stop start SUZUKI GRAND VITARA 1999 2.G Owners Manual

0B-8 MAINTENANCE AND LUBRICATION
6) Replenish oil until oil level is brought to FULL level mark on
dipstick. (oil pan and oil filter capacity). The filler inlet is at
the top of the cylinder head cover.
It is recommended to use engine oil of SE, SF, SG, SH or SJ
grade.
NOTE:
Select the appropriate oil viscosity according to the proper
engine oil viscosity chart [A].
Engine oil specification :
7) Check oil filter and drain plug for oil leakage.
8) Start engine and run it for 3 minutes. Stop it and wait 5 min-
utes before checking oil level. Add oil, as necessary, to bring
oil level to FULL level mark on dipstick.
[A]: Proper engine oil viscosity chart
H27 engine
Oil pan capacity liters (US/lmp pt.) About 5.0 (10.6/8.8)
Oil filter capacity liters (US/lmp pt.) About 0.5 (1.1/0.9)
Others liters (US/lmp pt.) About 0.7 (1.5/1.2)
Total liters (US/lmp pt.) About 6.2 (13.1/10.9)
NOTE:
Engine oil capacity is specified. However, note that the
amount of oil required when actually changing oil may
somewhat differ from the data in the table depending on
various conditions (temperature, viscosity, etc.)
1. Full level mark (hole)
2. Low level mark (hole)

AIR CONDITIONING (OPTIONAL) 1B-19
Refrigerant Recovery, Evacuation and Charging
Operation Procedure for Charging A/C with Refrigerant
WARNING:
Your eyes should not be exposed to refrigerant (liquid).
Any liquid Refrigerant-134a escaping by accident shows a temperature as low as approx. –6 °C
(21.2 °F) below freezing point. Should liquid HFC-134a (R-134a) get into your eyes, it may cause a
serious injury. To protect your eyes against such accident, it is necessary to always wear goggles.
Should it occur that HFC-134a (R-134a) strikes your eye(s), consult a doctor immediately.
–Do not use your hand to rub the affected eye(s). Instead, use quantities of fresh cold water to
splash it over the affected area to gradually raise temperature of such area above freezing point.
–Obtain proper treatment as soon as possible from a doctor or eye specialist.
Should the HFC-134a (R-134a) liquid come into contact with your skin, the affected area should be
treated in the same manner as when skin is frostbitten or frozen.
Refrigerant must not be handled near where welding or steam cleaning is performed.
Refrigerant should be kept at a cold and dark place. It should never be stored where a high temper-
ature is anticipated, e.g. where exposed to direct sun light, close to fire or inside vehicle (including
trunk room).
Avoid breathing fumes produced when HFC-134a (R-134a) is burned. Such fumes may be hazardous
to health.
Start evacuating
Charge proper amount of refrigerant
in gas form
Amount of refrigerant
Dual A/C model : 750±50g (1.65±0.11 lb, 26.45±1.76 oz)
Single A/C model : 500±50g (1.1±0.11 lb, 17.64±1.76 oz)

Inspect and repair connections Stop evacuating
Performance test
Check system for pressure tightness
Charge A/C with refrigerant
Check system for refrigerant leaks and
refrigerant charging quantity
20 minutes
Wait 10 minutes
If gauge shows abnormal conditions

AIR CONDITIONING (OPTIONAL) 1B-23
The initial charging of the A/C system is performed from the high-
pressure side with the engine stopped.
And next, this method must be followed by charging from the low-
pressure side with the engine running.
1) Check to make sure that hoses are routed properly after
evacuating the system.
2) Connect Low-side hose (1) and High side hose (2) of the
manifold gauge set (3) in position. Thus open refrigerant
container valve (4) to purge the charging line.
3) Open the high-pressure side valve (6) and charge refrigerant
to system.
4) After a while, open the low-pressure side valve (5) and close
the high-pressure side valve (6).
5) Start engine and keep engine speed at 1500 rpm. Then,
operate air conditioning.
6) Charge A/C system with refrigerant in vapor state. At this
time, refrigerant container should be held upright.
7) When refrigerant container (3) is emptied, the use following
procedure to replace it with a new refrigerant container (3).
a) Close low pressure valve.
b) Replace empty container (3) with a refrigerant container
which has been charged with refrigerant. When using
refrigerant container tap valve (4), use following procedure
for replacement.
i) Retract needle (1) and remove refrigerant container tap
valve (4) by loosening its plate nut (2).
ii) Install previously-removed refrigerant container tap valve
(4) to a new refrigerant container (3). WARNING:
Make sure that high pressure-side valve is closed
securely.
NOTE:
Dual A/C model must be operated rear A/C system, too.
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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

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-5
Fuel Pressure Relief Procedure
After making sure that engine is cold, relief fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T vehicle), set parking brake, and
block drive wheels.
2) Remove fuel pump relay (1) from its connector.
3) Remove fuel filler cap to release fuel vapor pressure in fuel
tank and then reinstall it.
4) Start engine and run it till it stops for lack of fuel. Repeat
cranking engine 2 – 3 times of about 3 seconds each time to
dissipate fuel pressure in lines. Fuel connections are now
safe for servicing.
5) Upon completion of servicing, install fuel pump relay to relay
box.
Fuel Leakage Check Procedure
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump)
and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pres-
sure to fuel line (till fuel pressure is felt by hand placed on
fuel return hose).
2) In this state, check to see that there are no fuel leakages
from any part of fuel system. CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
[A] : Left hand steering vehicle
[B] : Right hand steering vehicle
2. Fuse box

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-7
WARM-UP CYCLE
A warm-up cycle means sufficient vehicle operation such that the
coolant temperature has risen by at least 22°C (40°F) from
engine starting and reaches a minimum temperature of 70 °C
(160 °F).
DRIVING CYCLE
A “Driving Cycle” consists of engine startup, driving mode where
a malfunction would be detected if present and engine shutoff.
2 DRIVING CYCLE DETECTION LOGIC
The malfunction detected in the first driving cycle is stored in
ECM (PCM) memory (in the form of pending DTC) but the mal-
function indicator lamp does not light at this time. It lights up at the
second detection of same malfunction also in the next driving
cycle.
PENDING DTC
Pending DTC means a DTC detected and stored temporarily at 1
driving cycle of the DTC which is detected in the 2 driving cycle
detection logic.
FREEZE FRAME DATA
ECM (PCM) stores the engine and driving conditions (in the form
of data as shown in the figure) at the moment of the detection of a
malfunction in its memory. This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving conditions
(e.g., whether the engine was warm or not, where the vehicle was
running or stopped, where air/fuel mixture was lean or rich) when
a malfunction was detected by checking the freeze frame data.
Also, ECM (PCM) has a function to store each freeze frame data
for three different malfunctions in the order as the malfunction is
detected. Utilizing this function, it is possible to know the order of
malfunctions that have been detected. Its use is helpful when
rechecking or diagnosing a trouble.
1. 1st, 2nd or 3rd in parentheses here represents which position in the
order the malfunction is detected.
1. TROUBLE CODE
2. COOLANT TEMP.
3. ENGINE SPEED
4. SHORT FT B1
5. SHORT FT B2
6. LONG FT B1
7. LONG FT B2
8. CALC LOAD
9. FUEL SYSTEM B1
10. FUEL SYSTEM B2
11. MAP
12. VEHICLE SPEEDP0100
80 C
750 RPM
– 0.8
– 0.1
– 1.3
– 1.5
20.5
CLOSED
CLOSED
30.6 kPa
0 km/h(1st)
1

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-9
On-Board Diagnostic System (Vehicle with
Monitor Connector)
ECM diagnosis troubles which may occur in the area including the
following parts when the ignition switch is ON and the engine is
running, and indicates the result by turning on of flashing mal-
function indicator lamp (1).
• Heated oxygen sensor (if equipped)
•ECT sensor
•TP sensor
• IAT sensor
• CMP sensor
•MAF sensor
• Knock sensor
• EGR (if equipped)
•VSS
• CPU (Central Processing Unit) of ECM
ECM and malfunction indicator lamp (1) operate as follows.
• Malfunction indicator lamp (1) light when the ignition switch
is turned ON (but the engine at stop) with the diagnosis
switch terminal ungrounded regardless of the condition of
Engine and Emission control system. This is only to check
the malfunction indicator lamp (1) bulb and its circuit.
• If the above areas of Engine and Emission control system is
free from any trouble after the engine start (while engine is
running), malfunction indicator lamp (1) turns OFF.
• When ECM detects a trouble which has occurred in the
above areas, it makes malfunction indicator lamp (1) turn ON
while the engine is running to warn the driver of such occur-
rence of trouble and at the same time it stores the trouble
area in ECM back-up memory. (The memory is kept as it is
even if the trouble was only temporary and disappeared
immediately. And it is not erased unless the power to ECM is
shut off for specified time.)
ECM also indicates trouble area in memory by means of
flashing of malfunction indicator lamp (1) at the time of
inspection. (i.e. when diagnosis switch terminal (2) is con-
nected to ground terminal (3) with a service wire and ignition
switch is turned ON.)
NOTE:
When a trouble occurs in the above areas and disappears
soon while the diagnosis switch terminal is ungrounded
and the engine is running, malfunction indicator lamp (1)
lights and remains ON as the trouble exists but it turns
OFF when the normal condition is restored.

6-1-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
STEP 6. AND 7. RECHECKING AND RECORD OF DTC
Refer to “DTC Check” in this section for checking procedure.
STEP 8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE
Perform basic engine check according to the “ENGINE BASIC INSPECTION FLOW TABLE” first. When the end
of the flow table has been reached, check the parts of the system suspected as a possible cause referring to
“ENGINE DIAGNOSIS TABLE” and based on symptoms appearing on the vehicle (symptoms obtained through
steps of customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or
replace faulty parts, if any.
Engine Basic Inspection Flow Table
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 battery voltage.
Is it 11 V or more?Go to Step 3. Charge or replace battery.
3 Is engine cranked? Go to Step 4. Go to “DIAGNOSIS” in
Section 6H.
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check engine idle speed/IAC duty referring to
“IDLE SPEED/IAC DUTY INSPECTION” in
Section 6E2.
Is check result as specified?Go to Step 6. Go to “ENGINE DIAGNO-
SIS TABLE” in this sec-
tion.
6 Check ignition timing referring to “IGNITION
TIMING INSPECTION” in Section 6F2.
Is check result as specified?Go to “ENGINE DIAGNO-
SIS TABLE” in this sec-
tion.Adjust ignition timing.
7 Check fuel supply as follows :
1) Check to make sure that enough fuel is
filled in fuel tank.
2) Turn ON ignition switch for 3 seconds and
then OFF.
Repeat this a few times.
Is fuel return pressure (returning sounds) felt
from fuel return hose when ignition switch is
turned ON?Go to Step 9. Go to Step 8.
8 Check fuel pump for operating.
1) Was fuel pump operating sound heard from
fuel filler for about 3 seconds after ignition
switch ON and stop?Go to “DIAG. FLOW
TABLE B-3” in this sec-
tion.Go to “DIAG. FLOW
TABLE B-1” in this sec-
tion.
9 Check ignition spark referring to “IGNITION
SPARK TEST” in Section 6E2.
Is it in good condition?Go to Step 10. Go to “DIAGNOSIS” in
Section 6F2.
10 Check fuel injector referring to “Fuel INJECTOR
INSPECTION” in Section 6E2.
Is it in good condition?Go to “ENGINE DIAGNO-
SIS TABLE” in this sec-
tion.Go to “DIAG. FLOW
TABLE B-2” in this sec-
tion.

6-1-16 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Malfunction Indicator Lamp (MIL) Check
1) Turn ON ignition switch (but the engine at stop) and check
that MIL (1) lights.
If MIL does not light up, go to “Diagnostic Flow Table A-1” for
troubleshooting.
2) Start engine and check that MIL turns OFF.
3) If MIL remains ON, and no DTC is stored in ECM (PCM), go
to “Diagnostic Flow Table A-2” for troubleshooting.
Diagnostic Trouble Code (DTC) Check
[Using SUZUKI scan tool]
1) Prepare generic scan tool or SUZUKI scan tool (2).
2) With ignition switch OFF, connect it to data link connector
(DLC) (3) located on underside of instrument panel at
driver’s seat side.
Special tool
(A) : SUZUKI scan tool
3) Turn ignition switch ON and confirm that MIL lights.
4) Read DTC and freeze frame data according to instructions
displayed on scan tool and print them or write them down.
Refer to scan tool operator’s manual for further details.
If communication between scan tool and ECM (PCM) is not
possible, check if scan tool is communicable by connecting it
to ECM (PCM) in another vehicle. If communication is possi-
ble in this case, scan tool is in good condition. Then check
data link connector and serial data line (circuit) in the vehicle
with which communication was not possible.
5) After completing the check, turn ignition switch off and dis-
connect scan tool from data link connector.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-23
Fail-Safe Table
When any of the following DTCs is detected, ECM (PCM) enters fail-safe mode as long as malfunction continues
to exist but that mode is canceled when ECM (PCM) detects normal condition after that.
DTC NO. TROUBLE AREA FAIL SAFE OPERATION
P0100
(No.33, 34)MAF SENSOR• Injector drive time (fuel injection volume) is determined according to
throttle valve opening and engine speed.
• EGR valve stops.
• Air flow of IAC valve is limited.
P0110
(No.23, 25)IAT SENSOR Each control is performed on the basis of 22.1°C intake air temp.
P0115
(No.14, 15)ECT SENSOR• Each control except 4-A/T is performed on the basis of 29.9°C engine
coolant temp.
• 4-A/T control is performed assuming 31°C (engine warmed up) or
higher after 15 min. from engine start.
P0120
(No.21, 22)TP SENSOR• Each control except 4-A/T is performed on the basis of 124.5° throttle
valve opening.
• 4-A/T control is performed on the basis of 0° throttle valve opening.
P0460 FUEL LEVEL SENSOR Each control is performed in the basis of full fuel level.
P0500VEHICLE SPEED
SENSORAir flow of IAC valve is limited.
P1450BAROMETRIC
PRESSURE SENSOREach control is performed based on 760 mmHg barometric pressure.
P0705 TR SWITCH A/T control is performed in priority order of L, 2, N, D, R and P.
P0720OUTPUT SPEED
SENSOR CIRCUIT
MALFUNCTIONA/T control is performed by using signal from VSS.
P0753SHIFT SOLENOID
A (#1)• A/T control using 3rd gear is performed when D range, 1st, or 2nd
gear is used.
• TCC solenoid OFF
P0758SHIFT SOLENOID
B (#2)• A/T control using 4th gear is performed when D range, 2nd or 3rd
gear is used.
• When both shift solenoids A (#1) and B (#2) failed simultaneously,
A/T control using 4th gear is always performed in D range.
• TCC solenoid OFF
P0743TCC (Lock-up)
SOLENOIDTCC (Lock-up) solenoid OFF