Engine and emission control system SUZUKI GRAND VITARA 1999 2.G Workshop Manual

6E2-44 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Emission Control System
EGR system (if equipped)
EGR SYSTEM INSPECTION (USING SUZUKI SCAN TOOL)
1) Connect SUZUKI scan tool to data link connector (DLC) (1)
with ignition switch OFF.
Special tool
(A) : SUZUKI scan tool
2) Start engine and warm up it to normal operating tempera-
ture.
3) With engine idling (without depressing accelerator pedal),
open EGR valve by using “MISC. TEST” mode.
In this state, according as EGR valve opening increases
engine idle speed drops. If not, possible cause is clogged
EGR gas passage, stuck or faulty EGR valve.
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disconnect EGR valve coupler.
3) Remove wire harness bracket from intake collector.
4) Remove EGR valve (5) and gasket from intake collector.NOTE:
For operation procedure of cartridge, refer to its car-
tridge operator's manual.
1. SUZUKI scan tool display
2. EGR valve opening (0: Close, 100: Full Open)
1. EVAP canister purge valve 4. EGR pipe
2. EVAP canister purge valve hose 6. PCV hose
3. Breather hose

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-45
INSPECTION
1) Check resistance between following terminals of EGR valve
(1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance:
2) Remove carbon from EGR valve gas passage.
3) Inspect valve (2), valve seat (3) and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve (1) assembly.
INSTALLATION
Reverse removal procedure noting the followings.
•Clean mating surface of valve and intake manifold.
•Use new gasket.
EVAP canister
INSPECTION
Terminals Standard resistance
A – B
C – B
F – E
D – E20 – 24 Ω
ΩΩ Ω at 20°C (68°F)
B - valve body
E - valve bodyinfinity (∞
∞∞ ∞)
NOTE:
Do not use any sharp-edged tool to remove carbon.
Be careful not to damage or bend EGR valve, valve seat
and rod.
WARNING:
DO NOT SUCK nozzles on EVAP canister. Fuel vapor
inside EVAP canister is harmful.

6E2-46 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
1) Disconnect vacuum hoses from EVAP canister and remove
EVAP canister.
2) When air is blown into tank pipe, there should be no restric-
tion of flow through purge pipe and air pipe.
If operation differs from above description, EVAP canister
must be replaced.
3) Install EVAP canister and connect hoses to canister.
Vacuum passage
INSPECTION
Start engine and run it at idle speed. Disconnect vacuum hose
from EVAP canister purge valve. With finger placed against hose
disconnected, check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.
TANK PRESSURE CONTROL VALVE INSPECTION
1) Remove tank pressure control valve installed around EVAP
canister.
2) Air should pass through valve smoothly from black side (3) of
tank pressure control valve (1) to orange side (2) when
blown hard.
3) From orange side, even when blown softly, air should come
out of black side.
4) If air doesn’t pass through valve in Step 2) or hard blow is
required in Step 3), replace tank pressure control valve.
5) Plug orange nozzle and apply 26 kPa (20 cmHg) vacuum to
black nozzle. Check that vacuum is held at that level (there is
no leakage).
If vacuum leaks, replace.
6) Install tank pressure control valve.
1. Tank pipe
2. Purge pipe
3. Air pipe
4. Blow air
WARNING:
DO NOT SUCK air through tank pressure control valve.
Fuel vapor inside the valve is harmful.
4. To canister
5. From fuel tank

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-47
PCV System
PCV hose
INSPECTION
Check hoses for connection, leakage, clog, and deterioration.
Replace as necessary.
PCV valve
ON-VEHICLE INSPECTION
1) Disconnect PCV valve from cylinder head cover and plug
head cover hole.
2) Run engine at idle.
3) Place your finger over end of PCV valve (1) to check for vac-
uum. If there is no vacuum, check for clogged valve. Replace
as necessary.
4) After checking vacuum, stop engine and remove PCV valve
(1). Shake valve and listen for the rattle of check needle
inside the valve (1). If valve does not rattle, replace.
5) After checking, connect PCV valve (1), PCV hose and clamp
securely. NOTE:
Be sure to check that there is no obstruction in PCV
valve or its hoses before checking engine idle speed/IAC
duty for obstructed PCV valve or hose hampers its accu-
rate checking.

6E2-48 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
PCV system
PCV HOSE
Check hoses for connection, leakage, clog, and deterioration.
Replace as necessary.
Tightening Torque Specification
Special Tool
NOTE:
Be sure to check that there is no obstruction in PCV
valve or its hoses (6) before checking engine idle speed/
IAC duty for obstructed PCV valve or hose hampers its
accurate checking.
1. EVAP canister purge valve 4. EGR pipe
2. EVAP canister purge valve hose 5. EGR valve
3. Breather hose 6. PCV hose
Fastening partTightening torque
Nm kg-m lb-ft
Heated oxygen sensor 45 4.5 32.5
Fuel pressure regulator bolts 10 1.0 7.5
Fuel pipe union bolts 30 3.0 22.0
Engine coolant temp. sensor 15 1.5 11.0
09912-58441 09912-58431 09912-58490 09912-58421
Pressure gauge Pressure hose 3-way joint & hose Checking tool set
(See NOTE “A”.)

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-49
09917-47010 09930-88521 09931-76011
Vacuum pump gauge Injector test lead Tech 1A kit (SUZUKI scan
tool) (See NOTE “B”.)Mass storage cartridge for
Tech 1A
09931-76030
14/16 pin DLC cable for
Tech 1ATech 2 kit (SUZUKI scan
tool) (See NOTE “C”.)
NOTE:
“A”: This kit includes the following items.
1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder
5. Return hose & clamp, 6. Body attachment-2 & washer, 7. Hose attachment-1
8.Hose attachment-2
“B”: This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable, 5. Test lead/probe
6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
“C”: This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable,
6. DLC loopback adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter,
10. RS232 loopback connector, 11. Storage case, 12. Power supply

6E2-50 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)

AUTOMATIC TRANSMISSION (4 A/T) 7B1-7
Diagnosis
This vehicle is equipped with an electronic transmission control system, which control the automatic shift up and
shift down timing, TCC operation, etc. suitably to vehicle driving conditions.
PCM (ECM) has an On-Board Diagnosis system which detects a malfunction in this system and abnormality of
those parts that influence the engine exhaust emission.
When diagnosing a trouble in the transmission including this system, be sure to have full understanding of the
outline of “ON-BOARD DIAGNOSTIC SYSTEM” and each item in “PRECAUTION IN DIAGNOSING TROUBLE”
and execute diagnosis according to “AUTOMATIC TRANSMISSION DIAGNOSTIC FLOW TABLE” to obtain
correct result smoothly.
On-Board Diagnostic System (Vehicle without
monitor connector)
For automatic transmission control system, PCM (ECM) has fol-
lowing functions. Refer to Section 6-1 for details.
•When the ignition switch is turned ON with the engine at a
stop, malfunction indicator lamp (MIL) (1) turns ON to check
the bulb of the MIL.
•When PCM detects a malfunction in A/T control system
(and/or a malfunction which gives an adverse effect to vehi-
cle emission) while the engine is running, it makes the mal-
function indicator lamp in the meter cluster of the instrument
panel turn ON and stores the malfunction area.
(If it detects that continuously 3 driving cycles are normal
after detecting a malfunction, however, it makes MIL (1) turn
OFF although DTC stored in its memory will remain.)
•It is possible to communicate through DLC (3) by using not
only SUZUKI scan tool (2). (Diagnostic information can be
accessed by using a scan tool (2).)
2 DRIVING CYCLE DETECTION LOGIC
Refer to Section 6-1 for details.
PENDING DTC
Refer to Section 6-1 for details.
FREEZE FRAME DATA
Refer to Section 6-1 for details.