2001 SUZUKI GRAND VITARA egr valve

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-41
C51-2-1 Fuel injector No.2
10 – 14 V Ignition switch ON
C51-2-2 Fuel injector No.1
C51-2-3 – – –
C51-2-4Heater of HO2S-1 (bank 1)
(if equipped)10 – 14 V Ignition switch ON
0 – 2 VAt specified idle speed after engine
warmed up
C51-2-5Heater of HO2S-1 (bank 2)
(if equipped)10 – 14 V Ignition switch ON
0 – 2 VAt specified idle speed after engine
warmed up
C51-2-6 – – –
C51-2-7 Ground – –
C51-2-8 Fuel injector No.4
10 – 14 V Ignition switch ON
C51-2-9 Fuel injector No.3
C51-2-10 – – –
C51-2-11 – – –
C51-2-12EGR valve (stepper motor coil 4)
(if equipped)0 – 1 V
Ignition switch ON C51-2-13EGR valve (stepper motor coil 3)
(if equipped)10 – 14 V
C51-2-14EGR valve (stepper motor coil 2)
(if equipped)10 – 14 V
C51-2-15EGR valve (stepper motor coil 1)
(if equipped)0 – 1 V
C51-2-16Heater of HO2S-2 (bank 1)
(if equipped)10 – 14 V Ignition switch ON
0 – 1 VAt specified idle speed after engine
warmed up
C51-2-17Heater of HO2S-2 (bank 2)
(if equipped)10 – 14 V Ignition switch ON
0 – 1 VAt specified idle speed after engine
warmed up
C51-2-18 – – –
C51-2-19Crankshaft position sensor (+)
(if equipped)––
C51-2-20Crankshaft position sensor (–)
(if equipped)––
C51-2-21 Fuel injector No.6
10 – 14 V Ignition switch ON
C51-2-22 Fuel injector No.5
C51-2-23 Ignition coil assembly for No.6 – –
C51-2-24 Ignition coil assembly for No.5 – –
C51-2-25 Ignition coil assembly for No.4 – –
C51-2-26 Ignition coil assembly for No.3 – –
C51-2-27 Ignition coil assembly for No.2 – –
C51-2-28 Ignition coil assembly for No.1 – –
C51-2-29 – – –
C51-2-30Ground for CKP sensor shield wire
(if equipped)–– 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

6-1-80 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 Random Misfire/Cylinder
1 Misfire/Cylinder 2 Misfire/Cylinder 3 Misfire/Cylinder 4 Misfire Detected/Cyl-
inder 5 Misfire Detected/Cylinder 6 Misfire Detected
SYSTEM DESCRIPTION
ECM (PCM) measures the angle speed of the crankshaft based on the pulse signal from the CKP sensor and
CMP sensor for each cylinder. If it detects a large change in the angle speed of the crankshaft, it concludes
occurrence of a misfire. When the number of misfire is counted by the ECM (PCM) beyond the DTC detecting
condition, it determines the cylinder where the misfire occurred and outputs it as DTC.
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 and start
engine.
3) Increase vehicle speed to speed recorded as freeze frame data (V) ± 5 km/h when detecting misfire.
4) Keep driving above vehicle speed for 5 min.
5) Stop vehicle and check DTC (or pending DTC) by using scan tool.DTC DETECTING CONDITION TROUBLE AREA
DTC P0300 :
• Misfire which causes catalyst to overheat during 200 engine
revolutions is detected at 2 or more cylinders. (MIL flashes as
long as this misfire occurs continuously.)
• Misfire which affects exhaust emission adversely during 1000
engine revolutions is detected at 2 or more cylinders (2 driving
cycle detection logic)• Ignition system
• Fuel injector and its circuit
• Fuel line pressure
• Engine compression
• Abnormal air drawn in
• EGR system
• Fuel level sensor
• Valve lash adjuster
• Valve timing DTC P0301, P0302, P0303, P0304, P0305, P0306 :
• Misfire which causes catalyst to overheat during 200 engine
revolutions is detected at 1 cylinder. (MIL flashes as long as
this misfire occurs continuously.)
• Misfire which affects exhaust emission adversely during 1000
engine revolutions is detected at 1 cylinder
(2 driving cycle detection logic)
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
NOTE:
Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
Intake air temp. : – 8 – 70°C (18 – 158°F)
Engine coolant temp. : – 8°C (18°F) or higher
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-81
TROUBLESHOOTING
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 Ignition system inspection :
1) Check spark plug and ignition spark of cylin-
der where misfire occurs, referring to “IGNI-
TION SYSTEM” section.
Is it in good condition?Go to Step 3. Faulty ignition coil, wire
harness, or other system
parts.
3 Fuel injector circuit inspection :
1) Using sound scope, check each injector
operating sound at engine cranking or
idling.
Do all injectors make operating sound?Go to Step 4. Check coupler connec-
tion and wire harness of
injector not making oper-
ating sound and injector
itself.
If OK, substitute a known-
good ECM (PCM) and
recheck.
4 Fuel pressure inspection :
1) Check fuel pressure referring to “TABLE B-
3” in this section.
Is check result satisfactory?Go to Step 5. Repair or replace.
5 Fuel injector inspection :
1) Check fuel injector(s) referring to Section
6E2.
Is check result satisfactory?Go to Step 6. Replace.
6 Ignition timing inspection :
1) Check ignition timing referring to Section
6F2.
Is check result satisfactory?Go to Step 7. Adjust or check system
related parts.
7 EGR system inspection :
1) Check EGR system referring to Section
6E2.
Is check result satisfactory?Go to Step 8. Repair or replace.
8 Fuel level sensor inspection :
1) Check fuel level sensor referring to Section
6E2.
Is check result satisfactory?Go to Step 9. Repair or replace.
9 Check engine mechanical parts or system
which can cause engine rough idle or poor per-
formance.
• Engine compression (See Section 6A2).
• Valve lash or lash adjuster (See Section
6A2).
• Valve timing (Timing belt or chain installa-
tion. See Section 6A2).
Are they in good condition?Check wire harness and
connection of ECM (PCM)
ground, ignition system
and fuel injector for inter-
mittent open and short.Repair or replace.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-89
DTC P0400 Exhaust Gas Recirculation Flow Malfunction
SYSTEM/WIRING DIAGRAM
1. EGR valve 5. ECM (PC)
2. Intake manifold 6. MAP sensor
3. Exhaust gas 7. Main fuse
4. Sensed information 8. Main relay

6-1-90 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
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 and warm up
engine completely.
3) Increase vehicle speed to 55 – 60 km/h (35 – 40 mph).
4) Keep driving above vehicle speed for 7 min. or more.
5) Increase vehicle speed to 100 – 110 km/h (60 – 70 mph).
6) Release accelerator pedal and with engine brake applied, keep vehicle coasting and then stop vehicle.
7) Check if pending DTC exists by using scan tool. If not, check if EGR system monitoring test has completed
by using scan tool. If not in both of above checks (i.e., no pending DTC and EGR system monitoring test not
completed), check vehicle conditions (environmental) and repeat Steps 3) through 6).DTC DETECTING CONDITION TROUBLE AREA
During deceleration (engine speed high with closed
throttle position) in which fuel cut is involved, difference
in intake manifold pressure between when EGR valve is
opened and when it is closed is smaller than specified
value.
(2 driving cycle detection logic)•EGR valve
• EGR passage
• Manifold absolute pressure sensor
•ECM (PCM)
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
NOTE:
Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
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)
1. Vehicle speed km/h (mph)
2. Step

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-91
TROUBLESHOOTING
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 Is there DTC P0403 (EGR circuit malfunction)? Go to DTC P0403 Diag.
Flow Table.Go to Step 3.
3 Do you have SUZUKI scan tool? Go to Step 4. Go to Step 6.
4 EGR valve operation check :
1) With ignition switch OFF, install SUZUKI
scan tool.
2) Check EGR system referring to Section
6E2.
Is it in good condition?Go to Step 5. Go to Step 6.
5 MAP sensor check :
1) Check MAP sensor for performance refer-
ring to Section 6E2.
Is check result satisfactory?Intermittent trouble or
faulty ECM (PCM). Check
for intermittent referring to
“INTERMITTENT AND
POOR CONNECTION” in
Section 0A.Repair or replace.
6 EGR valve power supply circuit check :
1) With ignition switch OFF, disconnect EGR
valve coupler.
2) With ignition switch ON, check voltage
between C04-2 and ground, C04-5 and
ground.
Is each voltage 10 – 14 V?Go to Step 7. Faulty “BLU/BLK” wire.
7 EGR valve stepper motor coil circuit check :
1) With ignition switch OFF, connect EGR
valve coupler and disconnect ECM (PCM)
couplers.
2) Check resistance between C51-3-4 and
C51-2-12, C51-2-13, C51-2-14, C51-2-15.
Is each resistance 20 – 24 Ω at 20°C (68°F)?Go to Step 8. Faulty EGR valve.
8 MAP sensor check :
1) Check MAP sensor for performance refer-
ring to Section 6E2.
Is check result satisfactory?EGR passage clogged or
EGR valve malfunction.
If all above are OK, inter-
mittent trouble or faulty
ECM (PCM).
Check for intermittent
referring to “INTERMIT-
TENT AND POOR CON-
NECTION” in Section 0A.Repair or replace.

6-1-92 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P0403 (DTC No.51) Exhaust Gas Recirculation 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, pending DTC and freeze frame data by using scan tool.
3) Start engine and run it for 10 sec.
4) Check DTC by using scan tool.
1. Main fuse 4. ECM (PCM)
2. Main relay
3. EGR valve
DTC DETECTING CONDITION TROUBLE AREA
High voltage is detected at EGR valve stepping motor
electrical circuit for specified time continuously.
(Circuit open or short).EGR valve (stepping motor) or its 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)