364
  - Mass Air Flow Sensor (MAF Sensor)
    365
  - Intake Air Temperature (IAT) Sensor
    367
  - Throttle Position Sensor (TP Sensor)
    368
  - Engine Coolant Temperature Sensor (ECT Sensor)
    369
  - Heated Oxygen Sensor (Sensor 1)
    370
  - Heated Oxygen Sensor (Sensor 2)
    371
  - Vehicle Speed Sensor (VSS)
    372
  - Manifold Absolute Pressure Sensor
    372
  - Fuel Level Sensor (Sender Gauge)
    374
  - Crankshaft Position Sensor
    374
    
    Main Relay
    374
    
    Fuel Pump Relay
    375
    
    Fuel Cut Operation
    376
    
    EGR System (if Equipped)
    377
    
    Emission Control System
    377
    
    EVAP Canister
    378
    
    Vacuum Passage
    379
    
    PCV System
    380
    
    PCV Hose
    381
    
    PCV System
    381
- Tightening Torque Specification
  
  381
- Special Tool
  
  381
Section 6F2 Ignition System (for H27 Engine)

384
- General Description
  
  385
  - Components
    385
  - System Wiring
    386
- Diagnosis
  
  387
  - Diagnostic Flow Table
    387
  - Ignition Spark Check
    389
  - Ignition Timing Check and Adjustment
    389
- On-Vehicle Service
  
  391
  - Ignition Coil Assembly (Igniter and Ignition Coil)
    391
  - Spark Plug
    391
  - CMP Sensor
    393
  - Noise Suppressor
    395
- Special Tool
  
  396
Section 6H Charging System

398
- Charging System
  398
- General Description
  
  399
  - Generator
    399
- Unit Repair Overhaul
  
  400
  - Generator Assembly
    400
  - Inspection
    400
- Specifications
  
  403
  - Battery
    403
  - Generator
    403
    
    Exhaust System
    404
    
    Manual Transmission
    408
Automatic Transmission (4 A/T)

410
- General Description
  
  412
  - Electronic Shift Control System
    413
  - Automatic Gear Shift Diagram
    414
- Diagnosis
  
  416
  - On-Board Diagnostic System (Vehicle Without Monitor Connector)
    416
  - On-Board Diagnostic System (Vehicle with Monitor Connector)
    417
  - Precaution in Diagnosing Trouble
    418
  - Automatic Transmission Diagnostic Flow Table
    419
  - Malfunction Indicator Lamp (MIL) Check
    422
  - O/D OFF" Lamp Check
    422
  - POWER" Lamp Check
    422
  - Diagnostic Trouble Code (DTC) Check
    422
  - Diagnostic Trouble Code Clearance
    422
  - Visual Inspection
    423
  - A/T Basic Check
    423
  - Trouble Diagnosis Table 1
    424
  - Trouble Diagnosis Table 2
    424
  - Trouble Diagnosis Table 3
    425
  - Scan Tool Data
    426
  - Inspection of PCM and Its Circuit
    426
  - Wire Harness and Connectors
    426
  - DTC P0715 (DTC NO.76) - Input/Turbine Speed Sensor Circuit Malfunction
    438
  - DTC P0720 (DTC NO.75) Output Speed Sensor Circuit Malfunction
    441
  - DTC P0743 (DTC NO.65/66) - TCC (Lock-Up) Solenoid Electrical
    443
  - DTC P0753 (DTC NO.61/62) Shift Solenoid-A (#1) Electrical DTC P0758 (DTC NO.63/64) Shift Solenoid-B (#2) Electrical
    445
  - Stall Test
    447
  - Line Pressure Test
    448
  - Road Test
    449
  - Manual Road Test
    450
  - Time Lag Test
    450
  - Engine Brake Test
    451
  - P" Range Test
    451
- On-Vehicle Service
  
  452
  - Maintenance Service
    452
    
    Fluid Level
    452
    
    Fluid Change
    453
  - A/T Throttle Cable
    454
    
    Solenoid Valves (Shift Solenoid Valves and TCC Solenoid Valve)
    454
    
    Manual Selector Assembly
    455
    
    Select Cable
    457
- Unit Repair
  
  458
  - Sub-Assembly Repair
    458
    
    Overdrive (Case Side)
    458
    
    Forward Clutch
    459
    
    Front Upper Valve Body
    463
  - Unit Assembly
    468
- Tightening Torque Specification
  
  469
- Special Tool
  
  470
Section 7E Differential (Front)

474
- General Description
  
  475
  - 4WD Control System
    475
    
    System Circuit
    475
- Diagnosis
  
  476
  - Differential Assembly Diagnosis Table
    476
  - 4WD Control System Diagnostic Flow Table 7E-3
    476
    
    Notes on System Circuit Inspection
    476
    
    Flow Table
    477
  - 4WD Control System Circuit Inspection
    478
    
    Voltage Check
    478
  - 4WD Control System Inspection
    479
- On-Vehicle Service
  
  480
- Tightening Torque Specification
  
  484
- Special Tool
  
  484
- Unit Repair
  
  484
Section 7F Differential (Rear)

486
- General Description
  
  487
- Diagnosis
  
  487
  - Diagnosis Table
    487
- On-Vehicle Service
  
  488
  - Precaution for Maintenance Service
    489
  - Differential Gear Oil Change
    489
  - Rear Differential Assembly
    490
    
    Dismounting
    490
    
    Remounting
    490
- Unit Repair
  
  491
  - Disassembling Unit
    491
  - Component Inspection
    494
  - Sub-Assembly Adjustment and Reassembly 7F-9
    494
    
    Differential Carrier
    495
    
    Differential Case
    495
    
    Differential Side Bearing
    497
    
    Drive Bevel Pinion
    498
  - Assembling Unit
    503
- Tightening Torque Specification
  
  506
- Required Service Material
  
  506
- Special Tool
  
  507
  - Combination Meter
    513
  - Oil Pressure Light
    516
  - Brake Warning Light
    516
Section 8D Windows, Mirrors, Security and Locks

518
- General Description
  
  519
  - Rear Wiper and Washer (if Equipped)
    519
- On-Vehicle Service
  
  520
Cruise Control System

522
- General Description
  
  523
  - Cautions in Servicing
    523
  - Symbols and Marks
    523
  - Abbreviations
    523
  - Wiring Color Symbols
    523
  - Joint Connector
    523
  - Fuse Box and Relay
    523
  - Power Supply Diagram
    523
  - Cruise Control System
    524
    
    Cruise Control System Circuit
    524
    
    Components and Functions
    525
    
    Cancel Conditions
    526
- Diagnosis
  
  526
- On-Vehicle Service
  
  540
  - Cruise Main Switch
    540
  - Coast/Set, Resume/Accel and Cancel Switches
    541
  - Vehicle Speed Sensor (VSS)
    541
  - Transmission Range Switch
    541
  - Clutch Pedal Position (CPP) Switch
    542
  - Stop Lamp Switch (with Pedal Position Switch)
    543
  - Cruise Control Actuator Assembly (with Control Module)
    544
  - Cruise Cable
    545
Section 9 Body Service

546
- Glass, Windows and Mirror
  
  547
  - Quarter Window
    547
- Body Structure
  
  548
  - Under Body Dimensions
    548
  - Body Dimensions
    549
- Seat
  
  553
  - Second Seat
    553
  - Third Seat (if Equipped)
    554
- Paint and Coatings
  
  555
  - Sealant Application Area
    555
  - Undercoating/Anti-Corrosion Compound Application Area
    562
- Exterior and Interior Trim
  
  564
  - Floor Carpet
    564
    
    Front Floor Carpet
    564
    
    Rear Floor Carpet (Without Third Seat Vehicle)
    565
  - Head Lining
    565
    
    Restraint System
    568
    
    Seat Belt
    570
    
    Front Seat Belt
    572
Section 10B Air Bag System

578

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Suzuki SQ416 2001 Manuals

Suzuki SQ416 2001 Owner's Manual (656 pages)

Table of Contents

General Information

Precautions

Identification Information

Warning, Caution and Information Labels

Maintenance and Lubrication

Maintenance Schedule

Maintenance Service

Section 1B Air Conditioning (Optional)

General Description

Diagnosis

Refrigerant Recovery, Evacuation and Charging

On-Vehicle Service

Required Service Materials

Tightening Torque Specification

Special Tools

Section 3E Rear Suspension

Section 5A Brakes Pipe/Hose/Master Cylinder

General Description

On-Vehicle Service

Special Tool

Tightening Torque Specification

Section 5C Parking and Rear Brake

General Description

On-Vehicle Service

Tightening Torque Specification

Section 5E2 Antilock Brake System (Abs)

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specification

Special Tool

Section 6-1 Engine General Information and Diagnosis (H27 Engine)

General Information

Engine Diagnosis

Special Tool

Section 6A2 Engine Mechanical (H27 Engine)

On-Vehicle Service

Unit Repair Overhaul

Special Tool

Section 6E2 Engine and Emission Control System (Sequential Multiport Fuel Injection for H27 Engine)

Diagnosis

On-Vehicle Service

Tightening Torque Specification

Special Tool

Section 6F2 Ignition System (for H27 Engine)

General Description

Diagnosis

On-Vehicle Service

Special Tool

Section 6H Charging System

General Description

Unit Repair Overhaul

Specifications

Automatic Transmission (4 A/T)

General Description

Diagnosis

On-Vehicle Service

Unit Repair

Tightening Torque Specification

Special Tool

Section 7E Differential (Front)

General Description

Diagnosis

On-Vehicle Service

Tightening Torque Specification

Special Tool

Unit Repair

Section 7F Differential (Rear)

General Description

Diagnosis

On-Vehicle Service

Unit Repair

Tightening Torque Specification

Required Service Material

Special Tool

Section 8D Windows, Mirrors, Security and Locks

General Description