immobilizer SUZUKI GRAND VITARA 1999 2.G Owners Manual

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND
DIFFERENTIAL0A7A1
General Information0A
0B7B1
Maintenance and Lubrication0B
Manual Transmission7A1
7C1
HEATING AND AIR CONDITIONING
Automatic Transmission7B1
1A7D
Heater and Ventilation1A
Clutch7C1
1B7E
Air Conditioning1B
Transfer7D7F
STEERING, SUSPENSION, WHEELS
AND TIRESDifferential (Front)7E
3
Differential (Rear)7F
3A8
Steering, Suspension, Wheels and Tires3 ELECTRICAL SYSTEM3B18A
Front End Alignment3A
Electrical System8
3C18B
Power Steering (P/S) System3B1
Wiring Diagram8A3D8C
Air Bag Steering Wheel and Column3C1
Lightening System8B3E8D
Front Suspension3D
Instrumentation / Driver Information8C
3F8E
Rear Suspension3E
Windows, Mirrors, Security and Lock8D
8G
Wheels and Tires3F
Cruise Control System8E
4A2
DRIVE SHAFT AND PROPELLER SHAFT
Immobilizer control system (if equipped)8G4B9
Front Drive Shaft / Shaft Bearing,
Oil Seal4A2BODY SERVICE
Body Service9
510
Propeller Shaft4B RESTRAINT SYSTEM
5A10A
BRAKE SYSTEM
Restraint System10
5B10B
Brakes5
Seat Belt10A
5C
Brake Pipe / Hose / Master Cylinder5A
Air Bag System10B
5E2
Front Brake5B
Parking and Rear Brake5C
6-1
Antilock Brake System (ABS)5E2
6A2
ENGINE
6B
General Information and
Diagnosis (H27 Engine)6-1
6C
6E2
Engine Mechanical (H27 Engine)6A2
6F2
Engine Cooling6B
6G
Engine Fuel6C
6H
Engine and Emission Control System
(SFI For H27 Engine)6E2
6K
Ignition System (H27 Engines)6F2
Cranking System6G
Charging System6H
Exhaust System6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-1
6-1
SECTION 6-1
ENGINE GENERAL INFORMATION AND
DIAGNOSIS (H27 ENGINE)
CONTENTS
General Information ...................................... 6-1-3
Statement of Cleanliness and Care ............ 6-1-3
General Information on Engine Service ...... 6-1-3
Precaution on Fuel System Service ............ 6-1-4
Fuel Pressure Relief Procedure .................. 6-1-5
Fuel Leakage Check Procedure .................. 6-1-5
Engine Diagnosis .......................................... 6-1-6
General Description .................................... 6-1-6
On-Board Diagnostic System (Vehicle
without Monitor Connector) ......................... 6-1-6
On-Board Diagnostic System (Vehicle with
Monitor Connector) ..................................... 6-1-9
Precaution in Diagnosing Trouble ............. 6-1-10
Engine Diagnostic Flow Table ................... 6-1-11
Malfunction Indicator Lamp (MIL) Check... 6-1-16
Diagnostic Trouble Code (DTC) Check ..... 6-1-16
Diagnostic Trouble Code (DTC) Clearance 6-1-17
Diagnostic Trouble Code (DTC) Table ...... 6-1-18For A/T system (Refer to Section 7B1
for diagnosis)......................................... 6-1-21
For immobilizer control system (Refer to
Section 8G for diagnosis) ...................... 6-1-22
Fail-Safe Table.......................................... 6-1-23
Scan Tool Data ......................................... 6-1-24
Scan tool data definitions ...................... 6-1-27
Engine Diagnosis Table ............................ 6-1-31
Inspection of PCM (ECM) and its Circuits. 6-1-36
Table A-1 Malfunction Indicator Lamp
Circuit Check – Lamp Does Not Come
“ON” or Dims at Ignition Switch ON
(But Engine at Stop).................................. 6-1-43
Table A-2 Malfunction Indicator Lamp
Circuit Check – Lamp Remains “ON” after
Engine Starts ............................................ 6-1-44
Table A-3 Malfunction Indicator Lamp
Check – MIL Flashes at Ignition Switch
ON (Vehicle with Monitor Connector) ....... 6-1-45 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
Whether following systems (parts) are used in the particular vehicle or not depends on specifications.
Be sure to bear this in mind when performing service work.
Monitor connector
CKP sensor
MAP sensor
EGR valve
Heated oxygen sensor or CO adjusting resistor
Three way catalytic converter, Warm-up three way catalytic converter

6-1-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Priority of Freeze Frame Data
ECM (PCM) has 4 frames where the freeze frame data can be stored. The first frame stores the freeze frame
data of the malfunction which was detected first. However, the freeze frame data stored in this frame is updated
according to the priority described below. (If malfunction as described in the upper square “1” below is detected
while the freeze frame data in the lower square “2” has been stored, the freeze frame data “2” will be updated by
the freeze frame data “1”.)
In the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the mal-
function is detected. These data are not updated regardless of the priority.
Shown in the table below are examples of how freeze frame data are stored when two or more malfunctions are
detected.
Freeze Frame Data Clearance
The freeze frame data is cleared at the same time as clearance of DTC.
DATA LINK CONNECTOR (DLC)
DLC (1) is in compliance with SAEJ1962 in its installation posi-
tion, the shape of connector and pin assignment.
K line of ISO 9141 is used for SUZUKI scan tool or generic scan
tool to communicate with ECM (PCM), ABS control module and
Air bag SDM. SUZUKI serial data line is used for SUZUKI scan
tool to communicate with Immobilizer control module. PRIORITY FREEZE FRAME DATA IN FRAME 1
1Freeze frame data at initial detection of malfunction among misfire detected (P0300-P0306), fuel
system too lean (P0171, P0174) and fuel system too rich (P0172, P0175)
2 Freeze frame data when a malfunction other than those in “1” above is detected
FRAME 1 FRAME 2 FRAME 3 FRAME 4
FREEZE FRAME
DATA to be updated1st FREEZE
FRAME DATA2nd FREEZE
FRAME DATA3rd FREEZE
FRAME DATA
No malfunction No freeze frame dataNo freeze frame
dataNo freeze frame
dataNo freeze frame
data
MALFUNCTION
DETECTED ORDER
1P0110 (IAT)
detectedData at P0110
detectionData at P0110
detectionNo freeze frame
dataNo freeze frame
data
2P0171 (Fuel sys-
tem) detectedData at P0171
detectionData at P0110
detectionData at P0171
detectionNo freeze frame
data
3P0300 (Misfire)
detectedData at P0171
detectionData at P0110
detectionData at P0171
detectionData at P0300
detection
4P0301 (Misfire)
detectedData at P0171
detectionData at P0110
detectionData at P0171
detectionData at P0300
detection
2. B+
3. SUZUKI Serial data line
4. K line of ISO 9141
5. Body ground
6. ECM ground

6-1-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DATA LINK CONNECTOR (DLC)
DLC (1) is in compliance with SAEJ1962 in its installation posi-
tion, the shape of connector and pin assignment.
K line of ISO 9141 is used for SUZUKI scan tool to communicate
with ECM (PCM), ABS control module and air bag SDM. SUZUKI
serial data line is used for SUZUKI scan tool to communicate with
Immobilizer control module.
Precaution in Diagnosing Trouble
• Don’t disconnect couplers from ECM (PCM), battery cable from battery, ECM (PCM) ground wire harness
from engine or main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in
ECM (PCM) memory. Such disconnection will erase memorized information in ECM (PCM) memory.
• Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI
scan tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to
have good understanding as to what functions are available and how to use it.
• Priorities for diagnosing troubles (Vehicle without monitor connector)
If two or more diagnostic trouble codes (DTCs) are stored, proceed to the flow table of the DTC which was
detected earliest in the order and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
– Diagnostic trouble codes (DTCs) other than DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too
rich), DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire detected) and DTC P0400 (EGR
flow malfunction)
– DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too rich) and DTC P0400 (EGR flow malfunction)
– DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire detected)
• Be sure to read “PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE” in Section 0A before inspection
and observe what is written there.
• ECM (PCM) Replacement
When substituting a known-good ECM (PCM), check for following conditions. Neglecting this check may
cause damage to a known-good ECM (PCM).
– Resistance value of all relays, actuators is as specified respectively.
– MAF sensor, MAP sensor and TP sensor are in good condition and none of power circuits of these sen-
sors is shorted to ground.
2. B+
3. SUZUKI Serial data line
4. K line of ISO 9141
5. Body ground
6. ECM ground

6-1-22 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
For immobilizer control system (Refer to Section 8G for diagnosis)
P0753
(No.61)
(No.62)Shift solenoid A (#1) electricalMonitor signal OFF is detected when
shift solenoid A (#1) is ON or monitor
signal ON is detected when it is OFF.1 driving
cycleNot
applicable
P0756Shift solenoid B (#2) perfor-
mance or stuck offGear change control from PCM to A/T
does not agree with actual gear posi-
tion of A/T.2 driving
cyclesNot
applicable
P0758
(No.63)
(No.64)Shift solenoid B (#2) electricalMonitor signal OFF is detected when
shift solenoid B (#2) is ON or monitor
signal ON is detected when it is OFF.1 driving
cycleNot
applicable
P18754WD low switch circuit mal-
functionDifference between vehicle speed
detected by VSS and vehicle speed
detected by output speed sensor and
compensated by 4WD low switch is
larger than specification.2 driving
cyclesNot
applicable DTC NO. DETECTED ITEMDETECTING CONDITION
(DTC will set when detecting : )MIL
(vehicle
without
monitor
connector)MIL
(vehicle
with
monitor
connector)
DTC NO. DETECTED ITEMDETECTING CONDITION
(DTC will set when detecting : )MIL
(vehicle
without
monitor
connector)MIL
(vehicle
with
monitor
connector)
P1620
(No.84)ECU code not registered
Refer to Section 8G P1621
(No.83)NO ECU code transmitted
from Immobilizer Control Mod-
ule
P1622
(No.82)Fault ECM
P1623
(No.81)ECU code not matched
NOTE:
DTC NO. with (*) is detected only vehicle without monitor connector.
DTC No. with (**) is detected only vehicle with monitor connector.
For ( ) marked No. in DTC column, it is used for vehicle with monitor connector.
DTC No.12 appears when none of the other codes is identified.

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)

BODY ELECTRICAL SYSTEM 8-1
6F1
6F2
6G
6H
6K
7A
8
6K
7C1
7D
7E
7F
8A
8D
8E
9
10
10A
10B
SECTION 8
BODY ELECTRICAL SYSTEM
Wiring System
(Harnesses, Connectors, Fuses, Relay, Switches, Grounds, System Circuit Diagram) .......... Section 8A
Lighting System .............................................................................................................................. Section 8B
Instrumententation and Driver Information .................................................................................. Section 8C
Windows, Mirrors, Security and Locks ......................................................................................... Section 8D
Immobilizer Control System............................................................................................................Section 8F
CONTENTS
General Description .......................................... 8-3

WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
For the descriptions (items) not found in this section, refer to the same section of the Service Manual
mentioned in FOREWORD of this manual.

8C-2 INSTRUMENTATION/DRIVER INFORMATION
General Description
Combination Meter
1. Tachometer 8. Multifunction indicator light 15. Charge warning light
2. Speedometer 9. Turn signal pilot light (RH) 16. Brake fluid level, parking brake and EBD warning light
3. Fuel level meter 10. AIR BAG warning light 17. POWER indicator light (A/T vehicle only)
4. Engine coolant temperature meter 11. O/D OFF light (A/T vehicle only) 18. CRUISE indicator light
5. Turn signal pilot light (LH) 12. Fasten seat belt light (if equipped) 19. Immobilizer warning light (if equipped)
6. 4WD indicator 13. High beam light 20. Shift position indicator (A/T vehicle, if equipped)
7. ABS warning light 14. Engine oil pressure warning light

INSTRUMENTATION/DRIVER INFORMATION 8C-3
COMBINATION METER INTERNAL CIRCUITS
COMBINATION METER COUPLERS
[A] : Coupler A [B] : Coupler B [C] : Coupler C
1. To Cruise control module (if equipped) GRY/YEL 1. To door switch (drive side) BLK/BLU 1. To ground BLK
2. Blank–2. To transmission range switch
(A/T vehicle only, if equipped) LGRN/BLU 2. To ECM (PCM for A/T vehicle) BRN
3. To ignition switch BLK/WHT 3. To transmission range switch
(A/T vehicle only, if equipped) 2GRN/ORN 3. To ignition switch PPL/RED
4. Blank–4. To transmission range switch
(A/T vehicle only, if equipped) DYEL/GRN 4. To brake fluid level switch RED/BLK
5. To ABS control module (if equipped) BLU/ORN 5. To transmission range switch
(A/T vehicle only, if equipped) NORN/BLU 5. To parking brake switch PPL
6. To PCM (A/T vehicle only) GRY/BLU 6. To transmission range switch
(A/T vehicle only, if equipped) PORN/GRN 6. To seat belt switch GRY/RED
7. To ABS control module (if equipped) BRN 7. To transmission range switch
(A/T vehicle only, if equipped) RRED 7. To generator WHT/RED
8. To VSS BLU/YEL 8. To illumination control module RED/GRN 8. To engine oil pressure switch YEL/BLK
9. To combination switch GRN/RED 9. To PCM (A/T vehicle only) WHT/BLK 9. To combination switch RED/YEL
10. To air bag SDM BLU 10. To ECT sensor YEL/WHT 10. To ignition switch BLU/RED
11. To main fuse WHT/BLU 11. To fuel level gauge BLU/WHT
12. To fuse box WHT 12. To ground BLU/YEL
13. To combination switch RED 13. To combination switch GRN/YEL
14. To immobilizer control module
(if equipped)PPL
15. To ECM (PCM for A/T vehicle) PPL/YEL
16. To ECM (PCM for A/T vehicle) ORN/BLK
P R N D 2 LCRUISEPOWER4WDSPEED
METERTACHO
METERFUEL
METERTEMP.
METER
A-11
A-13 A-8 B-12 B-11 C-8 A-15 A-6 A-1 B-9 A-16 A-14 C-7 C-1 A-10 C-3 C-4 C-5 A-7 A-5 B-8 B-1B-10 C-2 A-12 A-3B-13 B-2 B-3 B-4 B-5 B- B-6 C-9 C-10 A-9ABS circuit EBD circuit Air bag circuit
or ABS or BRAKE
if equipped
or CHECK
ENGINE
NOTE:
Terminal arrangement of coupler viewed from harness side.

AIR BAG SYSTEM 10B-21
Table E - SDM Cannot Communicate through The Serial Data Circuit
WIRING DIAGRAM
TABLE TEST DESCRIPTION
STEP 1 : An improper connection to the data link connector (DLC) will prevent communications from being
established.
STEP 2 : This test checks whether it is possible to communicate with other control module.
STEP 3 : This test checks for an open in “PPL/RED” circuit (in air bag harness).
[A]: Air bag harness 5.“AIR BAG” fuse 10.“AIR BAG” monitor coupler
1. From main fuse 6. Connection detection pin 11. Ground for air bag system
2. Ignition switch 7. SDM 12. Ground on body
3.“IG METER” fuse 8. DLC 13. Ground on Engine block
4.“AIR BAG” warning lamp in combination lamp 9. To ECM, TCM (if equipped) and ABS con-
trol module (if equipped)14. Immobilizer control module (if equipped)
14
1PPL/WHT
BLK
BLK/YEL WHT
10
11
PPL
BLK
“Q04”Q01-15
Q01-17DNS
GND7
[A]5V
812
13
1
2
34 BLK/BLUBLU/BLK BLU/RED
BLK/WHT BLK/WHTBLUBLU
6
PPL/REDPPL/RED
9
Q01-2
Q01-20L1
L2
SDLLA
Q01-4
IG
12V
“G27”
“Q02”
5
CAUTION:
Be sure to perform AIR BAG DIAGNOSTIC SYSTEM CHECK before starting diagnosis according to
flow table.
When measurement of resistance or voltage is required in this table, use a tester along with a cor-
rect terminal adapter from special tool (Connector test adapter kit).
When a check for proper connection is required, refer to INTERMITTENT AND POOR CONNEC-
TIONS in this section.
If there is open circuit in the air bag wire harness, connector or terminal is found damaged, replace
the wire harness, connector and terminal as an assembly.