switch SUZUKI GRAND VITARA 1999 2.G Owners Manual

6-1-122 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
3 Check IAC valve referring to “IAC VALVE
INSPECTION” in Section 6E2.
Is check result as specified?Go to Step 4. IAC valve malfunction, “BLU/
BLK”, “LT GRN/BLK”, “PPL/
BLK”, “GRY/BLU” or “PPL/
YEL” wire open or short or
poor coupler connection.
If all above are OK, substi-
tute a known-good ECM
(PCM) and recheck.
4 Was idle speed within specification in
Step 1?Check for following :
FIA valve, Vacuum leaks, air inhal-
ing, EVAP canister purge control
system, accessory engine load,
stuck of PCV valve, clog of idle air
passage, MAF sensor, TP sensor,
ECT sensor, EGR valve malfunc-
tion (leakage from valve seat), A/C
signal, transmission range switch
signal and power steering switch
signal.Go to Step 5.
5 Was idle speed higher than specification
in Step 1?Go to Step 6. Go to Step 8.
6 Check A/C (input) signal circuit referring
to Step 1 of “Table B-5”. (A/C signal can
be also checked by using SUZUKI scan
tool.)
Is it in good condition?Go to Step 7. A/C signal circuit open or
short, or A/C system mal-
function.
7 Was IAC duty less than about 2% in Step
1 of this table?
Check FIA valve.
Check abnormal air inhaling from
intake manifold, throttle body, PCV
valve and EVAP canister purge
control system.Check TP sensor (closed
throttle position) and ECT
sensor for performance.
If sensors are OK, substitute
a known-good ECM (PCM)
and recheck.
8 Check transmission range switch signal
referring to “INSPECTION OF ECM
(PCM) AND ITS CIRCUIT” in this section.
Is check result satisfactory?Go to Step 9. Transmission range switch
malfunction or its circuits
open or short.
9 Was IAC duty more than about 30% in
Step 1 of this table?Check parts or system which can
cause engine low idle.
Check FIA valve.
Air inhaling from between throttle
body and MAF sensor, EGR valve
malfunction (leakage from valve
seat), accessory engine load, clog
of idle air passage and etc.Substitute a known-good
ECM (PCM) and recheck. Step Action Yes No

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-123
Table B-5 A/C Signal Circuits Inspection (If Equipped)
WIRING DIAGRAM
INSPECTION
1. A/C control module (amplifier)
2. ECM (PCM)
Step Action Yes No
1 Check A/C Signal Circuit.
1) Check voltage at terminal E61-17 with ignition
switch ON.
A/C signal circuit specification :
A/C switch and/or heater blower switch OFF (A/
C is not operating) : 10 – 14 V
Both A/C switch and heater blower switch ON :
0 – 1.5 V
Are check result as specified?Go to Step 2.“YEL/BLK” circuit open or
short, Evaporative tem-
perature is below 1°C
(34°F) or faulty A/C sys-
tem.
2 Check A/C Cut Signal Circuit.
1) Check voltage at terminal E61-8.
A/C cut signal specification :
While engine running and A/C switch and/or
heater blower switch OFF
(A/C is not operating) : 0 – 1.5 V
While engine running at idle speed and both A/
C switch and heater blower switch ON
(A/C is operating) : 10 – 14 V
Are check result as specified?A/C control signal cir-
cuits are in good con-
dition.“GRY/WHT” circuit open
or short, Poor perfor-
mance of ECT sensor, TP
sensor, Engine start sig-
nal inputted or A/C ampli-
fier malfunction.
If none of the above
exists, substitute a
known-good ECM (PCM)
and recheck.

6-1-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Table B-6 A/C Condenser Fan Motor Relay Control System Inspection (If
Equipped)
WIRING DIAGRAM
INSPECTION
1. To ignition switch 3. A/C fuse 5. A/C condenser fan motor
2. Main fuse 4. A/C condenser fan motor relay 6. ECM (PCM)
WARNING:
Keep hands, tools, and clothing away from A/C condenser fan to help prevent personal injury. This
fan is electric and can come on whether or not the engine is running. The fan can start automatically
in response to the ECT sensor with the ignition switch in the “ON” position.
Step Action Yes No
1 1) Check DTC referring to “DTC CHECK” in this sec-
tion.
Is there any malfunction DTC?Go to applicable DTC
Diag. Flow Table.Go to Step 2.
2 1) Check A/C condenser fan for operation.
A/C condenser fan should be operated under follow-
ing condition A or B only.
A : When engine is running and A/C is operating.
B : When engine coolant temp. is 113°C (235°F) or
more with ignition switch ON.
Is check result as specified?This system is in
good condition.Go to Step 3.
3 1) Remove ECM (PCM) cover.
2) Check voltage between E61-22 terminal of ECM
(PCM) connected coupler and ground.
Other than conditions A and B in Step 2 :
10 – 14 V
Under condition A or B in Step 2 :
0 – 1 V
Is check result as specified?Fuse blown, “RED”,
“RED/BLK” or “RED/
BLU” circuit open,
malfunction of con-
denser fan motor or
relay.“YEL/GRN” circuit
open, “YEL/BLU” cir-
cuit open or short, or
relay malfunction.
If above are OK, sub-
stitute a known-good
ECM (PCM) and
recheck.

ENGINE MECHANICAL (H27 ENGINE) 6A2-1
6A2
SECTION 6A2
ENGINE MECHANICAL (H27 ENGINE)
CONTENTS
On-Vehicle Service........................................6A2-2
Throttle Body and Intake Manifold .............. 6A2-2
Exhaust Manifold ......................................... 6A2-9
LH (No.1) Bank 2nd Timing Chain
and Chain Tensioner ................................. 6A2-13
Camshaft and Valve Lash Adjuster ........... 6A2-14
Valves and Cylinder Heads ....................... 6A2-17
Piston, Piston Rings, Connecting Rodsand Cylinders ............................................ 6A2-21
Unit Repair Overhaul .................................. 6A2-26
Engine Assembly ...................................... 6A2-26
Main Bearings, Crankshaft
and Cylinder Block .................................... 6A2-30
Special Tool ................................................. 6A2-36

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 service manual
mentioned in the FOREWORD of this manual.
Whether following systems (parts) are used in the particular vehicle or not depends on specifica-
tions. Be sure to bear this in mind when performing service work.
–EGR valve
–Warm up three way catalytic converter
–Heated oxygen sensor(s)
–Three way catalytic converter
–CKP sensor
–MAP sensor

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-1
6E2
SECTION 6E2
ENGINE AND EMISSION CONTROL SYSTEM
(SEQUENTIAL MULTIPORT FUEL INJECTION
FOR H27 ENGINE)
CONTENTS
General Description ..................................... 6E2-2
System Flow ............................................... 6E2-3
System Diagram ......................................... 6E2-4
Air Intake System ....................................... 6E2-6
Fuel Delivery System ................................. 6E2-7
Electronic Control System .......................... 6E2-8
Engine and Emission Control Input/Output
Table ........................................................ 6E2-12
Diagnosis .................................................... 6E2-12
On-Vehicle Service..................................... 6E2-13
General .................................................... 6E2-13
Accelerator Cable Adjustment .................. 6E2-14
A/T Throttle Cable Adjustment
(A/T Vehicle) ............................................ 6E2-14Idle Speed/Idle Air Control (IAC) Duty
Inspection................................................. 6E2-15
[Using SUZUKI scan tool] .................... 6E2-15
[Not using SUZUKI scan tool]
(vehicle with monitor connector) .......... 6E2-16
Idle mixture inspection/adjustment
(vehicle without heated oxygen sensor) 6E2-17
Air Intake System ..................................... 6E2-18
Throttle body ........................................ 6E2-18
Idle air control valve (IAC valve) .......... 6E2-21
Fast idle air valve ................................. 6E2-22
Fuel Delivery System ............................... 6E2-23
Fuel pressure inspection ...................... 6E2-23
Fuel pump ............................................ 6E2-24
Fuel pressure regulator ........................ 6E2-25 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:
Whether following systems (parts) are used in the particular vehicle or not depends on specifications.
Be sure to bear this in mind when performing service work.
Monitor connector
CKP sensor
MAP sensor
EGR valve
Heated oxygen sensor or CO adjusting resistor
Three way catalytic converter, Warm-up three way catalytic converter

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-5
1. Air cleaner 22. Fuel level sensor 39. A/C controller (if equipped)
2. Intake air temp. sensor 23. Monitor connector (if equipped) 40. Data link connector/Immobilizer control mod-
ule (if equipped)
3. Mass air flow sensor 23-1. Diag. switch terminal 41. ABS control module
4. EVAP canister purge valve 23-2. Test switch terminal 42. Main relay
5. Throttle position sensor 23-3. Output duty select switch terminal 43. Ignition switch
6. Idle air control valve 23-4. Duty output terminal 44. Park/Neutral position switch in TR switch (A/T)
7. Camshaft position sensor 24. Fuel filter 45. Battery
8. EGR valve 25. Fuel pressure regulator 46. Starter magnetic switch
9. Manifold absolute pressure sensor
(if equipped)26. Immobilizer indicator lamp (if equipped) 47.“O/D OFF” lamp (A/T)
10. Fuel injector 27. Tank pressure control valve 48.“POWER” lamp (A/T)
11. PCV valve 28. EVAP canister 49. Lighting switch (A/T)
12. Ignition coil assembly 29. Knock sensor 50. Stop lamp switch (A/T)
13. Engine coolant temperature sensor 30. ECM/PCM (Engine control module/Powertrain con-
trol module)51. O/D cut switch (A/T)
14. Heated oxygen sensor
(bank 1 sensor 1) (if equipped)31. Malfunction indicator lamp 52. POWER/NORMAL change switch (A/T)
15. Heated oxygen sensor
(bank 2 sensor 1) (if equipped)32. Electric loads (rear defogger (if equipped), lighting) 53. 4WD low switch (A/T)
16. Heated oxygen sensor
(bank 1 sensor 2) (if equipped)33. Power steering pressure switch 54. Transmission range switch (A/T)
17. Heated oxygen sensor
(bank 2 sensor 2) (if equipped)34. Heater blower fan switch 55. Solenoid valve A (A/T)
18. Warm-up three way catalytic converter
(if equipped)35. Cruise control module 56. Solenoid valve B (A/T)
19. Three way catalytic converter
(if equipped)36. Vehicle speed sensor 57. TCC solenoid valve (A/T)
20. Crankshaft position sensor
(if equipped)37. Combination meter 58. A/T input speed sensor (A/T)
21. Fuel pump 38. A/C condenser fan relay (if equipped) 59. A/T vehicle (output) speed sensor (A/T)

6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Electronic Control System
The electronic control system consists of 1) various sensors which detect the state of engine and driving condi-
tions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and 3) various
controlled devices.
Functionally, it is divided into the following sub systems:
•Fuel injection control system
•Heated oxygen sensor heater control system (if equipped)
•Idle air control system
•Fuel pump control system
•Evaporative emission control system
•Ignition control system
•EGR system (if equipped)
Also, with A/T model, PCM controls A/T.
INFORMATION SENSORS CONTROLLED DEVICES OTHERS
1. IAT sensor a : A/C condenser fan motor relay (if equipped) A : Main fuse box
2. MAP sensor (if equipped) b : Ignition coil assemblies B : ECM (PCM)
3. Heated oxygen sensor (sensor 1) (if equipped) c : EVAP canister purge valve C : Data link connector
4. ECT sensor d : EGR valve (if equipped) D : Combination meter
5. TP sensor e : Idle air control valve E : Fuse box
6. MAF sensor f : Injectors F : EVAP canister
7. Camshaft position sensor (CMP sensor) g : Malfunction indicator lamp
8. ABS control module h : Fuel pump relay
9. Crankshaft position sensor (CKP sensor) (if equipped) i : Main relay
10. Power steering pressure switch (PSP switch) j : Oxygen sensor heater relay (if equipped)
11. CO adjusting resistor (if equipped)
12. Monitor connector (if equipped)
13. Transmission range switch (A/T)
14. Knock sensor
NOTE:
Above figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are
installed at the side of symmetry.

6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE)
1. Fuel injector No.1 17.“O/D OFF” lamp (A/T) 34. Power steering pressure switch
2. Fuel injector No.2 18.“POWER” lamp (A/T) 35. Stop lamp switch (Brake pedal switch)
3. Fuel injector No.3 18-1.“4WD” lamp (4WD) 36. Lighting switch
4. Fuel injector No.4 18-2. 4WD air pump assembly (4WD) 37. Rear defogger switch (if equipped)
4-1. Fuel injector No.5 19. 4WD switch (4WD) 38. Heater blower motor (if equipped)
4-2. Fuel injector No.6 20. Power/Normal change switch (A/T) 39. A/C control module (amplifier)
5. EGR valve (if equipped) 21. O/D cut switch (A/T) 40. ABS control module
6. Idle air control 21-1. 4WD low switch (4WD) 41. Heated oxygen sensor-1 (Bank1) (if equipped)
7. EVAP canister purge valve 22. Main relay 41-1. Heated oxygen sensor-1 (Bank2) (if equipped)
8. Ignition coil for No.1 23. Transmission range switch (Park/Neutral
Position Switch) or clutch pedal position switch42. Heater oxygen sensor-2 (Bank1) (if equipped)
8-1. Ignition coil for No.2 24. Starter magnetic switch 42-1. Heater oxygen sensor-2 (Bank2) (if equipped)
9. Ignition coil for No.3 24-1. Cruise control module (if equipped) 43. Intake air temp. sensor
9-1. Ignition coil for No.4 25. Vehicle speed sensor 44. Engine coolant temp. sensor
10. Ignition coil for No.5 26. Combination meter 45. Throttle position sensor
10-1. Ignition coil for No.6 27. Data link connector 46. CO adjusting resistor (if equipped)
11. Fuel pump relay 28. TCC solenoid (A/T) 47. Manifold absolute pressure sensor (if
equipped)
12. Fuel pump 29. Shift solenoid-B (A/T) 48. Mass air flow sensor
13. A/C condenser fan relay (if equipped) 30. Shift solenoid-A (A/T) 49. Camshaft position sensor
14. A/C condenser fan motor (if equipped) 31. Transmission range switch (sensor) (A/T) 50. Crankshaft position sensor (if equipped)
15. Knock sensor 32. A/T input speed sensor (A/T) 51. Monitor connector (if equipped)
16. Malfunction indicator lamp 33. A/T vehicle (output) speed sensor (A/T) 52. Engine control module
(Powertrain control module)
TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT
E61-1 Power source for CO adjusting resistor
(if equipped)E61-13 Data link connector E61-25—
E61-2 Power source for back up E61-14 Test switch terminal (if equipped) E61-26—
E61-3—E61-15 Rear defogger switch (if equipped) E61-27—
E61-4 Cruise control module
(Throttle opening signal)E61-16 Heater blower switch E61-28—
E61-5 Duty output terminal (if equipped) E61-17 A/C signal (if equipped) E61-29 Diag. switch terminal (if equipped)
E61-6 Tachometer E61-18—E61-30 ABS control module (if equipped)
E61-7 MIL (“SERVICE INGINE SOON” lamp) E61-19“4WD” lamp E61-31 Power/Normal change switch (A/T)
E61-8 A/C cut signal (if equipped) E61-20“O/D OFF” lamp (A/T) E61-32 Lighting switch
E61-9 Main relay E61-21“POWER” lamp (A/T) E61-33 O/D cut switch (A/T)
E61-10 CO adjusting resistor (if equipped) E61-22 A/C fan motor relay (if equipped) E61-34 Stop lamp switch (Brake pedal switch)
E61-11—E61-23 Fuel pump relay E61-35 Cruise control module (if equipped)
E61-12—E61-24 Ground for CO adjusting resistor (if
equipped)

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-11
TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT
C51-3-1 Intake air temp. (IAT) sensor C51-3-13 Power source for TP sensor C51-3-25 Ground for IAT sensor, MAP sensor and
oxygen sensor (if equipped)
C51-3-2 Engine coolant temp. (ECT) sensor C51-3-14 Power source for MAP sensor (if
equipped)C51-3-26 Ground for CMP sensor
C51-3-3 Knock sensor C51-3-15 Power source
C51-3-4 Power source C51-3-16—
C51-3-5 Ground for MAF sensor C51-3-17 Ground
C51-3-6 Ground C51-3-18 Pressure switch in 4WD air pump
assembly
C51-3-7 4WD switch C51-3-19—
C51-3-8 Manifold absolute pressure (MAP)
sensor (if equipped)C51-3-20 Ignition switch
C51-3-9 Throttle position (TP) sensor C51-3-21 Heated oxygen sensor-1 (Bank2) (if
equipped)
C51-3-10 Mass air flow (MAF) sensor C51-3-22 Heated oxygen sensor-2 (Bank1) (if
equipped)
C51-3-11 Heated oxygen sensor-1 (Bank1) (if
equipped)C51-3-23 Heated oxygen sensor-2 (Bank2) (if
equipped)
C51-3-12 Ground for TP sensor C51-3-24 Ground for ECT sensor
TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT
C51-1-1 Shift solenoid-B (A/T) C51-1-13 CMP sensor C51-1-25 Power steering pressure switch
C51-1-2 Shift solenoid-A (A/T) C51-1-14 Vehicle speed sensor C51-1-26 4WD Low switch
C51-1-3—C51-1-15 EVAP canister purge valve C51-1-27 Transmission range switch “L” (A/T)
C51-1-4 IAC valve (stepper motor coil 2) C51-1-16 IAC valve (stepper motor coil 4) C51-1-28 Transmission range switch “2” (A/T)
C51-1-5 IAC valve (stepper motor coil 1) C51-1-17 IAC valve (stepper motor coil 3)
C51-1-6 Transmission range switch “R” (A/T) C51-1-18 Transmission range switch “D” (A/T)
C51-1-7 Transmission range switch “P” (A/T) C51-1-19 Transmission range switch “N” (A/T)
C51-1-8 TCC solenoid (A/T) C51-1-20 Shield wire ground for A/T output
speed sensor
C51-1-9 4WD air pump assembly C51-1-21 Shield wire ground for A/T input
speed sensor
C51-1-10 A/T input speed sensor (–) C51-1-22 A/T output speed sensor (–)
C51-1-11 A/T input speed sensor (+) C51-1-23 A/T output speed sensor (+)
C51-1-12 CMP sensor C51-1-24 Engine start signal
TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT
C51-2-1 Fuel injector No.2 C51-2-13 EGR valve (stepper motor coil 3) (if
equipped)C51-2-25 Ignition coil assembly for No.4
C51-2-2 Fuel injector No.1 C51-2-14 EGR valve (stepper motor coil 2) (if
equipped)C51-2-26 Ignition coil assembly for No.3
C51-2-3—C51-2-15 EGR valve (stepper motor coil 1) (if
equipped)C51-2-27 Ignition coil assembly for No.2
C51-2-4 Heater of HO2S-1 (Bank1) (if equipped) C51-2-16 Heater of HO2S-2 (Bank1) (if equipped) C51-2-28 Ignition coil assembly for No.1
C51-2-5 Heater of HO2S-1 (Bank2) (if equipped) C51-2-17 Heater of HO2S-2 (Bank2) (if equipped) C51-2-29—
C51-2-6—C51-2-18—C51-2-30 Ground for CKP sensor shield wire (if
equipped)
C51-2-7 Ground C51-2-19 CKP sensor (+) (if equipped)
C51-2-8 Fuel injector No.4 C51-2-20 CKP sensor (–) (if equipped)
C51-2-9 Fuel injector No.3 C51-2-21 Fuel injector No.6
C51-2-10—C51-2-22 Fuel injector No.5
C51-2-11—C51-2-23 Ignition coil assembly for No.6
C51-2-12 EGR valve (stepper motor coil 4) (if
equipped)C51-2-24 Ignition coil assembly for No.5

6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Engine and Emission Control Input/Output Table
Diagnosis
Refer to Section 6-1.
Ignition coil with igniter
HO2S heater control
Input
Output Function
Main relay control
Fuel pump control
Injection control
Ignition control
MIL control Idle air control
EVAP purge control
EGR control
A/C control
A/C condensor fan
controlMain relay
Fuel pump relay
Injectors
MIL
EVAP canister purge
valve IAC valve
EGR valve (if equipped)
HO2S (if equipped)
A/C amplifier
(if equipped)
A/C condensor fan
relay (if equipped)
CMP sensor
MAF sensor
TP sensor
ECT sensor
IAT sensor
HO2S (sensor 1)(if equipped)
VSS
Blower fan switch
Rear defogger switch
PSP switch
Ignition switch
Starter switch
A/C amplifier (if equipped)
TR switch (A/T VEHICLE)
Light switch
Knock sensor
CO adjusting resistor (if equipped)
Test swich terminal (Vehicle with monitor connector)
Diag. swich terminal (Vehicle with monitor connector)
Brake switch (A/T VEHICLE)
ABS control module