2001 SUZUKI GRAND VITARA check oil

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-31
Engine Diagnosis Table
Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality
has been found in visual inspection and engine basic inspection previously.
Condition Possible Cause Correction
Hard starting
(Engine cranks OK)Faulty idle air control system “DIAG. FLOW TABLE B-4” in this
section.
Faulty ECT sensor or MAF sensor ECT sensor or MAF sensor in Sec-
tion 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Low compression Compression check in Section
6A2.
Faulty hydraulic valve lash adjuster Valve lash adjuster in Section 6A2.
Compression leak from valve seat Valves inspection in Section 6A2.
Sticky valve stem Valves inspection in Section 6A2.
Weak or damaged valve springs Valves spring inspection in Section
6A2.
Compression leak at cylinder head gasket Cylinder head inspection in Section
6A2.
Sticking or damaged piston ring Piston ring inspection in Section
6A2.
Worn piston, ring or cylinder Cylinders, pistons and piston rings
inspection in Section 6A2.
Malfunctioning PCV valve PCV system inspection in Section
6E2.
Engine has no power
Engine overheating Refer to “OVERHEATING” in this
table.
Defective spark plug Spark plugs in Section 6F2.
Faulty ignition coil with ignitor Ignition coil in Section 6F2.
Fuel pressure out of specification
(dirty fuel filter, dirty or clogged fuel hose or
pipe, malfunctioning fuel pressure regulator,
malfunctioning fuel pump)“DIAG. FLOW TABLE B-3” in this
section.
Maladjusted TP sensor installation angle TP sensor in Section 6E2.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty injector Fuel injector in Section 6E2.
Faulty TP sensor, ECT sensor or MAF sensor TP sensor, ECT sensor or MAF
sensor in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Low compression Refer to the same item in “HARD
STARTING” of this table.
Dragging brakes Diagnosis in Section 5.
Slipping clutch Diagnosis in Section 7C1.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-33
Surges
(Engine power varia-
tion under steady
throttle or cruise.
Feels like the vehicle
speeds up and down
with no change in the
accelerator pedal.)Defective spark plug
(excess carbon deposits, improper gap, and
burned electrodes, etc.)Spark plugs in Section 6F2.
Variable fuel pressure
(clogged fuel filter, kinky or damaged fuel hose
and line, faulty fuel pressure regulator)“DIAG. FLOW TABLE B-3” in this
section.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty MAF sensor MAF sensor in Section 6E2.
Faulty injector Fuel injector in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Excessive detonation
(The engine makes
sharp metallic knocks
that change with throt-
tle opening. Sounds
like pop corn pop-
ping.)Engine overheating Refer to “OVERHEATING” in this
table.
Faulty spark plug Spark plugs in Section 6F2.
Improper ignition timing Ignition timing in Section 6F2.
Clogged fuel filter and fuel lines Fuel pressure check in Section
6E2.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty ECT sensor or MAF sensor ECT sensor or MAF sensor in Sec-
tion 6E2.
Faulty injector Fuel injector in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Excessive carbon deposits in combustion
chamberPiston and cylinder head cleaning
in Section 6A2.
Poor knock sensor performance “DTC P0325 DIAG. FLOW TABLE”
in this section.
Overheating
Inoperative thermostat Thermostat in Section 6B.
Poor water pump performance Water pump in Section 6B.
Clogged or leaky radiator Radiator in Section 6B.
Improper engine oil grade Engine oil and oil filter change in
Section 0B.
Clogged oil filter or oil strainer Oil pressure check in Section 6A2.
Poor oil pump performance Oil pressure check in Section 6A2.
Dragging brakes Diagnosis in Section 5.
Slipping clutch Diagnosis in Section 7C1.
Blown cylinder head gasket Cylinder head inspection in Section
6A2. Condition Possible Cause Correction

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-35
Engine noise
(Note : Before check-
ing the mechanical
noise, make sure the
followings : Ignition
timing is properly
adjusted, Specified
spark plug is used,
Specified fuel is used.)Faulty hydraulic valve lash adjuster Hydraulic valve lash adjuster in
Section 6A2.
Worn valve stem and guide Valves inspection in Section 6A2.
Weak or broken valve spring Valve springs inspection in Section
6A2.
Warped or bent valve Valves inspection in Section 6A2.
Loose camshaft housing bolts Camshafts in Section 6A2.
Worn piston, ring and cylinder bore Pistons and cylinders inspection in
Section 6A2.
Worn crankpin bearing Crankpin and connecting rod bear-
ing inspection in Section 6A2.
Worn crankpin Crankpin and connecting rod bear-
ing inspection in Section 6A2.
Loose connecting rod nuts Connecting rod installation in Sec-
tion 6A2.
Low oil pressure Refer to “LOW OIL PRESSURE” of
this table.
Worn crankshaft journal bearing Crankshaft and bearing inspection
in Section 6A2.
Worn crankshaft journal Crankshaft and bearing inspection
in Section 6A2.
Loose lower crankcase (bearing cap) bolts Crankshaft installation in Section
6A2.
Excessive crankshaft thrust play Crankshaft inspection in Section
6A2. Condition Possible Cause Correction

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

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.

6-1-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Fig. for Step 45 CMP sensor (REF) signal check :
1) With ignition switch OFF, connect CMP sensor
coupler.
2) Disconnect couplers from ignition coil assembly
and fuel injectors.
3) With ignition switch ON and crankshaft turned
slowly, check voltage between C51-1-13 and
C51-3-26 terminal.
Does voltmeter indicator deflect between 0 – 1 V
and 3 – 5.25 V 4 times while crankshaft turned two
revolutions?Go to Step 6. Faulty “YEL/GRN” wire
or CMP sensor.
If OK, substitute a
known-good ECM
(PCM) and recheck.
6 CMP sensor (POS) signal check :
1) With ignition switch ON and crankshaft turned
slowly, check voltage between C51-1-12 and
C51-3-26 terminal.
Does voltmeter indicator deflect between 0 – 1 V
and 3 – 5.25 V 6 times while crankshaft turned two
revolutions?Poor C51-1-12 and/or
C51-3-13 terminal of
ECM (PCM) coupler con-
nection.
If OK, substitute a
known-good ECM (PCM)
and recheck.Faulty “YEL/BLU” wire
or CMP sensor.
If OK, substitute a
known-good ECM
(PCM) and recheck. Step Action Yes No
1. Disconnected CMP sensor coupler
2. “BLU/BLK” wire (C09-2) terminal
3. “GRY/YEL” wire (C09-1) terminal

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.

6A2-12 ENGINE MECHANICAL (H27 ENGINE)
7) Reverse removal procedure to install front propeller shaft if
removed.
When installing propeller shaft, align match mark (1).
Use following specification to torque universal joint flange.
Tightening torque
Universal joint flange bolt (c) :
55 N·m (5.5 kg-m, 40.0 lb-ft)
8) Connect EGR pipe to left (No.1) bank exhaust manifold (1).
9) Install exhaust manifold covers (2).
10) Install oil level gauge guide (3) using new O-ring.
11) Install P/S pump assembly (4) if it was removed. Refer to
“POWER STEERING PUMP” in Section 3B1.
12) Adjust P/S pump drive belt tension, refer to “POWER
STEERING BELT CHECK AND ADJUSTMENT” in Section
3B1.
13) Connect oxygen sensor lead wire couplers.
Be sure to clamp its lead wires.
14) Connect negative (–) cable to battery.
Upon completion of installation, start engine and check that
no exhaust gas leakage exists.
1
4
32
1. HO2S-1 (Green connector)
2. HO2S-2 (Black connector)