ESP SUZUKI GRAND VITARA 1999 2.G User Guide

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-69
Fig. for Step 2
DTC P0153 HO2S-1 (Bank 2) Circuit Slow Response
WIRING DIAGRAM/CIRCUIT DESCRIPTION
Refer to DTC P0150.
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
Refer to DTC P0150.
TROUBLESHOOTING
4 Short term fuel trim check :
1) Run engine at 2000 r/min. for 60 sec.
2) With engine idling, check short term fuel trim displayed
on scan tool.
Is it within – 20 to +20 %?Intermittent trouble
or faulty ECM
(PCM).
Check for intermit-
tent referring to
“INTERMITTENT
AND POOR CON-
NECTION” in Sec-
tion 0A.Go to DTC P0174/
P0175 Diag. Flow
Table. Step Action Yes No
1. Normal
2. NG
DTC DETECTING CONDITION TROUBLE AREA
Following conditions are detected in idle state while running under driving
conditions described for “DTC CONFIRMATION PROCEDURE”.
Hi/Lo cycle (TRANS TIME displayed on scan tool) of HO2S-1 output voltage
is longer than specification or response rates of Hi → Lo and Lo → Hi
(TRANS TIME displayed as R → L threshold V or L → R threshold V on scan
tool) are longer than specification.
(2 driving cycle detection logic)HO2S-1
ECM (PCM)
Step Action Yes No
1 Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE” in this
section.
2 1) Replace HO2S-1 and recheck.
Is DTC P0153 detected?Substitute a known-good
ECM (PCM) and recheck.HO2S-1 malfunction.

6-1-94 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P0420 Catalyst System Efficiency Below Threshold (Bank 1)
SYSTEM DIAGRAM
CIRCUIT DESCRIPTION
Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1
and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel
injection volume. (Refer to Section 6E2.) While the above control is going on and if WU-TWC is in good condi-
tion, the output voltage of HO2S-2 is maintained at specified level. As WU-TWC becomes deteriorated, even
when the above control is going on, the exhaust gas which has passed WU-TWC then passes HO2S-2 at the
exhaust oxygen concentration similar to that of the pre-catalyst without being oxygenated or converted. Thus,
waveforms of HO2S-1 and HO2S-2 output voltages become alike. ECM (PCM) judges deterioration of WU-TWC
by comparing waveforms of HO2S-1 and HO2S-2.
DTC DETECTING CONDITION AND TROUBLE AREA
1. HO2S-1 (Bank-1) 4. TWC
2. HO2S-2 (Bank-1) 5. ECM (PCM)
3. WU-TWC
DTC DETECTING CONDITION TROUBLE AREA
While running under conditions described for DTC CON-
FIRMATION PROCEDURE, output waveform of HO2S-1
becomes similar to that of HO2S-2.
(2 driving cycle detection logic)• Exhaust gas leakage
• Warm up three way catalytic converter
• Heated oxygen sensor – 2 or its circuit
•ECM (PCM)

6-1-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2)
SYSTEM DIAGRAM
CIRCUIT DESCRIPTION
Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1
and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel
injection volume. (Refer to Section 6E2.) While the above control is going on and if WU-TWC is in good condi-
tion, the output voltage of HO2S-2 is maintained at specified level. As WU-TWC becomes deteriorated, even
when the above control is going on, the exhaust gas which has passed TWC then passes HO2S-2 at the
exhaust oxygen concentration similar to that of the pre-catalyst without being oxygenated or converted. Thus,
waveforms of HO2S-1 and HO2S-2 output voltages become alike. ECM (PCM) judges deterioration of WU-TWC
by comparing waveforms of HO2S-1 and HO2S-2.
DTC DETECTING CONDITION AND TROUBLE AREA
1. HO2S-1 (Bank-2) 4. TWC
2. HO2S-2 (Bank-2) 5. ECM (PCM)
3. WU-TWC
DTC DETECTING CONDITION TROUBLE AREA
While running under conditions described for DTC CON-
FIRMATION PROCEDURE, output waveform of HO2S-1
becomes similar to that of HO2S-2.
(2 driving cycle detection logic)• Exhaust gas leakage
• Warm up three way catalytic converter
• Heated oxygen sensor – 2 or its circuit
•ECM (PCM)

6-1-118 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
INSPECTION
Step Action Yes No
1 Check injector for operating sound :
Using sound scope, check each injector for
operating sound at engine cranking.
Do all 6 injectors make operating sound?Go to Step 2. Go to Step 3.
2 Wire harness check :
1) Remove ECM (PCM) cover and disconnect
connectors from ECM (PCM).
2) Check for resistance between following ter-
minals of ECM (PCM) connector discon-
nected.
Fuel injector and its circuit resistance (C51-
2-1 – C51-3-4, C51-2-2 – C51-3-4, C51-2-8 –
C51-3-4, C51-2-9 – C51-3-4, C51-2-21 – C51-
3-4 and C51-2-22 – C51-3-4) :
14.2 – 14.8
Ω
ΩΩ Ω at 20°C (68°F)
Is check result as specified?Fuel injector circuit is in
good condition.“PNK”, “PNK/BLK”, “PNK/
GRN”, “PNK/BLU”, “GRY/
GRN” and “GRY/BLK”
shorted each other.
3 Does none of 6 injectors make operating sound
at Step 1?Go to Step 4. Check coupler connec-
tion and wire harness of
injector not making oper-
ating sound and injector
itself (Refer to “FUEL
INJECTOR INSPEC-
TION” in Section 6E2).
4 Check power circuit of injectors for open and
short.
Is it normal?Check all 6 injectors for
resistance respectively.
It resistance is OK, substi-
tute a known-good ECM
(PCM) and recheck.Power circuit open or
short.

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) 6A2-25
3) Install piston rings to piston :
•As shown in the figure, 1st and 2nd rings have “RN” or “R”
mark respectively. When installing these piston rings to pis-
ton, direct marked side of each ring toward top of piston.
•1st rings differs from 2nd ring in thickness, shape and color
of surface contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to the figure.
•When installing oil ring, install spacer first and then 2 rails.
4) After installing three rings (1st, 2nd and oil rings), distribute
their end gaps as shown in the figure. NOTE:
Install circlip with its cut part facing as shown in the
figure.
Install so that circlip end gap comes within such range
as indicated by arrow “A”.
1. Piston
2. Arrow mark
3. Connecting rod
4. Oil hole
5. Crankshaft pulley side
1. 1st ring
2. 2nd ring
3. Oil ring
1. Arrow mark
2. 1st ring end gap
3. 2nd ring end gap and oil ring spacer gap
4. Oil ring upper rail gap
5. Oil ring lower rail gap
6. Intake side
7. Exhaust side

6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Air Intake System
The main components of the air intake system are air cleaner, mass air flow sensor, air cleaner, intake air pipe,
throttle body, intake collector, idle air control valve and intake manifold.
The air (by the amount corresponding to the throttle valve opening and engine speed) is filtered by the air
cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each com-
bustion chamber.
When the idle air control valve is opened according to the signal from ECM (PCM), the air bypasses the throttle
valve through bypass passage and is finally drawn into the intake manifold.
“A” : Air 1. Air cleaner 6. PCV hose 11. Breather hose 16. IAC valve and fast idle control system
“B” : EGR 2. IAT sensor 7. Brake booster 12. MAF sensor 17. FIA valve
“C” : Engine coolant 3. Resonator 8. Fuel pressure
regulator hose13. EGR valve 18. Thermo - WAX
4. Intake manifold 9. Intake air pipe 14. TP sensor
5. Intake collector 10. Throttle body 15. IAC valve
18
10
17
15
16

6F2-4 IGNITION SYSTEM (FOR H27 ENGINE)
Diagnosis
Diagnostic Flow Table
Condition Possible Cause Correction
Engine cranks, but will
not start or hard to
start (No spark)Blown fuse for ignition coil assembly Replace.
Loose connection or disconnection of lead wire Connect securely.
Faulty spark plug (s) Replace.
Faulty ignition coil assembly (s) Replace.
Faulty CMP sensor Replace.
Faulty ECM (or PCM) Replace.
Maladjusted ignition timing Adjust.
Poor fuel economy or
engine performanceIncorrect ignition timing Adjust.
Faulty spark plug(s) Replace.
Faulty ignition coil assembly (s) Replace.
Faulty CMP sensor Replace.
Faulty ECM (or PCM) Replace.
Faulty knock sensor Replace.
Step Action Yes No
1Was “ENGINE DIAGNOSTIC FLOW TABLE” in
Section 6-1 performed?Go to Step 2. Go to “ENGINE DIAG-
NOSTIC FLOW TABLE” in
Section 6-1.
2 Ignition Spark Test
1) Check all spark plug for condition and type,
referring to “SPARK PLUG” in this section.
2) If OK, perform ignition spark test, referring
to “IGNITION SPARK CHECK” in this sec-
tion.
Is spark emitted from all spark plugs?Go to Step 8. Go to Step 3.
3 Diagnostic Trouble Code (DTC) Check
1) Check DTC stored in ECM (or PCM), refer-
ring to “DIAGNOSTIC TROUBLE CODE
(DTC) CHECK” in Section 6E2.
Is DTC stored?Go to applicable flow table
corresponding to that
code No. in Section 6E2.Go to Step 4.
4 Electrical Connection Check
1) Check ignition coil assemblies for electrical
connection.
Are they connected securely?Go to Step 5. Connect securely.
5 Ignition Coil Assembly Power Supply, Ground
and Trigger Signal Circuits Check
1) Check these circuits for open and short.
Are circuits in good condition?Go to Step 6. Repair or replace.
6 Ignition Coil Assembly Check
1) Substitute a known-good ignition coil
assembly and then repeat Step 2.
Is check result of Step 2 satisfactory?Malfunction of ignition coil
assembly.Go to Step 7.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-27
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool and start engine.
3) Shift A/T selector lever to each of L, 2, D, N, R and P ranges for 30 seconds each.
4) Increase vehicle speed to about 70 km/h (45 mile/h) in D range.
5) Keep driving above vehicle speed for 30 seconds.
6) Release accelerator pedal, decrease vehicle speed and stop vehicle.
7) Check DTC and/or pending DTC.
TROUBLESHOOTING
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
Step Action Yes No
1Was “A/T DIAGNOSTIC FLOW TABLE” in this section
performed?Go to Step 2. Go to “A/T DIAGNOS-
TIC FLOW TABLE” in
this section.
2 Do you have SUZUKI scan tool? Go to Step 3. Go to Step 4.
3 Check Transmission range switch (sensor) circuit for
operation.
Check by using SUZUKI scan tool :
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON and check transmission
range signal (P, R, N, D, 2 or L) on display when
shifting select lever to each range.
Is applicable range indicated?
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to “INTER-
MITTENT AND POOR
CONNECTION” in
Section 0A.Go to Step 5.
4 Check Transmission range switch (sensor) circuit for
operation.
Check by not using SUZUKI scan tool :
1) Turn ignition switch ON.
2) Check voltage at terminals C51-1-6, C51-1-7,
C51-1-18, C51-1-19, C51-1-27 and C51-1-28
respectively with select lever shifted to each
range.
Taking terminal C51-1-28 as an example, is battery
voltage indicated only when select lever is shifted to
“2” range and 0 V for other ranges as shown in figure?
Check voltage at other terminals likewise, referring to
figure.
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to “INTER-
MITTENT AND POOR
CONNECTION” in
Section 0A.Go to Step 5.
5 Check select cable for adjustment referring to
“SELECT CABLE ADJUSTMENT” in this section.
Is it adjusted correctly?Go to Step 6. Adjust.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-41
Manual Road Test
This test check the gear being used in “L”, “2” or “D” range when
driven with unoperated gear shift control system. Test drive vehi-
cle on a level road.
1) Disconnect shift solenoid coupler (1) valves on transmission.
2) With select lever in “P”, start engine and warm it up.
3) With select lever in “L” range, start vehicle and accelerate to
20 km/h (12.5 mile/h). Check in this state that 1st gear is
being used.
4) At 20 km/h (12.5 mile/h), shift select lever to “2” range and
accelerate to 40 km/h (25 mile/h). Check in this state that 3rd
gear is being used.
5) At 40 km/h (25 mile/h), shift select lever to “D” range and
check that O/D gear is used when speed is higher than 40
km/h (25 mile/h).
6) After above checks, stop vehicle then engine, and connect
shift solenoids coupler (1) with ignition switch OFF.
7) Clear DTC with scan tool.
Time Lag Test
This test is to check conditions of clutch, reverse brake and fluid pressure. “Time lag” means time elapsed since
select lever is shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from “N” to “D” range and measure time from that moment till shock
is felt.
4) Similarly measure time lag by shifting select lever from “N“ to “R” range.
Specification for time lag :NOTE:
Before this test, check diagnostic trouble code (DTC).
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when disconnecting shift solenoid cou-
pler (1).
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when connecting shift solenoid coupler
(1).
“N” →
→→ → “D”Less than 1.2 sec.
“N” →
→→ → “R”Less than 1.5 sec.