SUZUKI GRAND VITARA 1999 2.G Owners Manual

6-1-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool and warm up
engine completely.
3) Increase vehicle speed to 55 – 60 km/h (35 – 40 mph).
4) Keep driving above vehicle speed for 7 min. or more.
5) Increase vehicle speed to 100 – 110 km/h (60 – 70 mph).
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting and then stop vehicle.
7) Check if pending DTC exists by using scan tool. If not, check if EGR system monitoring test has completed
by using scan tool. If not in both of above checks (i.e., no pending DTC and EGR system monitoring test not
completed), check vehicle conditions (environmental) and repeat Steps 3) through 6).DTC DETECTING CONDITION TROUBLE AREA
During deceleration (engine speed high with closed
throttle position) in which fuel cut is involved, difference
in intake manifold pressure between when EGR valve is
opened and when it is closed is smaller than specified
value.
(2 driving cycle detection logic)•EGR valve
• EGR passage
• Manifold absolute pressure sensor
•ECM (PCM)
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.
NOTE:
Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
1. Vehicle speed km/h (mph)
2. Step

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-91
TROUBLESHOOTING
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 Is there DTC P0403 (EGR circuit malfunction)? Go to DTC P0403 Diag.
Flow Table.Go to Step 3.
3 Do you have SUZUKI scan tool? Go to Step 4. Go to Step 6.
4 EGR valve operation check :
1) With ignition switch OFF, install SUZUKI
scan tool.
2) Check EGR system referring to Section
6E2.
Is it in good condition?Go to Step 5. Go to Step 6.
5 MAP sensor check :
1) Check MAP sensor for performance refer-
ring to Section 6E2.
Is check result satisfactory?Intermittent trouble or
faulty ECM (PCM). Check
for intermittent referring to
“INTERMITTENT AND
POOR CONNECTION” in
Section 0A.Repair or replace.
6 EGR valve power supply circuit check :
1) With ignition switch OFF, disconnect EGR
valve coupler.
2) With ignition switch ON, check voltage
between C04-2 and ground, C04-5 and
ground.
Is each voltage 10 – 14 V?Go to Step 7. Faulty “BLU/BLK” wire.
7 EGR valve stepper motor coil circuit check :
1) With ignition switch OFF, connect EGR
valve coupler and disconnect ECM (PCM)
couplers.
2) Check resistance between C51-3-4 and
C51-2-12, C51-2-13, C51-2-14, C51-2-15.
Is each resistance 20 – 24 Ω at 20°C (68°F)?Go to Step 8. Faulty EGR valve.
8 MAP sensor check :
1) Check MAP sensor for performance refer-
ring to Section 6E2.
Is check result satisfactory?EGR passage clogged or
EGR valve malfunction.
If all above are OK, inter-
mittent trouble or faulty
ECM (PCM).
Check for intermittent
referring to “INTERMIT-
TENT AND POOR CON-
NECTION” in Section 0A.Repair or replace.

6-1-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P0403 (DTC No.51) Exhaust Gas Recirculation Circuit Malfunction
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Start engine and run it for 10 sec.
4) Check DTC by using scan tool.
1. Main fuse 4. ECM (PCM)
2. Main relay
3. EGR valve
DTC DETECTING CONDITION TROUBLE AREA
High voltage is detected at EGR valve stepping motor
electrical circuit for specified time continuously.
(Circuit open or short).EGR valve (stepping motor) or its circuit ECM
(PCM)
NOTE:
Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION PRO-
CEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-93
TROUBLESHOOTING
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 EGR valve check :
1) With ignition switch OFF, disconnect connec-
tor from EGR valve.
2) Check for proper connection to EGR valve at
each terminal.
3) If OK, check EGR valve for resistance refer-
ring to “EGR VALVE INSPECTION” in Sec-
tion 6E2.
Is check result as specified?Go to Step 3. EGR valve malfunction.
3 Wire harness check :
1) Connect connector to EGR valve.
2) Remove ECM (PCM) cover and disconnect
connector from ECM (PCM).
3) Check for proper connection to ECM (PCM)
at system related terminals.
4) If OK, check for resistance between the fol-
lowing terminals of ECM (PCM) connector
disconnected.
EGR valve resistance :
C51-2-13 and C51-3-4, C51-2-14 and C51-3-4,
C51-2-15 and C51-3-4, C51-2-12 and C51-3-4 :
20 – 24
Ω
ΩΩ Ω at 20°C (68°F)
C51-2-13 and ground, C51-2-14 and ground,
C51-2-15 and ground, C51-2-12 and ground :
Infinity (
∞
∞∞ ∞)
Is check result as specified?Intermittent trouble or
faulty ECM (PCM).
Recheck referring to
“INTERMITTENT AND
POOR CONNECTION” in
Section 0A.“BLU/BLK”, “LT GRN”,
“LT GRN/WHT” “LT GRN/
YEL” or “LT GRN/RED”
circuit open or shorted to
ground.

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)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-95
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Increase vehicle speed to 80 – 90 km/h (50 – 56 mph).
4) Keep above vehicle speed for 5 min. or more (Throttle valve opening is kept constant in this step).
5) Stop vehicle and check if pending DTC exists by using scan tool. If not, check if catalyst monitoring test has
completed by using scan tool. If not in both of above checks (i.e., no pending DTC and catalyst monitoring
test not completed), check vehicle condition (environmental) and repeat Step 3) through 5).
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.
NOTE:
Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
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 Exhaust system visual inspection :
1) Check exhaust system for leaks, damage
and loose connection.
Is it in good condition?Go to Step 3. Repair or replace.
3 HO2S-2 output voltage check :
1) Check output voltage of HO2S-2 referring
Step 2 of DTC P0136 Diag. Flow Table.
Is check result satisfactory?Replace warm up three
way catalytic converter.Check “RED/BLK” and
“GRY/YEL” wires for open
and short, and connec-
tions for poor connection.
If wires and connections
are OK, replace HO2S-2.

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)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-97
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Increase vehicle speed to 80 – 90 km/h (50 – 56 mph).
4) Keep above vehicle speed for 5 min. or more (Throttle valve opening is kept constant in this step).
5) Stop vehicle and check if pending DTC exists by using scan tool. If not, check if catalyst monitoring test has
completed by using scan tool. If not in both of above checks (i.e., no pending DTC and catalyst monitoring
test not completed), check vehicle condition (environmental) and repeat Step 3) through 5).
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.
NOTE:
Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
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 Exhaust system visual inspection :
1) Check exhaust system for leaks, damage
and loose connection.
Is it in good condition?Go to Step 3. Repair or replace.
3 HO2S-2 output voltage check :
1) Check output voltage of HO2S-2 referring
Step 2 of DTC P0156 Diag. Flow Table.
Is check result satisfactory?Replace warm up three
way catalytic converter.Check “RED/YEL” and
“GRY/YEL” wires for open
and short, and connec-
tions for poor connection.
If wires and connections
are OK, replace HO2S-2.

6-1-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction
SYSTEM/WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1. Main fuse 3. EVAP canister purge valve
2. Main relay 4. ECM (PCM)
DTC DETECTING CONDITION TROUBLE AREA
Monitor signal of EVAP canister purge valve is different
from command signal. (Circuit open or short)
(2 driving cycle detection logic)• EVAP canister purge valve and its circuit
•ECM (PCM)
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.
NOTE:
Check to make sure that following condition is satisfied when using the “DTC Confirmation Proce-
dure.”
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-99
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Start engine and warm up it completely.
4) Increase vehicle speed to 55 km/h (35 mph) or more.
5) Keep driving above vehicle speed for 20 min or more (Change of vehicle speed is permitted in this step).
6) Release accelerator pedal, stop vehicle and run engine at speed for 2 min.
7) Check DTC and pending DTC by using scan tool.
TROUBLESHOOTING
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 Check EVAP canister purge system for opera-
tion referring to “EVAP CANISTER PURGE
SYSTEM INSPECTION” in this section.
Is check result satisfactory?Intermittent trouble or
faulty ECM (PCM).
Check for intermittent
referring to “INTERMIT-
TENT AND POOR CON-
NECTION” in Section 0A.Go to Step 3.
3 Check EVAP canister purge valve for resistance
referring to “EVAP CANISTER PURGE VALVE
INSPECTION” in this section.
Is resistance as specified?“GRN/BLK” or “BLU/BLK”
circuit open or short.
If wire and connections
are OK, substitute a
known-good ECM (PCM)
and recheck.Replace EVAP canister
purge valve.