2001 SUZUKI GRAND VITARA ESP

6E2-6 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Air Intake System
The main components of the air intake system are air cleaner, mass air flow sensor, air cleaner, intake air pipe,
throttle body, intake collector, idle air control valve and intake manifold.
The air (by the amount corresponding to the throttle valve opening and engine speed) is filtered by the air
cleaner, passes through the throttle body, is distributed by the intake manifold and finally drawn into each com-
bustion chamber.
When the idle air control valve is opened according to the signal from ECM (PCM), the air bypasses the throttle
valve through bypass passage and is finally drawn into the intake manifold.
“A” : Air 1. Air cleaner 6. PCV hose 11. Breather hose 16. IAC valve and fast idle control system
“B” : EGR 2. IAT sensor 7. Brake booster 12. MAF sensor 17. FIA valve
“C” : Engine coolant 3. Resonator 8. Fuel pressure
regulator hose13. EGR valve 18. Thermo - WAX
4. Intake manifold 9. Intake air pipe 14. TP sensor
5. Intake collector 10. Throttle body 15. IAC valve
18
10
17
15
16

6F2-4 IGNITION SYSTEM (FOR H27 ENGINE)
Diagnosis
Diagnostic Flow Table
Condition Possible Cause Correction
Engine cranks, but will
not start or hard to
start (No spark)Blown fuse for ignition coil assembly Replace.
Loose connection or disconnection of lead wire Connect securely.
Faulty spark plug (s) Replace.
Faulty ignition coil assembly (s) Replace.
Faulty CMP sensor Replace.
Faulty ECM (or PCM) Replace.
Maladjusted ignition timing Adjust.
Poor fuel economy or
engine performanceIncorrect ignition timing Adjust.
Faulty spark plug(s) Replace.
Faulty ignition coil assembly (s) Replace.
Faulty CMP sensor Replace.
Faulty ECM (or PCM) Replace.
Faulty knock sensor Replace.
Step Action Yes No
1Was “ENGINE DIAGNOSTIC FLOW TABLE” in
Section 6-1 performed?Go to Step 2. Go to “ENGINE DIAG-
NOSTIC FLOW TABLE” in
Section 6-1.
2 Ignition Spark Test
1) Check all spark plug for condition and type,
referring to “SPARK PLUG” in this section.
2) If OK, perform ignition spark test, referring
to “IGNITION SPARK CHECK” in this sec-
tion.
Is spark emitted from all spark plugs?Go to Step 8. Go to Step 3.
3 Diagnostic Trouble Code (DTC) Check
1) Check DTC stored in ECM (or PCM), refer-
ring to “DIAGNOSTIC TROUBLE CODE
(DTC) CHECK” in Section 6E2.
Is DTC stored?Go to applicable flow table
corresponding to that
code No. in Section 6E2.Go to Step 4.
4 Electrical Connection Check
1) Check ignition coil assemblies for electrical
connection.
Are they connected securely?Go to Step 5. Connect securely.
5 Ignition Coil Assembly Power Supply, Ground
and Trigger Signal Circuits Check
1) Check these circuits for open and short.
Are circuits in good condition?Go to Step 6. Repair or replace.
6 Ignition Coil Assembly Check
1) Substitute a known-good ignition coil
assembly and then repeat Step 2.
Is check result of Step 2 satisfactory?Malfunction of ignition coil
assembly.Go to Step 7.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-27
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF, if available.
2) Clear DTC, pending DTC and freeze frame data in PCM memory by using scan tool and start engine.
3) Shift A/T selector lever to each of L, 2, D, N, R and P ranges for 30 seconds each.
4) Increase vehicle speed to about 70 km/h (45 mile/h) in D range.
5) Keep driving above vehicle speed for 30 seconds.
6) Release accelerator pedal, decrease vehicle speed and stop vehicle.
7) Check DTC and/or pending DTC.
TROUBLESHOOTING
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.
Step Action Yes No
1Was “A/T DIAGNOSTIC FLOW TABLE” in this section
performed?Go to Step 2. Go to “A/T DIAGNOS-
TIC FLOW TABLE” in
this section.
2 Do you have SUZUKI scan tool? Go to Step 3. Go to Step 4.
3 Check Transmission range switch (sensor) circuit for
operation.
Check by using SUZUKI scan tool :
1) Connect SUZUKI scan tool to DLC with ignition
switch OFF.
2) Turn ignition switch ON and check transmission
range signal (P, R, N, D, 2 or L) on display when
shifting select lever to each range.
Is applicable range indicated?
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to “INTER-
MITTENT AND POOR
CONNECTION” in
Section 0A.Go to Step 5.
4 Check Transmission range switch (sensor) circuit for
operation.
Check by not using SUZUKI scan tool :
1) Turn ignition switch ON.
2) Check voltage at terminals C51-1-6, C51-1-7,
C51-1-18, C51-1-19, C51-1-27 and C51-1-28
respectively with select lever shifted to each
range.
Taking terminal C51-1-28 as an example, is battery
voltage indicated only when select lever is shifted to
“2” range and 0 V for other ranges as shown in figure?
Check voltage at other terminals likewise, referring to
figure.
Are check results satisfactory?Intermittent trouble.
Check for intermittent
referring to “INTER-
MITTENT AND POOR
CONNECTION” in
Section 0A.Go to Step 5.
5 Check select cable for adjustment referring to
“SELECT CABLE ADJUSTMENT” in this section.
Is it adjusted correctly?Go to Step 6. Adjust.

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.

7F-18 DIFFERENTIAL (REAR)
Assembling Unit
1) Place bearing outer races on their respective bearings.
Used left and right outer races are not interchangeable.
2) Install case assembly in carrier.
3) Install side bearing adjusters on their respective carrier,
making sure adjuster are threaded properly.
4) Align match marks (1) on cap and carrier. Screw in 2 side
bearing cap bolts 2 or 3 turns and press down bearing cap
by hand.
5) Tighten cap bolts (provisional torque).
Tightening torque
Bearing cap bolt (Provisional torque) (a) :
15 N·m (1.5 kg-m, 11.0 lb-ft)
6) Tighten both bearing adjusters (2) so as to obtain specified
gear backlash and at the same time, obtain preload of side
bearing.
Standard backlash
: 0.13 – 0.18 mm (0.005 – 0.007 in.)
Special tool
(A) : 09930-40120
(B) : 09930-40113
(C) : 09900-20701
NOTE:
If bearing cap does not fit tightly on carrier, side bearing
adjuster is not threaded properly. Reinstall adjuster.
NOTE:
Be sure to apply measuring tip of dial gauge at right
angles to convex side of tooth.
As a practical measure the following would be recom-
mended to obtain specified backlash and side bearing
preload at the same time.
–Obtain specified backlash by turning both adjusters
inward lightly.
–Tighten both adjusters further by one notch at a
time.
Measure at least 4 points on drive bevel gear periph-
ery.
1. Bearing cap bolt

9-2 BODY SERVICE
Glass, Windows and Mirror
Quarter Window
REMOVAL AND INSTALLATION
Refer to “WINDSHIELD” in this section as removal and installa-
tion procedures are basically the same. However, note the follow-
ings.
•Before applying primer to glass edge, install molding accord-
ing to installing position shown in the figure.
•Observe the following precautions when applying adhesive
along glass edge.
–Adhesive should be applied evenly especially in height.
–Be careful not to damage primer.
–Press glass against body quickly after adhesive is applied.
Adhesive amount specification (quarter window)
Height “a” : 12 mm (0.47 in.)
Width “b” : 8 mm (0.31 in.)
Width “c” : 16 mm (0.63 in.) for glass front, rear and upper
section.
Width “c” : 14 mm (0.55 in.) for glass bottom section.
Position “d” : 177 mm (6.97 in.) for left side glass front
section.
Position “d” : 75 mm (2.95 in.) for right side glass front
section.
Position “d” : 29 mm (1.15 in.) for glass rear section.
Position “d” : 39 mm (1.54 in.) for glass upper section.
Position “d” : 22 mm (0.87 in.) for glass bottom section.
1. Spacer 4. Adhesive
2. Glass 5. Primer
3. Molding 6. Ceramic print
“c” “A”
“a”
“b”“d”
6
5
4

10B-8 AIR BAG SYSTEM
Intermittents and Poor Connections
Most intermittents are caused by faulty electrical connections or
wiring. When a check for proper connection is requested in a
diagnostic flow table, perform careful check of suspect circuits for:
•Poor mating of connector halves, or terminals not fully
seated in the connector body (backed out).
•Dirt or corrosion on the terminals. The terminals must be
clean and free of any foreign material which could impede
proper terminal contact.
However, cleaning the terminal with a sand paper or the like
is prohibited.
•Damaged connector body, exposing the terminals to mois-
ture and dirt, as well as not maintaining proper terminal ori-
entation with the component or mating connector.
•Improperly formed or damaged terminals.
Check each connector terminal in problem circuits carefully
to ensure good contact tension by using the corresponding
mating terminal included in the connector test adapter kit
(special tool).
If contact tension is not enough, reform it to increase contact
tension or replace.
Special tool
(A) : 09932-75020 (Connector Test Adapter Kit)
•Poor terminal-to-wire connection.
Check each wire harness in problem circuits for poor con-
nection by shaking it by hand lightly. If any abnormal condi-
tion is found, change the wire harness assembly or
component parts with new ones.
•Wire insulation which is rubbed through, causing an intermit-
tent short as the bare area touches other wiring or parts of
the vehicle.
•Wire broken inside the insulation. This condition could cause
a continuity check to show a good circuit, but if only 1 or 2
strands of a multi-strand-type wire are intact, resistance
could be far too high.
If any abnormality is found, repair or replace as a wire harness
assembly.

10B-10 AIR BAG SYSTEM
Air Bag Diagnostic System Check Flow Table
Step Action Yes No
1 1) Make sure that battery voltage is
about 11V or higher.
2) Note “AIR BAG” warning lamp as
ignition switch is tuned ON.
Does “AIR BAG” warning lamp come
ON when ignition switch is tuned
ON?Go to step 2. Proceed to Diagnostic Flow Table B
(“AIR BAG” warning lamp circuit
check).
2Does “AIR BAG” warning lamp come
ON steady?Proceed to Diagnostic
Flow Table A
(“AIR BAG” warning lamp
circuit check).Go to step 3.
3Does “AIR BAG” warning lamp keep
flashing (indicating DTC) when igni-
tion switch is ON?Proceed to Diagnostic
Flow Table C
(“AIR BAG” warning lamp
circuit check).Go to step 4.
4Does “AIR BAG” warning lamp turn
OFF, after flashing 6 times?Go to step 5. Go to step 8.
5 Do you have SUZUKI scan tool? Go to step 6. Go to step 7.
6 1) Check DTC using SUZUKI scan
tool. Refer to DTC CHECK.
Is “NO CODES” displayed on
SUZUKI scan tool?Air bag system is in good
condition.An intermittent trouble has occurred
at some place.
Check the connector harness, etc.
related to the sensed DTC.
Refer to INTERMITTENT AND
POOR CONNECTIONS in this sec-
tion.
Then clear DTC (Refer to DTC
CLEARANCE.) and repeat this table.
7 1) Check DTC using monitor cou-
pler. Refer to DTC CHECK.
Is flashing pattern no. 12 indicated
on “AIR BAG” warning lamp?Air bag system is in good
condition.An intermittent trouble has occurred
at some place.
Check the connector harness, etc.
related to the sensed DTC.
Refer to INTERMITTENT AND
POOR CONNECTIONS in this sec-
tion.
Then clear DTC (Refer to DTC
CLEARANCE.) and repeat this table.
8 Do you have SUZUKI scan tool? Go to step 9. Go to step 10.
9 1) Check DTC using SUZUKI scan
tool. Refer to DTC CHECK.
Is “NO CODES” displayed on
SUZUKI scan tool?Substitute a known-good
SDM and recheck.Check and repair according to Flow
Table corresponding to that DTC.
10 1) Check DTC using monitor cou-
pler. Refer to DTC CHECK.
Is flashing pattern no. 12 indicated
on “AIR BAG” warning lamp?Substitute a known-good
SDM and recheck.Check and repair according to Flow
Table corresponding to that DTC.