2001 SUZUKI GRAND VITARA engine

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-41
INSTALLATION
1) Confirm that vacuum passage on intake manifold is free from
clog.
2) Apply engine oil to O-ring of sensor.
3) Install sensor (1) to intake manifold (2).
4) Connect connector to sensor (1) securely.
Fuel level sensor (sender gauge)
Refer to Section 8C.
Crankshaft position sensor
REMOVAL AND INSTALLATION
Refer to Section 6A4.
INSPECTION
Refer to Section 6-1.
Main relay
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove main relay (1) from its connector.
2. Fuel pump relay
3. Fuse box
4. Instrument panel
[A]: Left-hand steering vehicle
[B]: Right-hand steering vehicle

6E2-42 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
3) Check resistance between each two terminals as in table
below.
If check results are as specified, proceed to next operation
check. If not, replace.
Main relay resistance:
4) Check that there is continuity between terminals “A” and “B”
when battery is connected to terminals “C” and “D”.
If malfunction is found, replace.
Fuel pump relay
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove fuel pump relay (2) from connector.
3) Structure of fuel pump relay is the same as that of main
relay.
Check its resistance and operation using the same proce-
dure as that for main relay.
If malfunction is found, replace. TERMINALS RESISTANCE
Between “A” and “B”∞
∞∞ ∞ (Infinity)
Between “C” and “D”
79 – 95 Ω
ΩΩ Ω (at 20
°C (68°F))
1. Main relay
3. Fuse box
4. Instrument panel
[A]: Left-hand steering vehicle
[B]: Right-hand steering vehicle

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-43
Fuel cut operation
INSPECTION
1) Warm up engine to normal operating temperature.
2) While listening to sound of injector by using sound scope (1)
or such, increase engine speed to higher than 3,000 r/min.
3) Check to make sure that sound to indicate operation of injec-
tor stops when throttle valve is closed instantly and it is
heard again when engine speed is reduced to less than
about 2,000 r/min. NOTE:
Before inspection, check to make sure that gear shift
lever is in Neutral position (with A/T model, selector lever
in “P” range) and that parking brake lever is pulled all the
way up.

6E2-44 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Emission Control System
EGR system (if equipped)
EGR SYSTEM INSPECTION (USING SUZUKI SCAN TOOL)
1) Connect SUZUKI scan tool to data link connector (DLC) (1)
with ignition switch OFF.
Special tool
(A) : SUZUKI scan tool
2) Start engine and warm up it to normal operating tempera-
ture.
3) With engine idling (without depressing accelerator pedal),
open EGR valve by using “MISC. TEST” mode.
In this state, according as EGR valve opening increases
engine idle speed drops. If not, possible cause is clogged
EGR gas passage, stuck or faulty EGR valve.
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disconnect EGR valve coupler.
3) Remove wire harness bracket from intake collector.
4) Remove EGR valve (5) and gasket from intake collector.NOTE:
For operation procedure of cartridge, refer to its car-
tridge operator's manual.
1. SUZUKI scan tool display
2. EGR valve opening (0: Close, 100: Full Open)
1. EVAP canister purge valve 4. EGR pipe
2. EVAP canister purge valve hose 6. PCV hose
3. Breather hose

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-45
INSPECTION
1) Check resistance between following terminals of EGR valve
(1) in each pair.
If found faulty, replace EGR valve assembly.
EGR valve resistance:
2) Remove carbon from EGR valve gas passage.
3) Inspect valve (2), valve seat (3) and rod for fault, cracks,
bend or other damage.
If found faulty, replace EGR valve (1) assembly.
INSTALLATION
Reverse removal procedure noting the followings.
•Clean mating surface of valve and intake manifold.
•Use new gasket.
EVAP canister
INSPECTION
Terminals Standard resistance
A – B
C – B
F – E
D – E20 – 24 Ω
ΩΩ Ω at 20°C (68°F)
B - valve body
E - valve bodyinfinity (∞
∞∞ ∞)
NOTE:
Do not use any sharp-edged tool to remove carbon.
Be careful not to damage or bend EGR valve, valve seat
and rod.
WARNING:
DO NOT SUCK nozzles on EVAP canister. Fuel vapor
inside EVAP canister is harmful.

6E2-46 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
1) Disconnect vacuum hoses from EVAP canister and remove
EVAP canister.
2) When air is blown into tank pipe, there should be no restric-
tion of flow through purge pipe and air pipe.
If operation differs from above description, EVAP canister
must be replaced.
3) Install EVAP canister and connect hoses to canister.
Vacuum passage
INSPECTION
Start engine and run it at idle speed. Disconnect vacuum hose
from EVAP canister purge valve. With finger placed against hose
disconnected, check that vacuum is applied.
If it is not applied, clean vacuum passage by blowing compressed
air.
TANK PRESSURE CONTROL VALVE INSPECTION
1) Remove tank pressure control valve installed around EVAP
canister.
2) Air should pass through valve smoothly from black side (3) of
tank pressure control valve (1) to orange side (2) when
blown hard.
3) From orange side, even when blown softly, air should come
out of black side.
4) If air doesn’t pass through valve in Step 2) or hard blow is
required in Step 3), replace tank pressure control valve.
5) Plug orange nozzle and apply 26 kPa (20 cmHg) vacuum to
black nozzle. Check that vacuum is held at that level (there is
no leakage).
If vacuum leaks, replace.
6) Install tank pressure control valve.
1. Tank pipe
2. Purge pipe
3. Air pipe
4. Blow air
WARNING:
DO NOT SUCK air through tank pressure control valve.
Fuel vapor inside the valve is harmful.
4. To canister
5. From fuel tank

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-47
PCV System
PCV hose
INSPECTION
Check hoses for connection, leakage, clog, and deterioration.
Replace as necessary.
PCV valve
ON-VEHICLE INSPECTION
1) Disconnect PCV valve from cylinder head cover and plug
head cover hole.
2) Run engine at idle.
3) Place your finger over end of PCV valve (1) to check for vac-
uum. If there is no vacuum, check for clogged valve. Replace
as necessary.
4) After checking vacuum, stop engine and remove PCV valve
(1). Shake valve and listen for the rattle of check needle
inside the valve (1). If valve does not rattle, replace.
5) After checking, connect PCV valve (1), PCV hose and clamp
securely. NOTE:
Be sure to check that there is no obstruction in PCV
valve or its hoses before checking engine idle speed/IAC
duty for obstructed PCV valve or hose hampers its accu-
rate checking.

6E2-48 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
PCV system
PCV HOSE
Check hoses for connection, leakage, clog, and deterioration.
Replace as necessary.
Tightening Torque Specification
Special Tool
NOTE:
Be sure to check that there is no obstruction in PCV
valve or its hoses (6) before checking engine idle speed/
IAC duty for obstructed PCV valve or hose hampers its
accurate checking.
1. EVAP canister purge valve 4. EGR pipe
2. EVAP canister purge valve hose 5. EGR valve
3. Breather hose 6. PCV hose
Fastening partTightening torque
Nm kg-m lb-ft
Heated oxygen sensor 45 4.5 32.5
Fuel pressure regulator bolts 10 1.0 7.5
Fuel pipe union bolts 30 3.0 22.0
Engine coolant temp. sensor 15 1.5 11.0
09912-58441 09912-58431 09912-58490 09912-58421
Pressure gauge Pressure hose 3-way joint & hose Checking tool set
(See NOTE “A”.)