Suzuki Grand Vitara JB416 / JB420 / JB419. Service manual - part 198

1H-12 Ignition System: For Petrol Engine Model

Specifications

Tightening Torque Specifications

S6JB0A1807001

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fastener Information in Section 0A”.

Special Tools and Equipment

Special Tool

S6JB0A1808001

Fastening part

Tightening torque

Note

N

⋅m

kgf-m

lb-ft

Spark plug

25

2.5 

18.0

)

Ignition coil bolt for M16 engine

10

1.0 

7.5

)

Ignition coil bolt for J20 engine

6.5

0.65 

5.0

)

09930–76420

SUZUKI scan tool

Timing-light (dry cell type)

—

)

This kit includes following 
items. 1. Tech 2, 2. PCMCIA 
card, 3. DLC cable, 4. SAE 
16/19 adapter, 5. Cigarette 
cable, 6. DLC loop back 
adapter, 7. Battery power 
cable, 8. RS232 cable, 9. 
RS232 adapter, 10. RS232 
loop back connector, 11. 
Storage case, 12. )

Starting System: For Petrol Engine Model 1I-1

Engine

Starting System

For Petrol Engine Model

Precautions

Cranking System Note

S6JB0A1910001

NOTE
Starting motor varies depending on specifications, etc.
Therefore, be sure to check model and specification of the vehicle being serviced before replacing 
parts.

 

General Description

Cranking Circuit Introduction

S6JB0A1911001

The cranking circuit consists of the battery, starting motor, ignition switch, and related electrical wiring. These 
components are connected electrically.

Starting Motor Circuit Description

S6JB0A1911002

• The magnetic switch coils are magnetized when the ignition switch is closed.
• The resulting plunger and pinion drive lever movement causes the pinion to engage the engine flywheel gear and 

the magnetic switch main contacts to close, and cranking takes place.

• When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the switch 

is opened, at which time the return spring causes the pinion to disengage.

I5JB0A190004-01

1. Pinion drive lever

6. Magnetic switch contacts

11. Ignition & Starter switch

2. Pinion & Over-running clutch

7. Pull-in coil

12. Battery

3. Magnetic switch

8. Starting motor

13. To ECM

4. Hold-in coil

9. Starting motor control relay

5. Plunger

10. A/T: Transmission range switch (shift lever switch)

1I-2 Starting System: For Petrol Engine Model

Diagnostic Information and Procedures

Cranking System Symptom Diagnosis

S6JB0A1914001

Possible symptoms due to starting system trouble would be as follows:
• Starting motor does not run (or runs slowly)
• Starting motor runs but fails to crank engine
• Abnormal noise is heard
Proper diagnosis must be made to determine exactly where the cause of each trouble lies in battery, wiring harness, 
(including starting motor switch), starting motor or engine.
Do not remove motor just because starting motor does not run. Check the following items and narrow down scope of 
possible causes.

1) Condition of trouble
2) Tightness of battery terminals (including ground cable connection on engine side) and starting motor terminals
3) Discharge of battery
4) Mounting of starting motor

Condition

Possible cause

Correction / Reference Item

Motor not running – No 
operating sound of 
magnetic switch

Transmission range sensor is not in P or 
N, or not adjusted (A/T)

Shift in P or N, or adjust sensor.

Malfunction of clutch pedal position 
switch (M/T)

Adjust or replace.

Battery run down

Recharge battery.

Battery voltage too low due to battery 
deterioration

Replace battery.

Poor contact in battery terminal 
connection

Retighten or replace.

Loose grounding cable connection

Retighten.

Fuse set loose or blown off

Tighten or replace.

Poor contacting action of ignition switch 
and magnetic switch

Replace.

Lead wire coupler loose in place

Retighten.

Open-circuit between ignition switch and 
magnetic switch

Repair.

Open-circuit in pull-in coil

Replace magnetic switch.

Brushes are seating poorly or worn 
down

Repair or replace.

Poor sliding or plunger and/or pinion

Repair.

Faulty starting motor control relay

“Control Relay Inspection: For Petrol Engine 
Model in Section 1C”.

Faulty ECM and its circuit

“Inspection of ECM and Its Circuits: For Petrol 
Engine Model in Section 1A”.

Motor not running – 
Operating sound of 
magnetic switch heard

Battery run down

Recharge battery.

Battery voltage too low due to battery 
deterioration

Replace battery.

Loose battery cable connections

Retighten.

Burnt main contact point, or poor 
contacting action of magnetic switch

Replace magnetic switch.

Brushes are seating poorly or worn 
down

Repair or replace.

Weakened brush spring

Replace.

Burnt commutator

Replace armature.

Layer short-circuit of armature

Replace.

Crankshaft rotation obstructed

Repair.

Starting System: For Petrol Engine Model 1I-3

Starting Motor Performance Test

S6JB0A1914002

CAUTION

!

 

Each test must be performed within 3 – 5 seconds to avoid coil from burning.

 

Pull-In Test

1) Connect battery to magnetic switch as shown.
2) Check that plunger and pinion move outward. If plunger and pinion don’t move, replace magnetic switch.

NOTE
Before testing, disconnect lead wire from terminal “M”.

 

Starting motor running, 
but too slow (small 
torque) – Battery and 
wiring are satisfactory

Insufficient contact of magnetic switch 
main contacts

Replace magnetic switch.

Layer short-circuit of armature

Replace.

Disconnected, burnt or worn 
commutator

Repair commutator or replace armature.

Worn brushes

Replace brush.

Weakened brush springs

Replace spring.

Burnt or abnormally worn end bush

Replace bush.

Starting motor running, 
but not cranking engine

Worn pinion tip

Replace over-running clutch.

Poor sliding of over-running clutch

Repair.

Over-running clutch slipping

Replace over-running clutch.

Worn teeth of ring gear

Replace flywheel (M/T) or drive plate (A/T).

Noise

Abnormally worn bush

Replace bush.

Worn pinion or worn teeth of ring gear

Replace over-running clutch, flywheel (M/T) or 
drive plate (A/T).

Poor sliding of pinion (failure in return 
movement)

Repair or replace.

Worn internal or planetary gear teeth

Replace.

Lack of oil in each part

Lubricate.

Starting motor does not 
stop running

Fused contact points of magnetic switch Replace magnetic switch.
Short-circuit between turns of magnetic 
switch coil (layer short-circuit)

Replace magnetic switch.

Failure of returning action in ignition 
switch

Replace.

Condition

Possible cause

Correction / Reference Item

1. Terminal “S”

2. Terminal “M”

3. Lead wire (switch to motor)

IYSQ01190003-01