2001 SUZUKI GRAND VITARA coolant level

6-1-98 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P0443 Evap Control System Purge Control Valve Circuit Malfunction
SYSTEM/WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1. Main fuse 3. EVAP canister purge valve
2. Main relay 4. ECM (PCM)
DTC DETECTING CONDITION TROUBLE AREA
Monitor signal of EVAP canister purge valve is different
from command signal. (Circuit open or short)
(2 driving cycle detection logic)• EVAP canister purge valve and its circuit
•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 condition is satisfied when using the “DTC Confirmation Proce-
dure.”
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)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-103
DTC P0460 Fuel Level Sensor Circuit High Input
WIRING DIAGRAM/CIRCUIT DESCRIPTION
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 run
engine for 1 min.
3) Check pending DTC by using scan tool.
1. Fuel level sensor
2. Fuel meter in combination meter
3. ECM (PCM)
DTC DETECTING CONDITION TROUBLE AREA
Fuel level sensor output voltage higher than specified
value is detected for specified time.
(2 driving cycle detection logic)•Fuel level gauge or its circuit
•Fuel level sensor 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)

6-1-106 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
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 100 – 110 km/h (60 – 70 mph).
4) Release accelerator pedal and with engine brake applied, keep vehicle coasting for 5 seconds or more and
then stop vehicle.
5) Check pending DTC by using scan tool.
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.
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)
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG.
FLOW TABLE” in this
section.
2 Does speedometer indicate vehicle speed? Faulty “BLU/YEL” wire or
poor C51-1-14 connection.
If wire and connection are
OK, intermittent trouble or
faulty ECM (PCM).
Check for intermittent refer-
ring to “INTERMITTENT
AND POOR CONNECTION”
in Section 0A.Go to Step 3.
3 VSS power supply voltage check:
1) With ignition switch OFF, remove VSS
coupler.
2) With ignition switch ON leaving engine
OFF, check voltage between C20-3 and
C20-2 terminal of VSS coupler.
Is voltage 10 – 14 V?Go to Step 4.“BLK/BLU” or “BLK/YEL”
wire open/short.
4 VSS signal harness check:
1) With ignition switch ON leaving engine
OFF, check voltage between C20-1 and
C20-2 terminal of VSS coupler.
Is voltage 4 V or more?Go to Step 5. Go to Step 6.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-111
DTC P1408 Manifold Absolute Pressure Sensor Circuit Malfunction
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1. MAP sensor
2. ECM (PCM)
DTC DETECTING CONDITION TROUBLE AREA
•While engine is running after being warmed up and
with throttle opening smaller than specification,
higher than 4.6 V manifold absolute pressure sen-
sor output voltage is detected for specified time or
with throttle opening larger than specification, lower
than 0.2 V manifold absolute pressure output volt-
age is detected for specified time.
(2 driving cycle detection logic)•Manifold absolute pressure sensor
•Manifold absolute pressure sensor vacuum pas-
sage
•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 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)

6A2-26 ENGINE MECHANICAL (H27 ENGINE)
Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Release fuel pressure in fuel feed line. Refer to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6.
2) Disconnect negative (–) cable at battery.
3) Remove engine hood.
4) Drain engine oil.
5) Drain coolant.
6) Remove radiator, radiator fan shroud, cooling fan and radia-
tor reservoir. Refer to “COOLING FAN AND FAN CLUTCH”
and “RADIATOR” in Section 6B.
7) Disconnect accelerator cable (1) and A/T throttle cable (for
A/T vehicle) (2) from throttle body.
8) Remove strut tower bar and surge tank cover.
9) Disconnect IAT sensor coupler and MAF sensor coupler then
remove air cleaner upper case, intake air hose, intake air
pipe and surge tank pipe as a component.
10) Remove engine oil level gauge guide and A/T fluid level
gauge guide (for A/T vehicle).
11) Remove ignition coil covers.
12

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)

7B1-14 AUTOMATIC TRANSMISSION (4 A/T)
Diagnostic Trouble Code Table
Refer to the same item in Section 6-1.
Fail Safe Table
Refer to the same item in Section 6-1.
Visual Inspection
Visually check following parts and systems.
A/T Basic Check
This inspection is important for troubleshooting when PCM (ECM) has detected no DTC and no abnormality has
been noted in visual inspection. Follow flow table carefully.INSPECTION ITEM REFERRING SECTION
•A/T fluid - - - - - level, leakage, color SECTION 0B
•A/T fluid hoses - - - - - disconnection, looseness, deterioration SECTION 7B1
•Throttle (accelerator) cable - - - - - play, installation SECTION 6E2
•A/T throttle cable - - - - - play, installation SECTION 7B1
•A/T select cable - - - - - installation, operation SECTION 7B1
•Engine oil - - - - - level, leakage SECTION 0B
•Engine coolant - - - - - level, leakage SECTION 0B
•Battery - - - - - fluid level, corrosion of terminal
•Connectors of electric wire harness - - - - - disconnection, friction Section 6-1 or 7B1
•Fuses - - - - - burning SECTION 8
•Parts - - - - - installation, damage
•bolt - - - - - looseness
•Other parts that can be checked visually
•Also check following items at engine start, if possible.
–“O/D OFF” lamp - - - - - Operation SECTION 7B1
–“POWER” lamp - - - - - Operation SECTION 7B1
–Malfunction indicator lamp (“SERVICE ENGINE SOON” lamp) - -
- - - OperationSection 6-1
–Charge warning lamp - - - - - Operation SECTION 6H
–Engine oil pressure warning lamp - - - - - Operation SECTION 8C (SECTION 6A2 for pres-
sure check)
–Engine coolant temp. meter - - - - - Operation
–Other parts that can be checked visually
Step Action Yes No
1Was “AUTOMATIC TRANSMISSION DIAGNOSTIC
FLOW TABLE” performed?Go to Step 2. Go to “AUTOMATIC
TRANSMISSION DIAG-
NOSTIC FLOW TABLE”.
2Perform “MANUAL ROAD TEST” in this section.
Is it OK?Go to Step 3. Go to Step 4.
3Proceed to “TROUBLE DIAGNOSIS TABLE 1” in this
section.
Is trouble identified?Repair or replace
defective parts.Go to Step 5.