Starter SUZUKI GRAND VITARA 2001 2.G Owners Manual

6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Table A-4 Malfunction Indicator Lamp
Check – MIL Does Not Flash or Just
Remains ON Even with Grounding
Diagnosis Switch Terminal (Vehicle with
Monitor Connector) ................................... 6-1-45
Table A-5 ECM (PCM) Power and Ground
Circuit Check – MIL Doesn’t Light at
Ignition Switch ON and Engine Doesn’t
Start Though It Is Cranked Up .................. 6-1-46
DTC P0100 (DTC No.33, 34) Mass Air
Flow Circuit Malfunction ............................ 6-1-48
DTC P0110 (DTC No.23, 25) Intake Air
Temp. (IAT) Circuit Malfunction ................ 6-1-50
DTC P0115 (DTC No.14, 15) Engine
Coolant Temp. Circuit Malfunction ............ 6-1-52
DTC P0120 (DTC No.21, 22) Throttle
Position Circuit Malfunction....................... 6-1-54
DTC P0121 Throttle Position Circuit
Range/Performance Problem ................... 6-1-56
DTC P0130 (DTC No.13) HO2S-1 (Bank 1)
Circuit Malfunction or No Activity
Detected.................................................... 6-1-58
DTC P0133 HO2S-1 (Bank 1) Circuit Slow
Response .................................................. 6-1-60
DTC P0135 HO2S-1 (Bank 1) Heater
Circuit Malfunction .................................... 6-1-61
DTC P0136 HO2S-2 (Bank 1) Circuit
Malfunction................................................ 6-1-63
DTC P0141 HO2S-2 (Bank 1) Heater
Circuit Malfunction .................................... 6-1-65
DTC P0150 (DTC No.26) HO2S-1 (Bank 2)
Circuit Malfunction or No Activity
Detected.................................................... 6-1-67
DTC P0153 HO2S-1 (Bank 2) Circuit Slow
Response .................................................. 6-1-69
DTC P0155 HO2S-1 (Bank 2) Heater
Circuit Malfunction .................................... 6-1-70
DTC P0156 HO2S-2 (Bank 2) Circuit
Malfunction................................................ 6-1-72
DTC P0161 HO2S-2 (Bank 2) Heater
Circuit Malfunction .................................... 6-1-74
DTC P0171/P0172 Fuel System Too
Lean/Rich (Bank 1) ................................... 6-1-76
DTC P0174/P0175 Fuel System Too
Lean/Rich (Bank 2) ................................... 6-1-78
DTC P0300/P0301/P0302/P0303/P0304/
P0305/P0306 Random Misfire/Cylinder 1
Misfire/Cylinder 2 Misfire/Cylinder 3 Misfire/
Cylinder 4 Misfire Detected/Cylinder 5
Misfire Detected/Cylinder 6 Misfire
Detected.................................................... 6-1-80
DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction ..................................... 6-1-82
DTC P0335 Crankshaft Position Sensor
Circuit Malfunction ..................................... 6-1-84
DTC P0340 (DTC No.42) Camshaft
Position Sensor Circuit Malfunction ........... 6-1-86
DTC P0400 Exhaust Gas Recirculation
Flow Malfunction ........................................ 6-1-89
DTC P0403 (DTC No.51) Exhaust Gas
Recirculation Circuit Malfunction ............... 6-1-92
DTC P0420 Catalyst System Efficiency
Below Threshold (Bank 1) ......................... 6-1-94
DTC P0430 Catalyst System Efficiency
Below Threshold (Bank 2) ......................... 6-1-96
DTC P0443 Evap Control System Purge
Control Valve Circuit Malfunction............... 6-1-98
Evap canister purge system
inspection ............................................. 6-1-100
Vacuum passage inspection ................ 6-1-100
Vacuum hose inspection ...................... 6-1-101
Evap canister purge valve and its
circuit inspection .................................. 6-1-101
Evap canister purge valve inspection .. 6-1-101
DTC P0460 Fuel Level Sensor Circuit
High Input ................................................ 6-1-103
DTC P0500 (DTC No.24) Vehicle Speed
Sensor Malfunction .................................. 6-1-105
DTC P0505 Idle Air Control System
Malfunction .............................................. 6-1-108
DTC P0601 (DTC No.71) Internal Control
Module Memory Check Sum Error .......... 6-1-110
DTC P1408 Manifold Absolute Pressure
Sensor Circuit Malfunction ....................... 6-1-111
DTC P1450/P1451 Barometric Pressure
Sensor Circuit Malfunction/Performance
Problem ................................................... 6-1-113
DTC P1500 Engine Starter Signal Circuit
Malfunction .............................................. 6-1-114
DTC P1510 Ecm Back-Up Power Supply
Malfunction .............................................. 6-1-115
Table B-1 Fuel Pump Circuit Inspection .. 6-1-116
Table B-2 Fuel Injectors and Circuit
Inspection ................................................ 6-1-117
Table B-3 Fuel Pressure Inspection ........ 6-1-119
Table B-4 Idle Air Control System
Inspection ................................................ 6-1-121
Table B-5 A/C Signal Circuits Inspection
(If Equipped) ............................................ 6-1-123
Table B-6 A/C Condenser Fan Motor
Relay Control System Inspection
(If Equipped) ............................................ 6-1-124
Special Tool ............................................... 6-1-125

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-21
For A/T system (Refer to Section 7B1 for diagnosis)
P0505Idle air control system mal-
functionDifference between desired idle speed
and actual idle speed continues to
exceed specified value for longer than
specified time.2 driving
cyclesNot
applicable
P0601
(No.71)Internal control module mem-
ory check sum errorData write error (or check sum error)
when written into ECM1 driving
cycle1 driving
cycle
P1408Manifold absolute pressure
sensor circuit malfunctionManifold absolute pressure sensor
output voltage is higher or lower than
specified value (or sensor circuit
shorted to ground or open).2 driving
cyclesNot
applicable
P1450Barometric pressure sensor
circuit malfunctionBarometric pressure is lower or higher
than specification.1 driving
cycleNot
applicable
P1451Barometric pressure sensor
performance problemDifference between intake manifold
pressure and barometric pressure is
larger than specification.2 driving
cyclesNot
applicable
P1500Engine starter signal circuit
malfunctionEngine starts with no starter signal or
signal input during long period after
start.2 driving
cyclesNot
applicable
P1510ECM back-up power supply
malfunctionNo back-up power after starting
engine.1 driving
cycleNot
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)
P0705
(No.72)Transmission range switch cir-
cuit malfunctionMultiple signals inputted simulta-
neously or P, R, N, D, 2 or L range sig-
nal not inputted while running at
60km/h or more.2 driving
cyclesNot
applicable
P0715
(No.76)Input speed sensor circuit
malfunctionInput speed sensor signal is lower
than specification while running.2 driving
cyclesNot
applicable
P0720
(No.75)Output speed sensor circuit
malfunctionOutput speed sensor signal not input-
ted while VSS signal being inputted.2 driving
cyclesNot
applicable
P0741TCC (lock-up) solenoid perfor-
mance or stuck offActual TCC operation does not agree
with ON/OFF control from PCM to
TCC.2 driving
cyclesNot
applicable
P0743
(No.65)
(No.66)TCC (lock-up) solenoid electri-
calMonitor signal OFF is detected when
TCC control solenoid is ON or monitor
signal ON is detected when it is OFF.1 driving
cycleNot
applicable
P0751Shift solenoid A (#1) 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

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-87
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Crank engine for 3 seconds or more and keep it at idle for 1 min.
4) Check DTC by using scan tool.
TROUBLESHOOTING
DTC DETECTING CONDITION TROUBLE AREA
CMP sensor signal is not inputted for 3 sec. even though
engine start signal is being inputted.
or
REF signal pattern is incorrect while POS signal varies.
or
POS signal voltage too high or too low.CMP sensor circuit
CMP sensor
Engine starter signal circuit
ECM (PCM)
NOTE:
Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION PRO-
CEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
NOTE:
If starter circuit is open (i.e., starter signal circuit is OK but starter fails to run), this DTC is stored in
memory at starter switch ON, even through CMP sensor is in good condition.
When starter motor fails to run and this DTC appears, check starter circuit first.
Step Action Yes No
1 Was “ENGINE DIAG. FLOW TABLE” performed? Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE” in this
section.
2 Is engine cranked? Go to Step 3. Go to Section 6G.
3 Is there DTC P1500 (Engine starter signal circuit)? Go to DTC P1500 Diag.
Flow Table.Go to Step 4.
4 CMP sensor power supply voltage check :
1) With ignition switch OFF, disconnect CMP sen-
sor coupler.
2) With ignition switch ON, check voltage between
C09-2 and C09-1 terminal. (See Fig.)
Is the voltage 10 – 14 V?Go to Step 5. Faulty “BLU/BLK” wire
and/or “GRY/YEL” wire.

6-1-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P1500 Engine Starter Signal Circuit Malfunction
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC by using scan tool, then start engine and run it for 3 min. or more.
3) Check pending DTC by using scan tool.
TROUBLESHOOTING
1. Engine start switch in ignition (main) switch 2. Starting motor 3. Transmission range sensor (switch) 4. ECM (PCM)
DTC DETECTING CONDITION TROUBLE AREA
•Engine starts even though vehicle is at stop and engine start signal is
not inputted.
or
•Engine start signal is inputted continuously for specified time while
engine is running.
(2 driving cycle detection logic)•Engine start signal circuit
•ECM (PCM)
NOTE:
Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION PRO-
CEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”
in this section.
2 Check for voltage at terminal C51-1-24 of
ECM (PCM) connector connected, under fol-
lowing condition.
Engine starter signal specification :
While engine cranking : 6 – 14 V
After starting engine : 0 – 1 V
Is voltage as specified?Poor C51-1-24 connection or
intermittent trouble.
Check for intermittent referring to
“INTERMITTENT AND POOR
CONNECTION” in Section 0A.
If wire and connections are OK,
substitute a known-good ECM
(PCM) and recheck.“BLK/YEL” circuit open.

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

6A2-28 ENGINE MECHANICAL (H27 ENGINE)
24) Remove A/T fluid hose clamps (1) from engine mounting
bracket (2). (for A/T vehicle)
25) Remove clutch housing lower plate.
26) Remove torque converter bolts (for A/T vehicle).
27) Remove starter motor.
28) Lower vehicle.
29) Support transmission. For A/T vehicle, don’t jack under A/T
oil pan to support transmission.
30) Remove bolts and nuts fastening cylinder block and trans-
mission.
31) Install lifting device.
32) Disconnect engine side mounting brackets (1) to engine
mountings.
33) Before lifting engine, check to ensure all hoses, wires and
cables are disconnected from engine.
34) Remove engine assembly from chassis and transmission by
sliding toward front, and then, carefully hoist engine assem-
bly.
INSTALLATION
Reverse removal procedure for installation, noting the following
points.
1) Lower engine assembly into engine compartment. Connect
engine to transmission and engine side mounting brackets to
engine mountings.
2) Tighten nuts fastening engine side mounting brackets and
engine mountings.
Tightening torque
Engine side mounting bracket nut (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)

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)

6E2-10 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)

6E2-12 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Engine and Emission Control Input/Output Table
Diagnosis
Refer to Section 6-1.
Ignition coil with igniter
HO2S heater control
Input
Output Function
Main relay control
Fuel pump control
Injection control
Ignition control
MIL control Idle air control
EVAP purge control
EGR control
A/C control
A/C condensor fan
controlMain relay
Fuel pump relay
Injectors
MIL
EVAP canister purge
valve IAC valve
EGR valve (if equipped)
HO2S (if equipped)
A/C amplifier
(if equipped)
A/C condensor fan
relay (if equipped)
CMP sensor
MAF sensor
TP sensor
ECT sensor
IAT sensor
HO2S (sensor 1)(if equipped)
VSS
Blower fan switch
Rear defogger switch
PSP switch
Ignition switch
Starter switch
A/C amplifier (if equipped)
TR switch (A/T VEHICLE)
Light switch
Knock sensor
CO adjusting resistor (if equipped)
Test swich terminal (Vehicle with monitor connector)
Diag. swich terminal (Vehicle with monitor connector)
Brake switch (A/T VEHICLE)
ABS control module

CRUISE CONTROL SYSTEM 8E-21
Clutch Pedal Position (CPP) Switch
REMOVAL
1) Disconnect CPP switch connector with ignition switch OFF.
2) Remove CPP switch from pedal bracket.
INSPECTION
Check for resistance between terminals under each condition
below.
If check result is not satisfactory, replace.
CPP switch resistance
When switch shaft is free : Continuity
When switch shaft is pushed : No continuity
INSTALLATION
1) Install CPP switch to pedal bracket.
2) With clutch pedal released, adjust switch position so that
clearance between end of thread and clutch pedal bracket is
within specification.
Clearance “a” between end of thread and clutch pedal
bracket :
1.5 – 2.0 mm (0.06 – 0.08 in)
3) Tighten lock nut to specified torque.
Tightening torque
CPP switch lock nut (a) : 7.5 N·m (0.75 kg-m, 5.5 lb-ft)
4) Connect connector to CPP switch securely.
1. CPP switch for cruise control
2. Stop lamp switch
3. CPP switch for starter (if equipped)
1. Push
2. Free
1. Clutch pedal
2. CPP switch for cruise control
3. Lock nut