o2 sensor SUZUKI GRAND VITARA 1999 2.G Owners Manual

6F2-10 IGNITION SYSTEM (FOR H27 ENGINE)
CMP Sensor
REMOVAL
1) Disconnect CMP sensor coupler (2).
2) Remove A/T fluid level gauge and filler tube.
3) Remove CMP sensor (1) by removing bolt (3).
INSTALLATION
1) Install a new O-ring (2) with engine oil applied to CMP sen-
sor (1). CAUTION:
Disassembly is prohibited. If anything faulty is found,
replace as an assembly unit.
2
3
1
NOTE:
After installing CMP sensor, adjust ignition timing. (Refer
to “IGNITION TIMING CHECK AND ADJUSTMENT” in this
section).

IGNITION SYSTEM (FOR H27 ENGINE) 6F2-11
2) Install CMP sensor to camshaft.
Fit the dog of CMP sensor coupling into the slots of cam-
shaft, when installing. The dogs of CMP sensor coupling are
offset. Therefore, if the dogs can not be fitted into the slots,
turn the CMP sensor shaft by 180 degree and try again.
3) Tighten CMP sensor bolt (3).
Tightening torque
CMP sensor bolt (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft)
4) Connect CMP sensor coupler (2) to CMP sensor (1).
5) Install A/T fluid level gauge and filler tube.
Tightening torque
A/T filler tube bolt (a) : 85 N·m (8.5 kg-m, 61.5 lb-ft)
1. CMP sensor
2. CMP sensor coupling
3. Camshaft
A : Slot offset
12
2
3, (a)
1
(a)

6K-2 EXHAUST SYSTEM
On-Vehicle Service
Components
TYPE WITH WELD BOLT AT MUFFLER FRONT FLANGE
1-1 Exhaust manifold (without WU-TWC) 4. Heated oxygen sensor-1 (if equipped) 7. Exhaust pipe bolt 11. Muffler tail pipe
1-2 Exhaust manifold (with WU-TWC) 5. Exhaust pipe gasket 8. Muffler 12. Muffler gasket
2. Seal ring 6-1 Exhaust No.2 pipe (without WU-TWC) 8-1. Weld bolt 13. No.1 Exhaust pipe stiffener
3-1 Exhaust No.1 pipe (without WU-TWC) 6-2 Exhaust No.2 pipe (with WU-TWC) 9. Muffler mounting Tightening Torque
3-2 Exhaust No.1 pipe (with WU-TWC) 6-3 Exhaust No.2 pipe (without TWC) 10. Heated oxygen sensor-2
(if equipped)Do not reuse

EXHAUST SYSTEM 6K-3
TYPE WITHOUT WELD BOLT AT MUFFLER FRONT FLANGE
1-1 Exhaust manifold (without WU-TWC) 4. Heated oxygen sensor-1 (if equipped) 7. Exhaust pipe bolt 12. Muffler gasket
1-2 Exhaust manifold (with WU-TWC) 5. Exhaust pipe gasket 8. Muffler 13. No.1 Exhaust pipe stiffener
2. Seal ring 6-1 Exhaust No.2 pipe (without WU-TWC) 9. Muffler mounting Tightening Torque
3-1 Exhaust No.1 pipe (without WU-TWC) 6-2 Exhaust No.2 pipe (with WU-TWC) 10. Heated oxygen sensor-2
(if equipped)Do not reuse
3-2 Exhaust No.1 pipe (with WU-TWC) 6-3 Exhaust No.2 pipe (without TWC) 11. Muffler tail pipe

AUTOMATIC TRANSMISSION (4 A/T) 7B1-1
7B1
SECTION 7B1
AUTOMATIC TRANSMISSION (4 A/T)
CONTENTS
General Description ......................................7B1-3
Electronic Shift Control System ................... 7B1-4
Automatic gear shift diagram................... 7B1-5
Diagnosis .......................................................7B1-7
On-Board Diagnostic System
(Vehicle without monitor connector) ............ 7B1-7
On-Board Diagnostic System
(Vehicle with monitor connector) ................. 7B1-8
Precaution in Diagnosing Trouble ............... 7B1-9
Automatic Transmission Diagnostic Flow
Table ......................................................... 7B1-10
Malfunction Indicator Lamp (MIL) Check... 7B1-13
“O/D OFF” Lamp Check ............................ 7B1-13
“POWER” Lamp Check ............................. 7B1-13
Diagnostic Trouble Code (DTC) Check ..... 7B1-13
Diagnostic Trouble Code Clearance ......... 7B1-13
Diagnostic Trouble Code Table ................. 7B1-14
Fail Safe Table .......................................... 7B1-14
Visual Inspection ....................................... 7B1-14
A/T Basic Check ........................................ 7B1-14
Trouble Diagnosis Table 1 ........................ 7B1-15
Trouble Diagnosis Table 2 ........................ 7B1-15
Trouble Diagnosis Table 3 ........................ 7B1-16
Scan Tool Data ......................................... 7B1-17
Inspection of PCM and Its Circuit .............. 7B1-17Wire Harness and Connectors .................. 7B1-17
Table A-1 : No TCC Lock-Up Occurs ........ 7B1-18
Table A-2 : No Gear Shift to O/D .............. 7B1-20
Table B-1 : “O/D OFF” Light Circuit Check
(“O/D OFF” Light Doesn’t Light at Ignition
Switch ON But Engine Starts Up) ............. 7B1-22
Table B-2 : “O/D OFF” Light Circuit Check
(“O/D OFF” Light Comes ON Steadily) ..... 7B1-23
Table B-3 : “POWER” Light Circuit Check
(“POWER” Light Doesn’t Light at Ignition
Switch ON But Engine Starts Up) ............. 7B1-24
Table B-4 : “POWER” Light Circuit Check
(“POWER” Light Comes ON Steadily) ...... 7B1-25
DTC P0705 (DTC NO.72) - Transmission
Range Sensor (Switch) Circuit Malfunction7B1-26
DTC P0715 (DTC NO.76) - Input/Turbine
Speed Sensor Circuit Malfunction............. 7B1-29
DTC P0720 (DTC NO.75) Output Speed
Sensor Circuit Malfunction ........................ 7B1-32
DTC P0743 (DTC NO.65/66) -
TCC (Lock-Up) Solenoid Electrical ........... 7B1-34
DTC P0753 (DTC NO.61/62)
Shift Solenoid-A (#1) Electrical
DTC P0758 (DTC NO.63/64)
Shift Solenoid-B (#2) Electrical ................. 7B1-36 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
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 Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure 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.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

7B1-4 AUTOMATIC TRANSMISSION (4 A/T)
Electronic Shift Control System
1. PCM (ECM) 9. Transmission range sensor 17. MIL (“SERVICE ENGINE SOON” lamp)
2. VSS 10. Shift solenoid-A 18. O/D off switch
3. CMP sensor 11. Shift solenoid-B 19. P/N change switch
4. TP sensor 12. TCC solenoid 20. 4WD low switch
5. ECT sensor 13. Data link connector 21. Main relay
6. Stop lamp switch 14. Cruise control module 22. Ignition switch
7. Input shaft speed sensor 15.“POWER” lamp 23. Battery
8. Output shaft speed sensor 16.“O/D OFF” lamp 24. PCM (ECM) connector terminal (viewed from harness side)
5V
5V5V
5V5V
5V
5V 5V C51-1-14
C51-1-12
C51-1-13
C51-3-26
C51-3-12
C51-3-13
C51-3-9
C51-3-2
C51-3-24
C51-1-11
C51-1-10
C51-1-20 C51-1-21
C51-1-23
C51-1-22
C51-1-7
C51-1-6
C51-1-19
C51-1-18
C51-1-28
C51-1-27
C51-1-2
C51-1-1
C51-1-8
E61-13
E61-35
E61-4C51-1-26 E61-31 E61-33 E61-21 E61-20 E61-7
C51-3-20
E61-2
E61-9
C51-3-4
C51-3-15
C51-3-6
C51-3-17
C51-2-7
12V
12V 12V 12V
12V
12V
12V
12V
5V
12V
BLU/YEL
YEL/GRN
YEL/BLU
GRY/YEL
GRY/YEL
GRY/RED
RED/GRN
ORN/BLU
GRY/YEL
BLU/YEL
BLU/GRN
WHT
ORN
ORN/GRN
RED P
R
N
D
2
LORN/BLU
YEL/GRN
GRN/ORN
GRN/BLU
GRN
GRN/RED
GRN/YEL
PPL/RED
PNK/BLU
GRY
PPL/YEL
WHT/BLK
GRY/BLU
YEL/RED
ORN/BLU
WHT
BLU
BLU/BLK
BLU/BLK
BLK/GRN
BLK/ORN
BLK/GRNBLK/WHT ORN/WHT
8
7
23 22
35 346
20 21
335
19
3218
3117
3016 15
2914
284
13
273
12
26112
10
256
5
17 16
26 252
1
98
21 202
1
98
22 21 1
9
247
20
306
19
2918
27 17
2816 15
2614
25 5
13 4
12
24113
10
23 7
19
28654 3
18
2717 16
2615 14
2513
2412
2311
2210 4
15 14
2413
2312
2211 10 9 8 7
213
202
191
18
24
E61 C51-3 C51-1 C51-2 14
13
B+
B+
17
16
15
18
19
20
22
21
23
BB+
IG1
B+
IG2
1 2
3
4
5
7 6
8
IG1
9
10
11
12
BB+
E61-34 GRN/WHT
BB+

AUTOMATIC TRANSMISSION (4 A/T) 7B1-9
Precaution in Diagnosing Trouble
•Don’t disconnect couplers from PCM (ECM), battery cable
from battery, PCM ground wire harness from engine or main
fuse before checking the diagnosis information (DTC, freeze
frame data, etc.) stored in PCM memory. Such disconnec-
tion will clear memorized information in PCM memory.
•Using SUZUKI scan tool or also generic scan tool for vehicle
without monitor connector, the diagnostic information stored
in PCM memory can be checked and cleared as well. Before
its use, be sure to read Operator’s (Instruction) Manual sup-
plied with it carefully to have good understanding of its func-
tions and usage.
•Priorities for diagnosing troubles
If two or more diagnostic trouble codes (DTCs) are stored,
proceed to the flow table of the DTC which was detected
earliest in the order and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble
codes according to the following priorities.
–Diagnostic trouble codes (DTCs) other than DTC P0171/
P0172/P0174/P0175 (Fuel system too lean/too rich), DTC
P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire
detected) and DTC P0400 (EGR flow malfunction)
–DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too
rich) and DTC P0400 (EGR flow malfunction)
–DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306
(Misfire detected)
•Be sure to read “PRECAUTIONS FOR ELECTRICAL CIR-
CUIT SERVICE” in Section 0A before inspection and
observe what is written there.
•PCM replacement
When substituting a known-good PCM, check for following
conditions.
Neglecting this check may result in damage to a good PCM.
–All relays and actuators have resistance of specified value.
–MAF sensor, MDP sensor, TP sensor and fuel tank pres-
sure sensor are in good condition. Also, the power circuit of
these sensors is not shorted to the ground.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-11
STEP 1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a inspection form will facilitate collecting information to the point required for
proper analysis and diagnosis.
STEP 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK, RECORD AND
CLEARANCE
First, referring to DTC check section, check DTC (including pending DTC). If DTC exists, print or write down
DTC and freeze frame data and then clear them by referring to DTC clearance section. DTC indicates malfunc-
tion in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred in
the past and normal condition has been restored. In order to know that, check symptom in question according to
Step 5 and then recheck DTC according to Step 6.
Diagnosing a trouble based on the DTC in this step only or failure to clear the DTC in this step may result in an
faulty diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unneces-
sary.
STEP 3 and STEP 4. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the A/T and
engine referring to Visual Inspection section.
STEP 5. TROUBLE SYMPTOM CONFIRMATION
Check trouble symptoms based on information obtained in Step 1 “CUSTOMER COMPLAINT ANALYSIS” and
Step 2 “DTC/FREEZE FRAME DATA CHECK”.
Also, recheck DTC according to “DTC CONFIRMATION PROCEDURE” described in each “DTC FLOW
TABLE”.
STEP 6 and STEP 7. RECHECKING AND RECORD OF DTC/FREEZE FRAME DATA
Refer to “DTC CHECK” in this section for checking procedure.
STEP 8. A/T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE
Perform A/T basic check according to the “A/T Basic Check Flow Table” first. When the end of the flow table has
been reached, check the parts of the system suspected as a possible cause referring to “TROUBLE DIAGNO-
SIS TABLE” and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer
complaint analysis, trouble symptom confirmation and/or A/T basic check) and repair or replace faulty parts, if
any.
STEP 9. DIAGNOSTIC TROUBLE CODE FLOW TABLE
Based on the DTC indicated in Step 6 and 7 and referring to “DIAGNOSTIC TROUBLE CODE FLOW TABLE” in
this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, PCM
or other part and repair or replace faulty parts.11 Final Confirmation Test
1) Clear DTC if any.
2) Perform final confirmation test referring to
the next page.
Is there any problem symptom, DTC or abnor-
mal condition?Go to Step 6. End. Step Action Yes No

AUTOMATIC TRANSMISSION (4 A/T) 7B1-15
Trouble Diagnosis Table 1
Trouble Diagnosis Table 2
TRANSMISSION FLUID
RUNNING CONDITION
4 Perform stall test, time rag test, line pressure test,
engine brake test and “P” range test referring to
“STALL TEST”, “LINE PRESSURE TEST”, “ENGINE
BRAKE TEST” and ““P” RANGE TEST” in this section.
Are the test results satisfactory?Go to Step 5. Proceed to “TROUBLE
DIAGNOSIS TABLE 3” in
this section.
5 Proceed to “TROUBLE DIAGNOSIS TABLE 2” in this
section.
Is trouble identified?Repair or replace
defective parts.Proceed to “TROUBLE
DIAGNOSIS TABLE 3” in
this section. Step Action Yes No
Condition Possible Cause Correction
TCC does not operateBrake pedal (stop lamp) switch or its circuit
faulty (H25 engine only)Refer to “DIAGNOSTIC FLOW
TABLE A-1” in this section.
4WD low switch or its circuit faulty
Engine coolant temp. sensor or its circuit faulty
Cruise control signal circuit faulty (if equipped)
Gear does not change
to 4thO/D off switch or its circuit faulty Refer to “DIAGNOSTIC FLOW
TABLE A-2” in this section.
4WD low switch or its circuit faulty
Engine coolant temp. sensor or its circuit faulty
Cruise control signal circuit faulty (if equipped)
Condition Possible Cause Correction
Low fluid pressureClogged oil pump strainer Wash strainer.
Malfunction of pressure regulator valve Overhaul valve body.
High fluid pressurePressure regulator valve Overhaul valve body.
Condition Possible Cause Correction
Unable to run in all
rangeRegulator valve stick Replace.
Clogged oil strainer Wash strainer.
Seized or broken planetary gear Repair or replace.
Faulty manual valve Replace.
Poor 1st speed run-
ning or excessive slip-
page in “D” or “2”Faulty 1–2 shift valve Replace.

7B1-18 AUTOMATIC TRANSMISSION (4 A/T)
Table A-1 : No TCC Lock-Up Occurs
SYSTEM DESCRIPTION
PCM turns TCC solenoid OFF under any of the following conditions.
•Brake pedal switch : ON
•4WD LOW switch : ON
•Cruise control module : TCC OFF command signal is output (if equipped).
•ECT : ECT < 30 °C (86 °F)
TROUBLESHOOTING
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 person, a driver and tester, on a level road.
Step Action Yes No
1Was “AUTOMATIC TRANSMISSION DIAG-
NOSTIC FLOW TABLE” performed?Go to Step 2. Go to “AUTOMATIC
TRANSMISSION DIAG-
NOSTIC FLOW TABLE” in
this section.
2 ECT check :
1) Warm up engine to normal operating tem-
perature.
2) Check ECT using scan tool.
Is ECT more than 30 °C (86 °F)?Go to Step 3. Faulty ECT sensor, its cir-
cuit or engine cooling sys-
tem.
If OK, substitute a known-
good PCM and recheck.
3 Perform running test under the following condi-
tions and check voltage between C51-1-8 termi-
nal of PCM coupler and ground.
•Normal mode in “D” range.
•Transfer “2H” position.
•Cruise control is not operated (if equipped).
•Brake pedal released.
•Drive vehicle with TCC ON condition refer-
ring to “TCC LOCK-UP DIAGRAM” in this
section.
Is it battery voltage?Faulty TCC solenoid
valve, its circuit or trans-
mission.Go to Step 4.
4 Brake switch signal inspection :
With ignition switch ON, check voltage between
E61-34 terminal of PCM coupler terminal and
ground.
Brake switch specification
Brake pedal released : 0 V
Brake pedal depressed : Battery voltage
Is the result as specified?Go to Step 5. Faulty brake pedal switch
or its circuit.
If OK, substitute a known-
good PCM and recheck.