2001 SUZUKI GRAND VITARA Ign

5E2-30 ANTILOCK BRAKE SYSTEM (ABS)
9) Perform following checks with help of another person.
10) Brake pedal (1) should be depressed.
a) Ignition switch turned to ON position by one person.
b) Wheel should be turned by another person’s hand. At this
time, check that:
Operation sound of solenoid is heard and wheel turns only
about 0.5 sec. (brake force is depressurized).
Operation sound of pump motor is heard and pulsation is felt
at brake pedal.
11) If all 4-wheels cannot be checked during one ignition cycle
(OFF → ON), repeat Steps 8) and 9) till all 4 wheels are
checked.
If a faulty condition is found in Steps 9) and 10), replace
hydraulic unit/control module assembly.
Turn ignition switch to OFF position and remove service wire from
diagnosis connector.

5E2-32 ANTILOCK BRAKE SYSTEM (ABS)
3) Using special tool, loosen flare nuts (1) and disconnect brake
pipes (2) from ABS hydraulic unit/control module assembly
(3).
Special tool
09950-78220
4) Remove three bolts and take out ABS hydraulic unit/control
module assembly (1) from bracket using flat end rod or the
like (2).
INSTALLATION
1) Install hydraulic unit/control module assembly by reversing
removal procedure.
Tightening torque
Brake pipe flare nut (a) :
16 N·m (1.6 kg-m, 11.5 lb-ft)
ABS hydraulic unit/control module assembly bolt (b) :
9 N·m (0.9 kg-m, 6.5 lb-ft)
Bracket bolt (c) : 10 N·m (1.0 kg-m, 6.5 lb-ft)
2) Bleed air from brake system referring to “BRAKES” section.
3) Check each installed part for fluid leakage and perform “ABS
HYDRAULIC UNIT OPERATION CHECK” in this section. NOTE:
Put bleeder plug cap onto pipe to prevent fluid from spill-
ing. Do not allow brake fluid to get on painted surfaces.
2
1
3
CAUTION:
Do not give an impact to hydraulic unit.
Use care not to allow dust to enter hydraulic unit.
Do not place hydraulic unit on its side or upside down.
Handling it in inappropriate way will affect its original
performance.
NOTE:
For new ABS hydraulic unit/control module assembly, if
“ABS HYDRAULIC UNIT OPERATION CHECK” procedure
has not been performed, “ABS” warning lamp may flash
when ignition switch is turned ON position.
Accordingly preform “ABS HYDRAULIC UNIT OPERA-
TION CHECK” to stop flashing of ABS warning lamp.
(b) (b) (a)
(c) (c)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-1
6-1
SECTION 6-1
ENGINE GENERAL INFORMATION AND
DIAGNOSIS (H27 ENGINE)
CONTENTS
General Information ...................................... 6-1-3
Statement of Cleanliness and Care ............ 6-1-3
General Information on Engine Service ...... 6-1-3
Precaution on Fuel System Service ............ 6-1-4
Fuel Pressure Relief Procedure .................. 6-1-5
Fuel Leakage Check Procedure .................. 6-1-5
Engine Diagnosis .......................................... 6-1-6
General Description .................................... 6-1-6
On-Board Diagnostic System (Vehicle
without Monitor Connector) ......................... 6-1-6
On-Board Diagnostic System (Vehicle with
Monitor Connector) ..................................... 6-1-9
Precaution in Diagnosing Trouble ............. 6-1-10
Engine Diagnostic Flow Table ................... 6-1-11
Malfunction Indicator Lamp (MIL) Check... 6-1-16
Diagnostic Trouble Code (DTC) Check ..... 6-1-16
Diagnostic Trouble Code (DTC) Clearance 6-1-17
Diagnostic Trouble Code (DTC) Table ...... 6-1-18For A/T system (Refer to Section 7B1
for diagnosis)......................................... 6-1-21
For immobilizer control system (Refer to
Section 8G for diagnosis) ...................... 6-1-22
Fail-Safe Table.......................................... 6-1-23
Scan Tool Data ......................................... 6-1-24
Scan tool data definitions ...................... 6-1-27
Engine Diagnosis Table ............................ 6-1-31
Inspection of PCM (ECM) and its Circuits. 6-1-36
Table A-1 Malfunction Indicator Lamp
Circuit Check – Lamp Does Not Come
“ON” or Dims at Ignition Switch ON
(But Engine at Stop).................................. 6-1-43
Table A-2 Malfunction Indicator Lamp
Circuit Check – Lamp Remains “ON” after
Engine Starts ............................................ 6-1-44
Table A-3 Malfunction Indicator Lamp
Check – MIL Flashes at Ignition Switch
ON (Vehicle with Monitor Connector) ....... 6-1-45 WARNING:
For vehicles equipped with Supplemental Restraint (Air Bag) System:
Service on and around the air bag system components or wiring must be performed only by an
authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under
“General Description” in air bag system section in order to confirm whether you are performing ser-
vice on or near the air bag system components or wiring. Please observe all WARNINGS and “Ser-
vice Precautions” under “On-Vehicle Service” in air bag system section before performing service
on or around the air bag system components or wiring. Failure to follow WARNINGS could result in
unintentional activation of the system or could render the system inoperative. Either of these two
conditions may result in severe injury.
Technical service work must be started at least 90 seconds after the ignition switch is turned to the
“LOCK” position and the negative cable is disconnected from the battery. Otherwise, the system
may be activated by reserve energy in the Sensing and Diagnostic Module (SDM).
NOTE:
Whether following systems (parts) are used in the particular vehicle or not depends on specifications.
Be sure to bear this in mind when performing service work.
Monitor connector
CKP sensor
MAP sensor
EGR valve
Heated oxygen sensor or CO adjusting resistor
Three way catalytic converter, Warm-up three way catalytic converter

6-1-2 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Table A-4 Malfunction Indicator Lamp
Check – MIL Does Not Flash or Just
Remains ON Even with Grounding
Diagnosis Switch Terminal (Vehicle with
Monitor Connector) ................................... 6-1-45
Table A-5 ECM (PCM) Power and Ground
Circuit Check – MIL Doesn’t Light at
Ignition Switch ON and Engine Doesn’t
Start Though It Is Cranked Up .................. 6-1-46
DTC P0100 (DTC No.33, 34) Mass Air
Flow Circuit Malfunction ............................ 6-1-48
DTC P0110 (DTC No.23, 25) Intake Air
Temp. (IAT) Circuit Malfunction ................ 6-1-50
DTC P0115 (DTC No.14, 15) Engine
Coolant Temp. Circuit Malfunction ............ 6-1-52
DTC P0120 (DTC No.21, 22) Throttle
Position Circuit Malfunction....................... 6-1-54
DTC P0121 Throttle Position Circuit
Range/Performance Problem ................... 6-1-56
DTC P0130 (DTC No.13) HO2S-1 (Bank 1)
Circuit Malfunction or No Activity
Detected.................................................... 6-1-58
DTC P0133 HO2S-1 (Bank 1) Circuit Slow
Response .................................................. 6-1-60
DTC P0135 HO2S-1 (Bank 1) Heater
Circuit Malfunction .................................... 6-1-61
DTC P0136 HO2S-2 (Bank 1) Circuit
Malfunction................................................ 6-1-63
DTC P0141 HO2S-2 (Bank 1) Heater
Circuit Malfunction .................................... 6-1-65
DTC P0150 (DTC No.26) HO2S-1 (Bank 2)
Circuit Malfunction or No Activity
Detected.................................................... 6-1-67
DTC P0153 HO2S-1 (Bank 2) Circuit Slow
Response .................................................. 6-1-69
DTC P0155 HO2S-1 (Bank 2) Heater
Circuit Malfunction .................................... 6-1-70
DTC P0156 HO2S-2 (Bank 2) Circuit
Malfunction................................................ 6-1-72
DTC P0161 HO2S-2 (Bank 2) Heater
Circuit Malfunction .................................... 6-1-74
DTC P0171/P0172 Fuel System Too
Lean/Rich (Bank 1) ................................... 6-1-76
DTC P0174/P0175 Fuel System Too
Lean/Rich (Bank 2) ................................... 6-1-78
DTC P0300/P0301/P0302/P0303/P0304/
P0305/P0306 Random Misfire/Cylinder 1
Misfire/Cylinder 2 Misfire/Cylinder 3 Misfire/
Cylinder 4 Misfire Detected/Cylinder 5
Misfire Detected/Cylinder 6 Misfire
Detected.................................................... 6-1-80
DTC P0325 (DTC No.43) Knock Sensor Circuit Malfunction ..................................... 6-1-82
DTC P0335 Crankshaft Position Sensor
Circuit Malfunction ..................................... 6-1-84
DTC P0340 (DTC No.42) Camshaft
Position Sensor Circuit Malfunction ........... 6-1-86
DTC P0400 Exhaust Gas Recirculation
Flow Malfunction ........................................ 6-1-89
DTC P0403 (DTC No.51) Exhaust Gas
Recirculation Circuit Malfunction ............... 6-1-92
DTC P0420 Catalyst System Efficiency
Below Threshold (Bank 1) ......................... 6-1-94
DTC P0430 Catalyst System Efficiency
Below Threshold (Bank 2) ......................... 6-1-96
DTC P0443 Evap Control System Purge
Control Valve Circuit Malfunction............... 6-1-98
Evap canister purge system
inspection ............................................. 6-1-100
Vacuum passage inspection ................ 6-1-100
Vacuum hose inspection ...................... 6-1-101
Evap canister purge valve and its
circuit inspection .................................. 6-1-101
Evap canister purge valve inspection .. 6-1-101
DTC P0460 Fuel Level Sensor Circuit
High Input ................................................ 6-1-103
DTC P0500 (DTC No.24) Vehicle Speed
Sensor Malfunction .................................. 6-1-105
DTC P0505 Idle Air Control System
Malfunction .............................................. 6-1-108
DTC P0601 (DTC No.71) Internal Control
Module Memory Check Sum Error .......... 6-1-110
DTC P1408 Manifold Absolute Pressure
Sensor Circuit Malfunction ....................... 6-1-111
DTC P1450/P1451 Barometric Pressure
Sensor Circuit Malfunction/Performance
Problem ................................................... 6-1-113
DTC P1500 Engine Starter Signal Circuit
Malfunction .............................................. 6-1-114
DTC P1510 Ecm Back-Up Power Supply
Malfunction .............................................. 6-1-115
Table B-1 Fuel Pump Circuit Inspection .. 6-1-116
Table B-2 Fuel Injectors and Circuit
Inspection ................................................ 6-1-117
Table B-3 Fuel Pressure Inspection ........ 6-1-119
Table B-4 Idle Air Control System
Inspection ................................................ 6-1-121
Table B-5 A/C Signal Circuits Inspection
(If Equipped) ............................................ 6-1-123
Table B-6 A/C Condenser Fan Motor
Relay Control System Inspection
(If Equipped) ............................................ 6-1-124
Special Tool ............................................... 6-1-125

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-3
General Information
Statement of Cleanliness and Care
An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the thousands of an millimeter (ten thousands of inch). Accordingly, when any internal
engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood
that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This
is considered standard shop practice even if not specifically stated.
A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the
surface on initial operation.
Whenever valve train components, pistons, piston rings, connecting rods, rod bearings and crankshaft jour-
nal bearings are removed for service, they should be retained in order. At the time of installation, they should
be installed in the same locations and with the same mating surfaces as when removed.
Battery cables should be disconnected before any major work is performed on the engine. Failure to discon-
nect cables may result in damage to wire harness or other electrical parts.
Throughout this manual, the 6 cylinders of the engine are
identified by numbers; No.1, No.2, No.3, No.4, No.5 and No.6
as counted from crankshaft pulley side to flywheel side.
Figure at the left shows engine with intake manifold removed
and viewed from the top.
LH (No.1) bank consists of No.1, No.3 and No.5 cylinders.
RH (No.2) bank consists of No.2, No.4 and No.6 cylinders.
General Information on Engine Service
When raising or supporting engine for any reason, do not use a jack under oil pan. Due to small clearance
between oil pan and oil pump strainer, jacking against oil pan may cause it to be bent against strainer result-
ing in damaged oil pick-up unit.
It should be kept in mind, while working on engine, that 12-volt electrical system is capable of violent and
damaging short circuits.
When performing any work where electrical terminals could possibly be grounded, ground cable of the bat-
tery should be disconnected at battery.
Any time the air cleaner, air cleaner outlet hose, throttle body, surge tank pipe, intake collector or intake man-
ifold is removed, the intake opening should be covered. This will protect against accidental entrance of for-
eign material which could follow intake passage into cylinder and cause extensive damage when engine is
started.
1. No.1 cylinder 6. No.6 cylinder
2. No.2 cylinder 7. LH (No.1) bank
3. No.3 cylinder 8. RH (No.2) bank
4. No.4 cylinder 9. Crank shaft pulley side
5. No.5 cylinder
CAUTION:
The following information on engine service should be noted carefully, as it is important in preventing
damage, and in contributing to reliable engine performance.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-5
Fuel Pressure Relief Procedure
After making sure that engine is cold, relief fuel pressure as fol-
lows.
1) Place transmission gear shift lever in “Neutral” (shift selector
lever to “P” range for A/T vehicle), set parking brake, and
block drive wheels.
2) Remove fuel pump relay (1) from its connector.
3) Remove fuel filler cap to release fuel vapor pressure in fuel
tank and then reinstall it.
4) Start engine and run it till it stops for lack of fuel. Repeat
cranking engine 2 – 3 times of about 3 seconds each time to
dissipate fuel pressure in lines. Fuel connections are now
safe for servicing.
5) Upon completion of servicing, install fuel pump relay to relay
box.
Fuel Leakage Check Procedure
After performing any service on fuel system, check to make sure
that there are no fuel leakages as follows.
1) Turn ON ignition switch for 3 seconds (to operate fuel pump)
and then turn it OFF.
Repeat this (ON and OFF) 3 or 4 times and apply fuel pres-
sure to fuel line (till fuel pressure is felt by hand placed on
fuel return hose).
2) In this state, check to see that there are no fuel leakages
from any part of fuel system. CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
[A] : Left hand steering vehicle
[B] : Right hand steering vehicle
2. Fuse box

6-1-6 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Engine Diagnosis
General Description
This vehicle is equipped with an engine and emission control system which are under control of ECM (PCM).
The engine and emission control system in this vehicle are controlled by ECM (PCM). ECM (PCM) has an On-
Board Diagnostic system which detects a malfunction in this system and abnormality of those parts that influ-
ence the engine exhaust emission. When diagnosing engine troubles, be sure to have full understanding of the
outline of “ON-BOARD DIAGNOSTIC SYSTEM” and each item in “PRECAUTION IN DIAGNOSING TROUBLE”
and execute diagnosis according to “ENGINE DIAGNOSTIC FLOW TABLE” in this section.
There is a close relationship between the engine mechanical, engine cooling system, ignition system, exhaust
system, etc. and the engine and emission control system in their structure and operation. In case of an engine
trouble, even when the malfunction indicator lamp (MIL) doesn’t turn ON, it should be diagnosed according to
“ENGINE DIAGNOSTIC FLOW TABLE” in this section.
On-Board Diagnostic System (Vehicle without
Monitor Connector)
ECM (PCM) in this vehicle has following functions.
When the ignition switch is turned ON with the engine at a
stop, malfunction indicator lamp (MIL) (1) turns ON to check
the bulb of the malfunction indicator lamp (1).
When ECM detects a malfunction which gives an adverse
effect to vehicle emission while the engine is running, it
makes the malfunction indicator lamp (1) in the meter cluster
of the instrument panel turn ON or flash (flashing only when
detecting a misfire which can cause damage to the catalyst)
and stores the malfunction area in its memory.
(If it detects that continuously 3 driving cycles are normal
after detecting a malfunction, however, it makes MIL (1) turn
OFF although DTC stored in its memory will remain.)
As a condition for detecting a malfunction in some areas in
the system being monitored by ECM (PCM) and turning ON
the malfunction indicator lamp (1) due to that malfunction, 2
driving cycle detection logic is adopted to prevent erroneous
detection.
When a malfunction is detected, engine and driving condi-
tions then are stored in ECM (PCM) memory as freeze frame
data. (For the details, refer to description on Freeze frame
data.)
It is possible to communicate by using not only SUZUKI scan
tool (2) but also generic scan tool. (Diagnostic information
can be accessed by using a scan tool.)

6-1-8 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Priority of Freeze Frame Data
ECM (PCM) has 4 frames where the freeze frame data can be stored. The first frame stores the freeze frame
data of the malfunction which was detected first. However, the freeze frame data stored in this frame is updated
according to the priority described below. (If malfunction as described in the upper square “1” below is detected
while the freeze frame data in the lower square “2” has been stored, the freeze frame data “2” will be updated by
the freeze frame data “1”.)
In the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as the mal-
function is detected. These data are not updated regardless of the priority.
Shown in the table below are examples of how freeze frame data are stored when two or more malfunctions are
detected.
Freeze Frame Data Clearance
The freeze frame data is cleared at the same time as clearance of DTC.
DATA LINK CONNECTOR (DLC)
DLC (1) is in compliance with SAEJ1962 in its installation posi-
tion, the shape of connector and pin assignment.
K line of ISO 9141 is used for SUZUKI scan tool or generic scan
tool to communicate with ECM (PCM), ABS control module and
Air bag SDM. SUZUKI serial data line is used for SUZUKI scan
tool to communicate with Immobilizer control module. PRIORITY FREEZE FRAME DATA IN FRAME 1
1Freeze frame data at initial detection of malfunction among misfire detected (P0300-P0306), fuel
system too lean (P0171, P0174) and fuel system too rich (P0172, P0175)
2 Freeze frame data when a malfunction other than those in “1” above is detected
FRAME 1 FRAME 2 FRAME 3 FRAME 4
FREEZE FRAME
DATA to be updated1st FREEZE
FRAME DATA2nd FREEZE
FRAME DATA3rd FREEZE
FRAME DATA
No malfunction No freeze frame dataNo freeze frame
dataNo freeze frame
dataNo freeze frame
data
MALFUNCTION
DETECTED ORDER
1P0110 (IAT)
detectedData at P0110
detectionData at P0110
detectionNo freeze frame
dataNo freeze frame
data
2P0171 (Fuel sys-
tem) detectedData at P0171
detectionData at P0110
detectionData at P0171
detectionNo freeze frame
data
3P0300 (Misfire)
detectedData at P0171
detectionData at P0110
detectionData at P0171
detectionData at P0300
detection
4P0301 (Misfire)
detectedData at P0171
detectionData at P0110
detectionData at P0171
detectionData at P0300
detection
2. B+
3. SUZUKI Serial data line
4. K line of ISO 9141
5. Body ground
6. ECM ground