Suzuki Grand Vitara Diesel SQ420VD SQ420WD RHW Engine Supplementary Service Manual – 2004 PDF Edition

Description

This Suzuki Grand Vitara diesel supplementary service manual is the workshop reference for the SQ420VD and SQ420WD models powered by the RHW diesel engine – the 2.0 TD Grand Vitara built for European and other diesel markets. Across 746 pages it documents the systems that differ from the petrol Grand Vitara: the common rail fuel system, the RHW engine management in both EOBD and non-EOBD specification, the 4-speed automatic transmission with transfer case, and the front and rear differentials, alongside the shared maintenance, brake, suspension, HVAC and body chapters. Suzuki Motor Corporation published it as the companion volume to the GRAND VITARA (SQ416/SQ420/SQ625) Service Manual, and the closing pages carry a 1st Edition, January 2004 printing date.

File Details

• Manual type: Supplementary Service Manual
• Brand: Suzuki
• Model: Grand Vitara SQ420VD / SQ420WD (RHW diesel engine)
• Language: English
• Page count: 746 pages
• File format: PDF
• Edition: 1st Edition, January 2004
• Companion manuals referenced in the foreword: GRAND VITARA (SQ416/SQ420/SQ625) Service Manual 99500-65D20-01E, Unit Repair Manual 99501-65D50-01E, Wiring Diagram Manual 99512-68D40-01

How This Supplement Is Organised

The foreword is explicit about scope: this volume describes the service information that differs on the RHW diesel model compared with the base Grand Vitara, so it should be consulted first when working on an SQ420VD or SQ420WD. Where a section, item or description is not found here, the base GRAND VITARA Service Manual applies. For gearbox, transfer and differential unit repair, and for wiring diagrams, the Unit Repair Manual and Wiring Diagram Manual listed above are the referenced companions. Reading the manual with that in mind keeps the coverage honest – what is inside these pages is fully indexed and detailed, and the cross-references point you to the right companion document for anything outside the diesel-specific scope.

Chapters Covered

• General Information (0A)
• Maintenance and Lubrication (0B)
• Heater and Ventilation (1A)
• Air Conditioning – Optional (1B)
• Steering, Suspension, Wheels and Tires (3A to 3F, including Power Steering 3B1 and Rear Suspension 3E)
• Drive Shaft and Propeller Shaft (4A2, 4B)
• Brake System (5, 5A, 5B, 5C, 5E)
• Engine General Information and Diagnosis – RHW Engine (6-1)
• Engine Mechanical – RHW Engine (6A3)
• Engine Cooling (6B)
• Engine Fuel (6C)
• Engine and Emission Control System – RHW Engine (6E3)
• Cranking System – 2.0 kW Reduction Type (6G)
• Charging System (6H)
• Exhaust System (6K)
• Manual Transmission – Type 3 (7A2)
• Automatic Transmission – 4 A/T (7B1)
• Clutch (7C1)
• Transfer (7D)
• Differential – Front (7E)
• Differential – Rear (7F)
• Electrical System and Wiring Diagram (8A to 8H, including Immobilizer Control System 8G)
• Body Service (9)
• Restraint System and Air Bag System (10, 10A, 10B)

Engine General Information and Diagnosis (RHW)

Section 6-1 is split into two parallel diagnostic books, Other Than EOBD Spec and EOBD Spec, because the two emission builds use different glow plug supply layouts – a metal plate on one, a wire harness on the other. Each part carries the engine diagnostic flow table, DTC tables with detecting conditions and driving cycles, fail-safe tables, pending DTC and freeze frame handling, ECM connector voltage and resistance checks, and individual flow charts for mass air flow, fuel rail pressure, injector, glow plug, EGR, turbo boost, crankshaft and camshaft position, immobilizer and communication circuits.

Engine Mechanical (RHW)

Compression and oil pressure checks, intercooler and turbocharger service, cylinder head cover, intake and exhaust manifolds, and a complete timing belt procedure with the tensioner set using the special gauge – first at 98 +/- 2, then rechecked and reset at 54 +/- 2 after two crankshaft revolutions. The cylinder head chapter covers valve protrusion measurement, gasket selection by measured piston protrusion grade A to D, and the staged bolt sequence of 20 N.m, 60 N.m, loosen one turn, repeat, then a final 220 degree turn. Oil pump, oil pan, pistons, connecting rods and main bearings are covered through to crankshaft and cylinder block measurement.

Engine Cooling, Fuel and Exhaust

6B covers the degassing tank, the thermostat opening at 83 degrees C and fully open at 95 degrees C, water pump, radiator, fan motors and fan relays. 6C covers water draining and air bleeding of the fuel filter, filter element and assembly replacement, fuel tank, fuel pump, fuel level gauge and the low-pressure fuel system. 6K covers the exhaust manifold, turbocharger outlet pipe, catalytic converter pipes and muffler with their torque values.

Engine and Emission Control System (RHW)

This is the core diesel chapter: system location and wiring diagrams, vacuum hose routing, throttle valve assembly, EGR throttle solenoid valve, vacuum pump, boost pressure regulator solenoid valve, glow plugs, low-pressure fuel supply testing, injector removal and installation with the two-stage union nut sequence, common rail service, injection pump, MAF, throttle position, fuel temperature and rail pressure sensors, ECT sensor, CMP and CKP sensors, radiator fan control, double relay, pre/post heating relay, EGR valve and cooler, and the swirl control solenoid valve. ECM registration of the injector type (A, B or C) and transmission type is described step by step, with the caution that incorrect registration causes engine noise or vibration.

Cranking and Charging

6G documents the 2.0 kW reduction-type starting motor – disassembly and reassembly, brush and commutator inspection with wear limits, and the pull-in, hold-in, plunger return and no-load performance tests. 6H covers the generator belt with its dynamic roller tensioner and the special tools used to release and reset it, generator removal, disassembly and reassembly, and torque values for the terminal nuts.

Transmission, Clutch and Transfer

7A2 gives the Type 3 five-speed manual transmission with gear oil specification API GL-4 in SAE 75W-85, 75W-90 or 80W-90 and a 2.3 litre capacity. 7B1 is the complete 4 A/T book: clutch and brake function tables, electronic shift control, DTCs for the range sensor, input and output speed sensors, TCC, shift and pressure control solenoids and engine torque signal, plus stall, time lag, line pressure and road tests, and full unit disassembly and reassembly with clutch pack clearances and flange selection. 7C1 covers clutch cover, disc and flywheel service.

Differentials

7E covers the front differential and its 4WD control system – 4WD switch, air pump assembly, actuator, free axle hub and axle lock clutch – including the 4WD diagnostic flow table and 4WD controller voltage checks. 7F takes the rear differential through disassembly, pinion bearing preload of 0.9 to 1.7 N.m, backlash of 0.13 to 0.18 mm, side bearing preload, shim selection by mounting-distance measurement, and tooth contact pattern diagnosis with the high and low contact remedies.

Steering, Suspension, Wheels and Tires

3B1 covers the vane-type power steering pump – exploded views, rotor and vane clearance limits, relief valve spring free length, and hydraulic pressure testing with relief pressure of 7650 to 8350 kPa. The suspension chapters cover front end alignment, struts, control arms, rear coil spring and shock absorber work, rear axle shaft and wheel bearing, and the tightening torques for every suspension fastener.

Brakes

Section 5 covers diagnosis, brake pipe, hose and master cylinder, front brake, parking and rear brake, and ABS (SUMITOMO). The LSPV fluid pressure test is documented with the specified front-to-rear pressure ratios, along with bleeding, brake pedal free height, brake light switch adjustment and the special tools used to connect the pressure gauges.

Heating, Ventilation and Air Conditioning

1A details the supplementary electric heater that switches on below 75 degrees C coolant temperature, the blower unit and motor, HVAC control module voltage tables, actuators and heater unit. 1B covers the R-134a system – component layout, general diagnosis tables, performance and compression diagnosis, DTCs, recovery, evacuation and charging, compressor, condenser, evaporator and expansion valve service.

Electrical System, Immobilizer, Body and Restraint

Section 8 covers the electrical system, wiring diagram, lighting, instrumentation, windows and locks, immobilizer control system and body electrical control module. The immobilizer chapter includes DTC 11 through 43, registration of up to four transponder codes, and the mandatory procedures after replacing the ECM or the immobilizer control module. Section 9 covers body service, and Section 10 covers seat belts and the air bag system with its service precautions.

General Information and Maintenance

0A covers how to use the manual, vehicle lifting points, electrical circuit inspection, abbreviations and metric fasteners. 0B carries the maintenance schedule for normal and severe driving conditions, the fluid and lubricant chart, and the service procedures for accessory and compressor belts, engine oil and filter, coolant, glow plugs, air cleaner, fuel filter, transmission and differential oils, and power steering.

What This Manual Lets You Do

With the RHW diesel Grand Vitara, the expensive mistakes are specific: a timing belt tensioned by feel instead of by the gauge, a high-pressure fuel union torqued in one pull instead of the two stages the manual specifies, a differential reassembled without checking pinion preload or tooth contact, an injector swapped without registering its type to the ECM. Every one of those procedures is written out here with the sequences, clearances and limits that Suzuki published for this engine and drivetrain. You get the full DTC flow tables for both emission specifications, so a fault code on an EOBD or non-EOBD vehicle can be chased to the circuit rather than guessed at.

Beyond the engine, the same depth applies to the 4-speed automatic with its valve body, clutch packs and solenoid diagnostics, to the transfer case and both differentials, to the power steering pump and hydraulic pressure testing, to the LSPV brake pressure checks, and to the immobilizer system with its key and ECU code registration procedures. Maintenance intervals and fluid specifications are gathered in one place so scheduled servicing is straightforward.

IMAGES PREVIEW

The file is a PDF that downloads instantly after payment – no shipping, no waiting for a disc. Read it on a laptop or tablet in the workshop, or print only the pages you need for the job in front of you. Whether you are a independent workshop taking on a diesel Grand Vitara for the first time or an owner handling your own servicing, this is the reference that keeps the torque wrench and the diagnostic tool pointed in the right direction.