2001 SUZUKI GRAND VITARA Pump relay

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

6-1-38 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
E61-22A/C condenser fan motor relay
(if equipped)10 – 14 VIgnition switch ON, A/C not oper-
ated and Engine coolant temp. :
less than 113°C, 235°F
E61-23 Fuel pump relay0 – 2.5 VFor 3 sec. after ignition switch ON
or while engine running
10 – 14 VAfter 3 sec. from ignition switch ON
with engine stopped
E61-24Ground for CO adjusting resistor
(if equipped)––
E61-25 – – –
E61-26 – – –
E61-27 – – –
E61-28 Fuel level sensor 0 – 6 VIgnition switch ON
Voltage depends on fuel level
E61-29Diag. switch terminal
(vehicle with monitor connector)10 – 14 V Ignition switch ON
E61-30 ABS control module 10 – 14 V Ignition switch ON
E61-31Power/Normal change switch
(A/T vehicle)0 – 1 VIgnition switch ON, P/N change
switch : POWER mode
10 – 14 VIgnition switch ON, P/N change
switch : NORMAL mode
E61-32 Lighting switch0 – 1 VIgnition switch ON, lighting switch
OFF
10 – 14 VIgnition switch ON, lighting switch
ON
E61-33 Overdrive cut switch (A/T vehicle)10 – 14 VIgnition switch ON, overdrive cut
switch released
0 – 1 VIgnition switch ON, overdrive cut
switch pressed
E61-34 Stop lamp switch0 – 1 VBrake pedal released (switch OFF),
Ignition switch ON
10 – 14 VBrake pedal depressed (switch ON),
Ignition switch ON
E61-35 Cruise control module (if equipped) 10 – 14 V Ignition switch ON
C51-3-1 Intake air temp. sensor 2.2 – 3.0 VIgnition switch ON, Sensor ambient
temp. : 20°C, 68°F
C51-3-2 Engine coolant temp. sensor 0.5 – 0.9 VIgnition switch ON, Engine coolant
temp. : 80°C, 176°F
C51-3-3 Knock sensor About 2.5 VWith engine running at idle after
warned up
C51-3-4 Power source 10 – 14 V Ignition switch ON
C51-3-5 Ground for MAF sensor – –
C51-3-6 Ground – –
C51-3-7 4WD switch0 – 1 VIgnition switch ON, Transfer lever :
4H or 4L range
10 – 14 VIgnition switch ON, Transfer lever :
2H range
C51-3-8 Manifold absolute pressure sensor 3.3 – 4.3 V Ignition switch ON and engine stops TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION

6-1-42 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
RESISTANCE CHECK
1) Disconnect couplers (1) from ECM/PCM with ignition switch
OFF.
2) Check resistance between each pair of terminals of discon-
nected couplers (1) as listed in following table. CAUTION:
Never touch terminals of ECM/PCM itself or connect volt-
meter or ohmmeter (2).
CAUTION:
Be sure to connect ohmmeter (2) probe from wire har-
ness side of coupler.
Be sure to turn OFF ignition switch for this check.
Resistance in table represents that when parts temper-
ature is 20°C (68°F).
TERMINALS CIRCUIT STANDARD
RESISTANCECONDITION
E61-9 and E61-2 Main relay 79 – 95 Ω–
E61-22 and C51-3-20 A/C fan motor relay (if equipped) 75 – 110 ΩBattery disconnected
and ignition switch ON
E61-23 and C51-3-20 Fuel pump relay 79 – 95 Ω–
C51-3-6 and Body ground Ground Continuity –
C51-3-17 and Body ground Ground Continuity –
C51-1-1 and Body ground Shift solenoid B (A/T) 11 – 15 Ω–
C51-1-2 and Body ground Shift solenoid A (A/T)
C51-1-4 and C51-3-4 IAC valve (stepper motor coil 2) 25.5 – 33.5 Ω–
C51-1-5 and C51-3-4 IAC valve (stepper motor coil 1)
C51-1-8 and Body ground TCC solenoid (A/T) 11 – 15 Ω–
C51-1-15 and C51-3-4 EVAP canister purge valve 28 – 35 Ω–
C51-1-16 and C51-3-4 IAC valve (stepper motor coil 4) 25.5 – 33.5 Ω–
C51-1-17 and C51-3-4 IAC valve (stepper motor coil 3)
C51-2-1 and C51-3-4 Fuel injector No.2 13 – 16 Ω–
C51-2-2 and C51-3-4 Fuel injector No.1
C51-2-4, C51-2-5 and E61-9 Heater of HO2S-1 5.0 – 6.4 Ω–
C51-2-7 and Body ground Ground Continuity –
C51-2-8 and C51-3-4 Fuel injector No.4 13 – 16 Ω–
C51-2-9 and C51-3-4 Fuel injector No.3
C51-2-12 and C51-3-4 EGR valve (stepper motor coil 4) 20 – 24 Ω–
C51-2-13 and C51-3-4 EGR valve (stepper motor coil 3)
C51-2-14 and C51-3-4 EGR valve (stepper motor coil 2)
C51-2-15 and C51-3-4 EGR valve (stepper motor coil 1)
C51-2-16, C51- 2-17 and
E61-9Heater of HO2S-2 11.7 – 14.3 Ω–
C51-2-21 and C51-3-4 Fuel injector No.6
13 – 16 Ω–
C51-2-22 and C51-3-4 Fuel injector No.5

6-1-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Table B-1 Fuel Pump Circuit Inspection
WIRING DIAGRAM
INSPECTION
1. To ignition switch 4. Fuel pump relay
2. Main fuse 5. Fuel pump
3. Main relay 6. ECM (PCM)
CAUTION:
Check to make sure that connection is made between correct terminals.
Wrong connection can cause damage to ECM, wire harness etc.
Step Action Yes No
1 Fuel pump operation check :
1) Remove fuel filler cap.
2) Turn ON ignition switch.
Is fuel pump operation sound heard for 3 sec.
after ignition switch ON?Fuel pump circuit is in
good condition.Go to Step 2.
2 Fuel pump circuit check :
1) With ignition switch OFF, remove fuel pump
relay from connector.
2) Check for proper connection to relay at
each terminal.
3) If OK, using service wire, connect terminals
E07-7 and E07-8 of relay connector. (See
Fig.)
Is fuel pump heard to operate at ignition switch
ON?Go to Step 3.“BLU/BLK”, “PNK/BLK” or
“BLK” circuit open or fuel
pump malfunction.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-117
Fig. for Step 2
Table B-2 Fuel Injectors and Circuit Inspection
WIRING DIAGRAM
3 Fuel pump relay check :
1) Check fuel pump relay referring to “FUEL
PUMP RELAY INSPECTION” in Section
6E2.
Is it in good condition?“BLK/WHT” or “WHT/
GRN” circuit open or poor
E61-23 connection.
If wire and connection are
OK, substitute a known-
good ECM (PCM) and
recheck.Replace fuel pump relay. Step Action Yes No
1. Fuel pump relay connector
1. To ignition switch 4. Injector No.1 7. Injector No.4 10. ECM (PCM)
2. Main fuse 5. Injector No.2 8. Injector No.5
3. Main relay 6. Injector No.3 9. Injector No.6

6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Fuel injector.......................................... 6E2-26
Electronic Control System........................ 6E2-31
Engine control module (ECM)/
powertrain control module (PCM) ........ 6E2-31
Mass air flow sensor (MAF sensor)...... 6E2-32
Intake air temperature (IAT) sensor ..... 6E2-34
Throttle position sensor (TP sensor) .... 6E2-35
Engine coolant temperature sensor
(ECT sensor) ........................................ 6E2-36
Heated oxygen sensor (sensor 1) ........ 6E2-37
Heated oxygen sensor (sensor 2) ........ 6E2-38
Vehicle speed sensor (VSS) ................ 6E2-39
Manifold absolute pressure sensor ...... 6E2-39
Fuel level sensor (sender gauge)......... 6E2-41
Crankshaft position sensor................... 6E2-41Main relay ............................................ 6E2-41
Fuel pump relay ................................... 6E2-42
Fuel cut operation ................................ 6E2-43
Emission Control System......................... 6E2-44
EGR system (if equipped) .................... 6E2-44
EVAP canister ...................................... 6E2-45
Vacuum passage ................................. 6E2-46
PCV System ............................................ 6E2-47
PCV hose ............................................. 6E2-47
PCV valve ............................................ 6E2-47
PCV system ......................................... 6E2-48
Tightening Torque Specification.............. 6E2-48
Special Tool ............................................... 6E2-48

General Description
The engine and emission control system has 4 major sub-systems: air intake system, fuel delivery system, elec-
tronic control system and emission control system.
Air intake system includes air cleaner, mass air flow sensor, throttle body, idle air control valve and intake man-
ifold.
Fuel delivery system includes fuel pump, delivery pipe, fuel pressure regulator, fuel injectors, etc.
Electronic control system includes ECM (PCM), various sensors and controlled devices.
Emission control system includes EGR, EVAP and PCV systems.

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.