2001 SUZUKI GRAND VITARA 4 wheel drive

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-15
Idle Speed/Idle Air Control (IAC) Duty Inspec-
tion
Before idle speed/IAC duty check, make sure of the following.
•Lead wires and hoses of engine/emission control systems
are connected securely.
•Accelerator cable is adjusted.
•Ignition timing is within specification.
•All accessories (wipers, heater, lights, A/C, etc.) are out of
service.
•Air cleaner has been properly installed and is in good condi-
tion.
•ECM (PCM) does not detect any malfunction DTC.
After above items are all confirmed, check idle speed and IAC
duty as follows.
[Using SUZUKI scan tool]
1) Connect SUZUKI scan tool to DLC with ignition switch OFF.
Special tool
(A) : SUZUKI scan tool
2) Warm up engine to normal operating temperature.
3) Check IAC duty and idle speed by using “Data List” mode of
SUZUKI scan tool.
Engine idle speed:
A/C OFF: 700 ± 50 r/min.
A/C ON: 750 ± 50 r/min.
IAC duty at specified idle speed:
5 – 40 % (at A/C OFF)
4) If duty and/or idle speed is out of specifications, check idle
air control system referring to “DIAG. FLOW TABLE B-4” in
Section 6-1.
5) Check that specified engine idle speed is obtained with A/C
ON if vehicle is equipped with A/C. If not, check A/C ON sig-
nal circuit and idle air control system. NOTE:
Before starting engine, place transmission gear shift
lever in “Neutral” (shift selector lever to “P” range for A/T
vehicle), and set parking brake and block drive wheels.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-41
Manual Road Test
This test check the gear being used in “L”, “2” or “D” range when
driven with unoperated gear shift control system. Test drive vehi-
cle on a level road.
1) Disconnect shift solenoid coupler (1) valves on transmission.
2) With select lever in “P”, start engine and warm it up.
3) With select lever in “L” range, start vehicle and accelerate to
20 km/h (12.5 mile/h). Check in this state that 1st gear is
being used.
4) At 20 km/h (12.5 mile/h), shift select lever to “2” range and
accelerate to 40 km/h (25 mile/h). Check in this state that 3rd
gear is being used.
5) At 40 km/h (25 mile/h), shift select lever to “D” range and
check that O/D gear is used when speed is higher than 40
km/h (25 mile/h).
6) After above checks, stop vehicle then engine, and connect
shift solenoids coupler (1) with ignition switch OFF.
7) Clear DTC with scan tool.
Time Lag Test
This test is to check conditions of clutch, reverse brake and fluid pressure. “Time lag” means time elapsed since
select lever is shifted with engine idling till shock is felt.
1) With chocks placed before and behind front and rear wheels respectively, depress brake pedal.
2) Start engine.
3) With stop watch ready, shift select lever from “N” to “D” range and measure time from that moment till shock
is felt.
4) Similarly measure time lag by shifting select lever from “N“ to “R” range.
Specification for time lag :NOTE:
Before this test, check diagnostic trouble code (DTC).
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when disconnecting shift solenoid cou-
pler (1).
WARNING:
To avoid the danger of being burned, do not touch the hot
exhaust system when connecting shift solenoid coupler
(1).
“N” →
→→ → “D”Less than 1.2 sec.
“N” →
→→ → “R”Less than 1.5 sec.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-43
On-Vehicle Service
Maintenance Service
Fluid level
LEVEL CHECK AT NORMAL OPERATING TEMPERATURE
1) Stop vehicle and place it level.
2) Apply parking brake and place chocks against wheels.
3) With selector at P position, start engine.
4) Warm up engine till fluid temperature reaches normal oper-
ating temperature (70 – 80 °C (158 – 176 °F)). As a guide to
check fluid temperature, warm up engine till engine coolant
temperature meter indicated around 1 unit above “C” point.
5) Keep engine idling and shift selector slowly to “L” and back
to “P” position.
6) With engine idling, pull out dipstick, wipe it off with a clean
cloth and put it back into place.
7) Pull out dipstick again and check fluid level indicated on it.
Fluid level should be between FULL HOT and LOW HOT. if it
is below LOW HOT, add an equivalent of DEXRON
®-III up to
FULL HOT.
Fluid specification :
An equivalent of DEXRON
®-III
[A] : Shift the select lever with its button pushed in.
[B] : Shift the select lever without pushing its button.
NOTE:
DO NOT RACE ENGINE while checking fluid level, even
after the engine start.
DO NOT OVERFILL. Overfilling can causes foaming
and loss of fluid through breather. Then slippage and
transmission failure can result.
Bringing the level from LOW HOT to FULL HOT
requires 0.3 liters (0.64/0.53 US/lmp.pt).
If vehicle was driven under high load such as pulling a
trailer, fluid level should be checked about half an hour
after it is stopped.

DIFFERENTIAL (FRONT) 7E-7
On-Vehicle Service
Differential Mountings
REMOVAL AND INSTALLATION
1) Lift up vehicle and turn steering wheel all way to the right.
2) Separate front mounting bracket R (2) from differential hous-
ing (3) by removing bolts (1) from its lower part.
3) Remove front mounting bracket R (2) by removing mounting
front bolt (4) from its upper part.
4) Remove front mounting bracket L (3) from differential hous-
ing (1) by removing upper and lower fastening bolts (2, 4).
5) Check conditions of each bush. If it is damaged or deterio-
rated, drive it out with special tools and press for replace-
ment.
Special tool
(A) : 09951-26010
(B) : 09951-16080

7F-6 DIFFERENTIAL (REAR)
3) Install propeller shaft to joint flange aligning match marks
and torque flange nuts to specification. Apply thread lock
cement to thread part of bolt if reused.
“A” : Cement 99000-32110
Tightening torque
Propeller shaft flange nuts (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
4) Install right and left rear axle shafts and drums.
(Refer to “REAR AXLE INSTALLATION” of Section 3E and
rear brake drum installation of Section 5.)
5) Install wheels.
6) Fill hypoid gear oil as specified and tighten plug to specifica-
tion.
7) Lower lift.
Unit Repair
Disassembling Unit
1) Hold differential assembly securely and put identification
marks on differential side bearing caps (6).
2) Take off differential side bearing lock plates (4) and differen-
tial side bearing caps (6) by removing their bolts and then
take out bearing adjusters (5), side bearing outer races and
drive bevel gear with differential case.
3) Remove drive bevel gear (hypoid gear), differential gears,
differential pinions and pinion shafts.
a) With aluminum plates (2) placed on vise first, grip differen-
tial case with it and remove drive bevel gear (hypoid gear)
(3) by removing its bolts (1).
1. Differential carrier
2. Drive bevel gear assembly
3. Differential case
A: Identification mark
1
3
2

AIR BAG SYSTEM 10B-7
Special tool
(B) : 09932-75010 (Air Bag Driver/Passenger Load Tool)
This tool is used only when called for in this section. It is used as
a diagnostic aid and safety device to prevent inadvertent air bag
(inflator) module deployment.
The load tool has three connectors attached to its case which are
electrically functional and serve as resistive load substitutions.
No more than two connectors are used at any time.
One of connectors (“STEERING WHEEL”) is used to substitute
the load of followings.
•Driver air bag (inflator) module when it is connected at the
top of the column to the contact coil assembly.
•Passenger air bag (inflator) module when it is connected to
the air bag harness connector for passenger air bag (inflator)
module.
•Each of driver and passenger seat belt pretensioners when it
is connected to air bag harness connector for driver and pas-
senger seat belt pretensioner (if equipped).
Another connector (“BASE OF COLUMN”) is used to substitute
the load of the driver air bag (inflator) module and the contact coil
assembly when it is connected at the base of the column to the air
bag wire harness.
The third connector (“PASSENGER INFLATOR”) is not used.
By substituting the resistance of the load tool when called for, a
determination can be made as to whether an inflator circuit com-
ponent is causing system malfunction and which component is
causing the malfunction.
The load tool should be used only when specifically called for in
the diagnostic procedures.
1. Connector for contact coil and driver air bag (inflator) module
(Located near the base of the steering column)
2. Connector for driver, passenger air bag (inflator) module and driver and
passenger seat belt pretensioners
3. Not used

AIR BAG SYSTEM 10B-29
DIAGNOSTIC FLOW TABLE
DTC B1021 :
[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 B1021 current?Go to step 2. Go to step 3.
2 1) With ignition switch OFF, disconnect SDM connector.
2) Check proper connection to SDM at terminals “Q01-9”
and “Q01-10”.
3) If OK then measure resistance between “Q01-9” and
“Q01-10” terminals with connected Special Tool (B).
Is resistance 4.5 Ω or less?Substitute a known-
good SDM and
recheck.Repair high resis-
tance or open in
“GRN” or “GRN/RED”
wire 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 B1021 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.

10B-30 AIR BAG SYSTEM
DTC B1022 :
[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 B1022 current?Go to step 2. Go to step 3.
2 1) With ignition switch OFF, disconnect SDM connector.
2) Check proper connection to SDM at terminals “Q01-9”
and “Q01-10”.
3) If OK then measure resistance between “Q01-9” and
“Q01-10” terminals with connected Special Tool (B).
Is resistance 1.7 Ω or more?Substitute a known-
good SDM and
recheck.Repair short from
“GRN” wire circuit to
“GRN/RED” wire cir-
cuit or from “GRN” or
“GRN/RED” wire cir-
cuit to other wire cir-
cuit.
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 B1022 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.