Trans SUZUKI GRAND VITARA 1999 2.G Owner's Manual

6-1-60 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Fig. for Step 2
DTC P0133 HO2S-1 (Bank 1) Circuit Slow Response
WIRING DIAGRAM/CIRCUIT DESCRIPTION
Refer to DTC P0130.
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
Refer to DTC P0130.
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 P0171/
P0172 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 P0133 detected?Substitute a known-good
ECM (PCM) and recheck.HO2S-1 malfunction.

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.

6-1-100 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Evap canister purge system inspection
1) Warm up engine to normal operating temperature.
2) Hoist vehicle so that all wheels rotate freely.
3) Set M/T in “Neutral” or A/T in “P” position and parking brake.
4) Disconnect purge hose (1) from EVAP canister.
5) Place finger against the end of disconnected hose (1) and
check that vacuum is not felt there when engine is running at
idle speed.
6) Release parking brake lever, set transfer in “2H” and M/T in
“1st” or A/T in “L”.
7) Also check that vacuum is felt when engine speed is
increased to higher than about 1,500 r/min. and keep it for 3
min. or more. If check result is not described in steps 5) and
7), check EVAP canister purge valve, wire harness and vac-
uum passage.
Vacuum passage inspection
Start engine and run it at idle speed. With finger placed against
vacuum nozzle (1), check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.
WARNING:
Make sure that transfer is set to “2H” range position for
this check. If it is set to “4H” or “4L” position, front and
rear wheels turn at high speed and a very dangerous sit-
uation may occur.
1

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-107
[A] Fig. for Step 3 / [B] Fig. for Step 4, 6, 7
Fig. for Step 55 VSS visual inspection:
1) Remove VSS referring to “TRANSFER”
section.
2) Check VSS drive and driven gears for
damage and excessive wear.
Are they in good condition?Poor VSS connection or VSS
malfunction.
If connection is OK, substi-
tute a known-good VSS and
recheck.Replace VSS.
6 Speedometer circuit check:
1) With ignition switch OFF, disconnect
G11 coupler from combination meter.
2) With ignition switch ON leaving engine
OFF, check voltage between C20-1 and
C20-2 terminal of VSS coupler.
Is voltage 4 V or more?Substitute a known-good
combination meter and
recheck.Go to Step 7.
7 Cruise control module circuit check (if
equipped):
1) With ignition switch OFF, disconnect
E132 coupler from cruise control mod-
ule.
2) With ignition switch ON leaving engine
OFF, check voltage between C20-1 and
C20-2 terminal of VSS coupler.
Is voltage 4 V or more?Substitute a known-good
cruise control module and
recheck.“BLU/YEL” wire open/
short or faulty ECM
(PCM).
If wire and connection are
OK, substitute a known-
good ECM (PCM) and
recheck.
1. VSS coupler
2.“BLU/YEL” (C20-1) terminal
3.“BLK/YEL” (C20-2) terminal
4.“BLU/BLK” (C20-3) terminal
Step Action Yes No
1. VSS coupler
2. VSS driven gear
3. VSS drive gear

6-1-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P1500 Engine Starter Signal 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 by using scan tool, then start engine and run it for 3 min. or more.
3) Check pending DTC by using scan tool.
TROUBLESHOOTING
1. Engine start switch in ignition (main) switch 2. Starting motor 3. Transmission range sensor (switch) 4. ECM (PCM)
DTC DETECTING CONDITION TROUBLE AREA
•Engine starts even though vehicle is at stop and engine start signal is
not inputted.
or
•Engine start signal is inputted continuously for specified time while
engine is running.
(2 driving cycle detection logic)•Engine start signal 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)
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”
in this section.
2 Check for voltage at terminal C51-1-24 of
ECM (PCM) connector connected, under fol-
lowing condition.
Engine starter signal specification :
While engine cranking : 6 – 14 V
After starting engine : 0 – 1 V
Is voltage as specified?Poor C51-1-24 connection or
intermittent trouble.
Check for intermittent referring to
“INTERMITTENT AND POOR
CONNECTION” in Section 0A.
If wire and connections are OK,
substitute a known-good ECM
(PCM) and recheck.“BLK/YEL” circuit open.

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 MECHANICAL (H27 ENGINE) 6A2-27
12) Disconnect the following electric lead wires :
•Injector wire coupler
•CMP sensor coupler
•Ignition coil couplers
•CKP sensor coupler
•MAP sensor coupler
•TP sensor (1) coupler
•IAC valve (2) coupler
•Earth wire (3) from surge tank
•EVAP canister purge valve coupler
•EGR valve coupler
•Oxygen sensor -1 and -2 couplers referring to “Exhaust Man-
ifold” in this section
•Coolant temperature sensor coupler
•Knock sensor coupler
•Generator wires
•Starter wires
•Oil pressure wire
•P/S pump wire
•Earth wire from generator bracket
•Engine block heater (if equipped)
13) Remove clamps and brackets.
14) Disconnect the following hoses :
•Heater hose from heater water pipe
•Heater hose from water outlet cap
•EVAP canister hose from canister pipe
•Brake booster vacuum hose
15) Remove EVAP canister purge valve (5).
16) Disconnect the following hoses at the location shown in the
figure :
•Fuel feed hose (1) from fuel feed pipe
•Fuel return hose from (2) fuel return pipe
17) Remove P/S pump assembly. Refer to “POWER STEERING
PUMP” in Section 3B1.
18) Remove A/C compressor assembly. Refer to “COMPRES-
SOR ASSEMBLY” in Section 1B.
19) Remove steering shaft lower assembly. Refer to “STEERING
LOWER SHAFT ASSEMBLY” in Section 3C1.
20) Raise vehicle.
21) Remove front differential housing with differential from chas-
sis if equipped. Refer to “DISMOUNTING” in Section 7E.
22) Remove exhaust No.1 pipe. Refer to “EXHAUST MANI-
FOLD” in this section.
23) Remove exhaust manifold stiffener from transmission.
4. Clamp bracket
6. EGR valve
7. Heater hose
2
14
3
75
6

6A2-28 ENGINE MECHANICAL (H27 ENGINE)
24) Remove A/T fluid hose clamps (1) from engine mounting
bracket (2). (for A/T vehicle)
25) Remove clutch housing lower plate.
26) Remove torque converter bolts (for A/T vehicle).
27) Remove starter motor.
28) Lower vehicle.
29) Support transmission. For A/T vehicle, don’t jack under A/T
oil pan to support transmission.
30) Remove bolts and nuts fastening cylinder block and trans-
mission.
31) Install lifting device.
32) Disconnect engine side mounting brackets (1) to engine
mountings.
33) Before lifting engine, check to ensure all hoses, wires and
cables are disconnected from engine.
34) Remove engine assembly from chassis and transmission by
sliding toward front, and then, carefully hoist engine assem-
bly.
INSTALLATION
Reverse removal procedure for installation, noting the following
points.
1) Lower engine assembly into engine compartment. Connect
engine to transmission and engine side mounting brackets to
engine mountings.
2) Tighten nuts fastening engine side mounting brackets and
engine mountings.
Tightening torque
Engine side mounting bracket nut (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)

ENGINE MECHANICAL (H27 ENGINE) 6A2-29
3) Tighten bolts and nuts fastening cylinder block and transmis-
sion to specified torque.
Tightening torque
Transmission to cylinder block bolt and nut (b) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
4) Remove lifting device
5) Tighten torque converter bolts to specified torque (for A/T
vehicle).
Tightening torque
Torque converter bolt (c) :
65 N·m (6.5 kg-m, 47.0 lb-ft)
6) Tighten bolts and nuts of exhaust No.1 pipe (1) to specified
torque.
Tightening torque
Exhaust No.1 pipe bolt and nut (d) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
7) Install front differential housing with differential to chassis if
removed. Refer to “REMOUNTING” in Section 7E.
8) Install steering shaft lower assembly. Refer to “STEERING
LOWER SHAFT ASSEMBLY” in Section 3C1.
9) Install A/C compressor assembly. Refer to “COMPRESSOR
ASSEMBLY” in Section 1B.
10) Install P/S pump assembly. Refer to “POWER STEERING
PUMP” in Section 3B1.
11) Connect hoses, cables and electric wires.
12) Adjust accelerator cable play and A/T throttle cable play (for
A/T vehicle). Refer to “ACCELERATOR CABLE ADJUST-
MENT” and “A/T THROTTLE CABLE ADJUSTMENT (A/T
VEHICLE)” in Section 6E2.
13) Refill engine with engine oil referring to “ENGINE OIL
CHANGE” in Section 0B.
14) Refill cooling system, referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
15) Check to ensure that all fasteners and clamps are tightened.
16) Upon completion of installation, verify that there is no fuel
leakage, coolant leakage, P/S fluid leakage or exhaust gas
leakage at each connection.
1. Bolt (short)
2. Bolt (Long)

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)