power steering SUZUKI GRAND VITARA 2001 2.G User Guide

6A2-12 ENGINE MECHANICAL (H27 ENGINE)
7) Reverse removal procedure to install front propeller shaft if
removed.
When installing propeller shaft, align match mark (1).
Use following specification to torque universal joint flange.
Tightening torque
Universal joint flange bolt (c) :
55 N·m (5.5 kg-m, 40.0 lb-ft)
8) Connect EGR pipe to left (No.1) bank exhaust manifold (1).
9) Install exhaust manifold covers (2).
10) Install oil level gauge guide (3) using new O-ring.
11) Install P/S pump assembly (4) if it was removed. Refer to
“POWER STEERING PUMP” in Section 3B1.
12) Adjust P/S pump drive belt tension, refer to “POWER
STEERING BELT CHECK AND ADJUSTMENT” in Section
3B1.
13) Connect oxygen sensor lead wire couplers.
Be sure to clamp its lead wires.
14) Connect negative (–) cable to battery.
Upon completion of installation, start engine and check that
no exhaust gas leakage exists.
1
4
32
1. HO2S-1 (Green connector)
2. HO2S-2 (Black connector)

6A2-20 ENGINE MECHANICAL (H27 ENGINE)
12) Install oil pan and oil pump strainer.
Refer to “OIL PAN AND OIL PUMP STRAINER” in this sec-
tion.
13) Install cylinder head cover.
Refer to “CYLINDER HEAD COVER” in this section.
14) Install exhaust manifold.
Refer to “EXHAUST MANIFOLD” in this section.
15) Install radiator outlet pipe, radiator, cooling fan and water
hose.
Refer to “COOLING WATER PIPES OR HOSES”, “RADIA-
TOR” and “COOLING FAN AND FAN CLUTCH” in Section
6B.
16) Install throttle body and intake manifold.
Refer to “THROTTLE BODY AND INTAKE MANIFOLD” in
this section.
17) Adjust water pump drive belt tension.
Refer to “COOLING FAN BELT TENSION CHECK AND
ADJUSTMENT” in Section 6B.
18) Adjust power steering pump drive belt tension.
Refer to “POWER STEERING PUMP DRIVE BELT” in Sec-
tion 3B1.
19) Adjust accelerator cable play and A/T throttle cable play.
Refer to “ACCELERATOR CABLE ADJUSTMENT” and “A/T
THROTTLE CABLE ADJUSTMENT (A/T VEHICLE)” in Sec-
tion 6E2.
20) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
21) Refill engine with engine oil, referring to “ENGINE OIL
CHANGE” in Section 0B.
22) Refill cooling system referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
23) Refill front differential housing with gear oil if drained, refer-
ring to “MAINTENANCE SERVICE” in Section 7E.
24) Connect negative cable at battery.
25) Check ignition timing and adjust as necessary, referring to
“IGNITION TIMING CHECK AND ADJUSTMENT” in Section
6F2.
26) Verify that there is no fuel leakage, water leakage, oil leak-
age and exhaust gas leakage at each connection.
27) Check wheel alignment, referring to “STEERING ANGLE” in
Section 3A.

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

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)

6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Electronic Control System
The electronic control system consists of 1) various sensors which detect the state of engine and driving condi-
tions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and 3) various
controlled devices.
Functionally, it is divided into the following sub systems:
•Fuel injection control system
•Heated oxygen sensor heater control system (if equipped)
•Idle air control system
•Fuel pump control system
•Evaporative emission control system
•Ignition control system
•EGR system (if equipped)
Also, with A/T model, PCM controls A/T.
INFORMATION SENSORS CONTROLLED DEVICES OTHERS
1. IAT sensor a : A/C condenser fan motor relay (if equipped) A : Main fuse box
2. MAP sensor (if equipped) b : Ignition coil assemblies B : ECM (PCM)
3. Heated oxygen sensor (sensor 1) (if equipped) c : EVAP canister purge valve C : Data link connector
4. ECT sensor d : EGR valve (if equipped) D : Combination meter
5. TP sensor e : Idle air control valve E : Fuse box
6. MAF sensor f : Injectors F : EVAP canister
7. Camshaft position sensor (CMP sensor) g : Malfunction indicator lamp
8. ABS control module h : Fuel pump relay
9. Crankshaft position sensor (CKP sensor) (if equipped) i : Main relay
10. Power steering pressure switch (PSP switch) j : Oxygen sensor heater relay (if equipped)
11. CO adjusting resistor (if equipped)
12. Monitor connector (if equipped)
13. Transmission range switch (A/T)
14. Knock sensor
NOTE:
Above figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are
installed at the side of symmetry.

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

10B-32 AIR BAG SYSTEM
DTC B1025 :
[A] Fig. for STEP 1 and 2/[B] Fig. for STEP 2/[C] Fig. for STEP 3
Special tool
(A) : 09932-75020
(B) : 09932-75010 Step Action Yes No
1 1) With ignition switch OFF, disconnect contact coil con-
nector located near the base of the steering column.
2) Check proper connection to contact coil at terminals
in “Q06” connector.
3) If OK then connect Special Tool (B) to contact coil
connector disconnected at step 1).
With ignition switch ON, is DTC B1025 current?Go to step 2. Go to step 3.
2 1) With ignition switch OFF, disconnect Special Tool (B)
and SDM connector.
2) Measure voltage from “Q01-9” terminal to body
ground and from “Q01-10” terminal to body ground.
With ignition switch ON, are they 1 V or less?Substitute a known-
good SDM and
recheck.Repair short from
“GRN” or “GRN/RED”
wire circuit to power
circuit.
3 1) With ignition switch OFF, disconnect Special Tool (B)
then reconnect contact coil connector located near
the base of the steering column.
2) Remove driver air bag (inflator) module from steering
wheel (Refer to DRIVER AIR BAG (INFLATOR)
MODULE in Section 3C1).
3) Check proper connection to driver air bag (inflator)
module at terminals in “Q05” connector.
4) If OK then connect Special Tool (B) to “Q05” connec-
tor.
With ignition switch ON, is DTC B1025 current?Ignition switch OFF.
Replace contact coil
assembly (Refer to
COMBINATION
SWITCH/CON-
TACT COIL AND
COMBINATION
SWITCH ASSEM-
BLY in Section
3C1).Ignition switch OFF.
Replace driver air
bag (inflator) module
(Refer to DRIVER
AIR BAG (INFLA-
TOR) MODULE in
Section 3C1).
NOTE:
Upon completion of inspection and repair work, perform following items.
Reconnect all air bag system components, ensure all components are properly mounted.
Clear diagnostic trouble codes (Refer to DTC CLEARANCE), if any.
Repeat AIR BAG DIAGNOSTIC SYSTEM CHECK to confirm that the trouble has been corrected.

AIR BAG SYSTEM 10B-49
On-Vehicle Service
Service Precautions
Service and diagnosis
WARNING/CAUTION labels are attached on each part of air bag system components (SDM, air bag (inflator)
modules and seat belt pretensioners). Be sure to follow the instructions.
•Many of service procedures require disconnection of “AIR BAG” fuse and air bag (inflator) module(s) (driver
and passenger) from initiator circuit to avoid an accidental deployment.
•Do not apply power to the air bag system unless all components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble code (DTC).
•The “AIR BAG DIAGNOSTIC SYSTEM CHECK” must be the starting point of any air bag diagnostics. The
“AIR BAG DIAGNOSTIC SYSTEM CHECK” will verify proper “AIR BAG” warning lamp operation and will
lead you to the correct table to diagnose any air bag malfunctions. Bypassing these procedures may result in
extended diagnostic time, incorrect diagnosis, and incorrect parts replacements.
•Never use air bag component parts from another vehicle.
•If the vehicle will be exposed to temperatures over 93°C (200°F) (for example, during a paint baking pro-
cess), remove the air bag system components beforehand to avoid component damage or unintended sys-
tem activation.
•When handling the air bag (inflator) modules (driver and passenger), seat belt pretensioners (driver and
passenger) or SDM, be careful not to drop it or apply an impact to it. If an excessive impact was applied
(e.g., SDM is dropped, air bag (inflator) module is dropped from a height of 90 cm (3 ft) or more, seat belt
pretensioner (retractor assembly) is dropped from a height of 30 cm (1 ft) or more), never attempt disassem-
bly or repair but replace it with a new one.
•When using electric welding, be sure to disconnect air bag (inflator) module connectors (driver and passen-
ger) and seat belt pretensioner connectors (driver and passenger) respectively.
•When applying paint around the air bag system related parts, use care so that the harness or connector will
not be exposed to the paint mist.
•Never expose air bag system component parts directly to hot air (drying or baking the vehicle after painting)
or flames. WARNING:
If the air bag system and another vehicle system both need repair, Suzuki recommends that the air
bag system be repaired first, to help avoid unintended air bag system activation.
Do not modify the steering wheel, dashboard or any other on or around air bag system compo-
nents. Modifications can adversely affect air bag system performance and lead to injury.
Failure to follow procedures could result in possible air bag system activation, personal injury or
unneeded air bag system repairs.
WARNING:
When performing service on or around air bag system components or air bag wiring, follow the proce-
dures listed in the following pages to temporarily disable the air bag system.
Failure to follow procedures could result in possible air bag system activation, personal injury or
unneeded air bag system repairs.