Throttle SUZUKI GRAND VITARA 1999 2.G Service Manual

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

6E2-14 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Accelerator Cable Adjustment
1) With throttle valve closed, check accelerator pedal play
which should be within following specification.
If measured value is out of specification, adjust accelerator
cable (1) to specification with cable adjusting nut (2).
Accelerator pedal play “a”:
2 – 5 mm (0.08 – 0.20 in.)
2) With accelerator pedal depressed fully, check clearance
between throttle lever (2) and lever stopper (1) (throttle body)
which should be within following specification.
If measured value is out of specification, adjust it to specifi-
cation by changing height of pedal stopper bolt (3).
Clearance “b” between throttle lever and lever stopper
(throttle body) (with accelerator pedal depressed fully):
0.5 – 2.0 mm (0.02 – 0.07 in.)
A/T Throttle Cable Adjustment (A/T Vehicle)
1) Make sure that accelerator cable is adjusted as specified.
2) With throttle valve closed, check clearance “c” which should
be within the following specification.
If it is out of specification, adjust A/T throttle cable (1) by
turning cable adjusting nut (2).
A/T throttle cable installing position specification clear-
ance “c”:
0.8 – 1.5 mm (0.03 – 0.06 in.)

6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Air Intake System
Throttle body
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Drain cooling system.
3) Remove strut tower bar.
4) Disconnect accelerator cable (1) and or A/T throttle cable (2)
from throttle body.
5) Disconnect water hoses from throttle body.
1. Throttle body 4. Water hose
2. Intake collector 5. MAF sensor
3. Breather hose 6. TP sensor

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-19
6) Remove surge tank cover.
Remove intake air pipe (1) and surge tank pipe (2).
7) Disconnect connectors of TP sensor and IAC valve.
8) Disconnect ground wire at connector.
9) Remove clamp bracket (1) and harness clamps from intake
collector.
10) Disconnect connectors of EVAP canister purge valve (1),
MAP sensor and EGR valve (5).
11) Disconnect PCV valve (6) from cylinder head with hose con-
nected, breather hose (3) from cylinder head and EVAP can-
ister purge valve hose (2).
12) Detach EGR pipe (4) from intake air collector.
13) Remove throttle body (3) and intake collector (2) from intake
manifold (1).
14) Disconnect hoses of PCV from throttle body.
15) Remove throttle body from intake collector.
NOTE:
TP sensor (4), or other components containing rubber
must not be placed in a solvent or cleaner bath. A
chemical reaction will cause these parts to swell,
harden or get distorted.
Don’t put drills or wires into passages for cleaning. It
causes damages in passages.

6E2-20 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
CLEANING
Clean throttle body bore and bypass air passages (1) by blowing
compressed air.
INSTALLATION
1) Clean mating surfaces and install throttle body gasket to
intake collector (1) with new gasket (2).
2) Install throttle body to intake collector and tighten bolts.
3) Connect PCV hose.
4) Install throttle body and intake collector to intake manifold
with new intake collector gaskets.
5) Install EGR pipe with new gaskets.
6) Connect breather hose and EVAP canister purge valve hose
and install PCV valve to cylinder head.
7) Connect connectors of EVAP canister purge valve, MAP
sensor and EGR valve.
Fix wire harness with clamps.
8) Install clamp bracket to intake collector.
9) Connect ground wire connector.
10) Connect connectors of TP sensor, ground and IAC valve.
11) Install surge tank pipe to intake manifold with new gaskets
and intake air pipe to throttle body. Install surge tank cover.
12) Connect engine coolant hoses to throttle body.
13) Connect accelerator cable and A/T throttle cable (A/T).CAUTION:
Do not blow compressed air through bypass air pas-
sage with IAC valve installed to throttle body. This will
cause IAC valve to malfunction.
TP sensor, idle air control valve or other components
containing rubber must not be places in a solvent or
cleaner bath.
A chemical reaction will cause these parts to swell,
harden or get distorted.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-21
14) Install strut tower bar (1) and tighten bolts.
15) Refill cooling system.
16) Connect negative (–) cable at battery.
17) Adjust accelerator cable and A/T throttle cable, refer to
“ACCELERATOR CABLE ADJUSTMENT” and “A/T THROT-
TLE CABLE ADJUSTMENT” in this section.
Idle air control valve (IAC valve)
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disconnect IAC valve connector.
3) Remove IAC valve (1) from throttle body.
INSPECTION
1) Disconnect connector from IAC valve.
2) Check each coil of IAC valve for resistance.
If resistances is out of specification, replace.
IAC valve resistance:
Terminals Resistance
Between “1” and “2”
25.5 - 33.5 Ω
ΩΩ Ω Between “3” and “2”
Between “4” and “5”
Between “6” and “5”

6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
3) Remove air cleaner outlet hose and remove IAC valve from
throttle body.
4) Connect connector to IAC valve.
5) Check that plunger (1) of IAC valve moves once and then
stops as soon as ignition switch (2) is turned OFF after
cranking engine for 2 sec.
If plunger (1) of IAC valve does not operate at all, check wire
harnesses for open and short. If wire harnesses are in good
condition, replace IAC valve and recheck.
INSTALLATION
1) Install new O-ring to throttle body.
2) Install IAC valve to throttle body.
3) Tighten IAC valve screws to specified torque.
Tightening torque
IAC valve screw (a) : 3.5N·m (0.35 kg-m, 2.5 lb-ft)
4) Connect IAC valve connector securely.
5) Connect negative (–) cable to battery.
Fast idle air valve
1) Disconnect IAC valve coupler with ignition switch OFF.
2) Check that with cold engine started, as cooling water tem-
perature rises, engine idle speed reduces gradually.
If check result is as described above, fast idle air valve is in
good condition.
If not, fast idle air valve, air passage or coolant passage is
faulty. NOTE:
This check should be performed by two people, one per-
son operates ignition switch while the other checks
plunger operation.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-27
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6-1.
2) Remove throttle body intake collector, refer to “THROTTLE
BODY” in this section.
3) Disconnect fuel feed hose (1) and fuel return hose (2).
4) Disconnect vacuum hose (4) and fuel return hose from fuel
pressure regulator (5).
5) Remove fuel feed pipe (8) and fuel connect pipe (7) from
delivery pipes (6) (right and left).
6) Disconnect connector (3) from each injector.
7) Remove delivery pipes (1) (right and left) from intake mani-
fold.
8) Remove fuel injector(s).
INSPECTION
CAUTION:
A small amount of fuel may be released when it is from
delivery pipe.
Place a shop cloth under delivery pipe so that released
fuel is absorbed in it.
WARNING:
As fuel is injected in this inspection, perform in a well
ventilated area and away from open flames.
Use special care to prevent sparking when connecting
and disconnecting test lead to and from battery.

6E2-30 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
5) Install fuel connect pipe (1) and tighten union bolts to speci-
fied torque with new gaskets (3).
Tightening torque
Fuel connect pipe union bolt
(b) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
6) Install fuel feed pipe (2) and tighten union bolt to specified
torque with new gaskets.
Tightening torque
Fuel feed pipe union bolt
(a) : 30 N·m (3.0 kg-m, 22.0 lb-ft)
7) Connect vacuum hose (5) and fuel return hose (4) to fuel
pressure regulator.
8) Connect fuel feed hose (1) and fuel return hose (2).
9) Connect connectors of injector wire (3) to injectors.
10) Install throttle body and intake collector, refer to “THROTTLE
BODY” in this section.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks around fuel line connection.