2001 SUZUKI GRAND VITARA air condition

ANTILOCK BRAKE SYSTEM (ABS) 5E2-23
INSPECTION
Step Action Yes No
1 1) Disconnect applicable ABS wheel speed sensor coupler
with ignition switch OFF.
2) Measure resistance between terminals of ABS wheel
speed sensor. Refer to “FRONT WHEEL SPEED SEN-
SOR” and/or “REAR WHEEL SPEED SENSOR” in this
section.
Is measured resistance value as specified?Go to Step 2. Replace ABS wheel
speed sensor
assembly.
2 1) Turn ignition switch OFF.
2) Disconnect ABS hydraulic unit/control module connec-
tor.
3) Check for proper connection to ABS control module at
each sensor terminal.
4) If OK, then turn ignition switch ON and measure voltage
between sensor terminal of module connector and body
ground.
Is it 0V?Go to Step 3. ABS wheel speed
sensor circuit
shorted to power.
3 1) Turn ignition switch OFF.
2) Connect ABS wheel speed sensor coupler.
3) Measure resistance between the following points.
Both ABS hydraulic unit/control module connector termi-
nals of the corresponding sensor.
This check result should be the same as above Step 1.
Either terminal of wheel speed sensor coupler and body
ground.
This check result should be no continuity.
Are both check results OK?Go to Step 4. Circuit open or
shorted to ground.
4 1) Remove applicable ABS wheel speed sensor.
2) Check sensor for damage or foreign material attached.
Is it in good condition?Go to Step 5. Clean, repair or
replace.
5 Check front and/or rear sensor ring for the following
(remove rear drum as necessary) :
Rotor serration (teeth) neither missing nor damaged.
No foreign material being attached.
Rotor not being eccentric.
Wheel bearing free from excessive play.
Are they in good condition?Go to Step 6. Clean, repair or
replace.
6 1) Install ABS wheel speed sensor to knuckle.
2) Tighten sensor bolt to specified torque and check that
there is no clearance between sensor and knuckle.
Is it OK?Go to Step 7. Replace ABS wheel
speed sensor.
7 Referring to “Reference” of “FRONT WHEEL SPEED SEN-
SOR” and/or “Reference” of “REAR WHEEL SPEED SEN-
SOR” in this section, check output voltage or waveform.
Is specified voltage and/or waveform obtained?Substitute a known-
good ABS hydrau-
lic unit/control mod-
ule assembly and
recheck.Replace sensor and
recheck.

ANTILOCK BRAKE SYSTEM (ABS) 5E2-27
DTC C1063 (DTC 63) – ABS Fail-Safe Relay Circuit
DESCRIPTION
ABS control module monitors the voltage at the terminal of solenoid circuit constantly with ignition switch turned
ON. Also, immediately after ignition switch is turned ON, perform initial check as follows.
Switch fail-safe relay in the order of OFF → ON and check if voltage changes to Low → High. If anything faulty is
found in the initial check and when the voltage is low with ignition switch turned ON, this DTC will be set.
INSPECTION
1. Ignition switch 3. ABS hydraulic unit/control module connector 5. Fail-safe relay
2. ABS hydraulic unit/control module assembly 4. To solenoid valves
Step Action Yes No
1 Check battery voltage. Is it about 11 V or
higher?Go to Step 2. Check charging system
referring to “CHARGING
SYSTEM” section.
2 Check ABS main fuse and connection.
Is it in good condition?Go to Step 3. Repair and/or replace
fuse.
3 1) Ignition switch OFF.
2) Disconnect ABS hydraulic unit/control mod-
ule connector.
3) Check proper connection to ABS hydraulic
unit/control module at terminal “E136-25”.
4) If OK, then measure voltage between con-
nector terminal “E136-25” and body ground.
Is it 10 – 14 V?Substitute a known-good
ABS hydraulic unit/con-
trol module assembly and
recheck.“WHT/BLU” circuit open
or short to ground.

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

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-7
WARM-UP CYCLE
A warm-up cycle means sufficient vehicle operation such that the
coolant temperature has risen by at least 22°C (40°F) from
engine starting and reaches a minimum temperature of 70 °C
(160 °F).
DRIVING CYCLE
A “Driving Cycle” consists of engine startup, driving mode where
a malfunction would be detected if present and engine shutoff.
2 DRIVING CYCLE DETECTION LOGIC
The malfunction detected in the first driving cycle is stored in
ECM (PCM) memory (in the form of pending DTC) but the mal-
function indicator lamp does not light at this time. It lights up at the
second detection of same malfunction also in the next driving
cycle.
PENDING DTC
Pending DTC means a DTC detected and stored temporarily at 1
driving cycle of the DTC which is detected in the 2 driving cycle
detection logic.
FREEZE FRAME DATA
ECM (PCM) stores the engine and driving conditions (in the form
of data as shown in the figure) at the moment of the detection of a
malfunction in its memory. This data is called “Freeze frame data”.
Therefore, it is possible to know engine and driving conditions
(e.g., whether the engine was warm or not, where the vehicle was
running or stopped, where air/fuel mixture was lean or rich) when
a malfunction was detected by checking the freeze frame data.
Also, ECM (PCM) has a function to store each freeze frame data
for three different malfunctions in the order as the malfunction is
detected. Utilizing this function, it is possible to know the order of
malfunctions that have been detected. Its use is helpful when
rechecking or diagnosing a trouble.
1. 1st, 2nd or 3rd in parentheses here represents which position in the
order the malfunction is detected.
1. TROUBLE CODE
2. COOLANT TEMP.
3. ENGINE SPEED
4. SHORT FT B1
5. SHORT FT B2
6. LONG FT B1
7. LONG FT B2
8. CALC LOAD
9. FUEL SYSTEM B1
10. FUEL SYSTEM B2
11. MAP
12. VEHICLE SPEEDP0100
80 C
750 RPM
– 0.8
– 0.1
– 1.3
– 1.5
20.5
CLOSED
CLOSED
30.6 kPa
0 km/h(1st)
1

6-1-10 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
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 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.
Precaution in Diagnosing Trouble
• Don’t disconnect couplers from ECM (PCM), battery cable from battery, ECM (PCM) ground wire harness
from engine or main fuse before confirming diagnostic information (DTC, freeze frame data, etc.) stored in
ECM (PCM) memory. Such disconnection will erase memorized information in ECM (PCM) memory.
• Diagnostic information stored in ECM (PCM) memory can be cleared as well as checked by using SUZUKI
scan tool or generic scan tool. Before using scan tool, read its Operator’s (Instruction) Manual carefully to
have good understanding as to what functions are available and how to use it.
• Priorities for diagnosing troubles (Vehicle without monitor connector)
If two or more diagnostic trouble codes (DTCs) are stored, proceed to the flow table of the DTC which was
detected earliest in the order and follow the instruction in that table.
If no instructions are given, troubleshoot diagnostic trouble codes according to the following priorities.
– Diagnostic trouble codes (DTCs) other than DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too
rich), DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire detected) and DTC P0400 (EGR
flow malfunction)
– DTC P0171/P0172/P0174/P0175 (Fuel system too lean/too rich) and DTC P0400 (EGR flow malfunction)
– DTC P0300/P0301/P0302/P0303/P0304/P0305/P0306 (Misfire detected)
• Be sure to read “PRECAUTIONS FOR ELECTRICAL CIRCUIT SERVICE” in Section 0A before inspection
and observe what is written there.
• ECM (PCM) Replacement
When substituting a known-good ECM (PCM), check for following conditions. Neglecting this check may
cause damage to a known-good ECM (PCM).
– Resistance value of all relays, actuators is as specified respectively.
– MAF sensor, MAP sensor and TP sensor are in good condition and none of power circuits of these sen-
sors is shorted to ground.
2. B+
3. SUZUKI Serial data line
4. K line of ISO 9141
5. Body ground
6. ECM ground

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-11
Engine Diagnostic Flow Table
Refer to following pages for the detail of each step.
Step Action Yes No
1 Customer Complaint Analysis
1) Perform customer complaint analysis.
Was customer complaint analysis performed?Go to Step 2. Perform customer com-
plaint analysis.
2 DTC(s)/Freeze Frame Data Check
1) Check DTC(s)/Freeze frame data.
Is there any malfunction DTC(s)?Record DTC(s)/Freeze
frame data.
Clear DTC(s).
Go to Step 3.Go to Step 4.
3 Visual Inspection
1) Perform visual inspection.
Is there any faulty condition?Repair or replace mal-
function part.
Go to Step 11.Go to Step 5.
4 Visual Inspection
1) Perform visual inspection.
Is there any faulty condition?Repair or replace mal-
function part.
Go to Step 11.Go to Step 8.
5 Trouble Symptom Confirmation
1) Confirm trouble symptom based on cus-
tomer complaint analysis, DTC(s)/freeze
frame data in Step 1.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6 DTC/Freeze Frame Data Recheck
1) Recheck DTC/freeze frame data.
Is there any malfunction DTC(s)?Go to Step 9. Go to Step 8.
7 DTC/Freeze Frame Data Recheck
1) Recheck DTC/freeze frame data.
Is there any malfunction DTC(s)?Go to Step 9. Go to Step 10.
8 Engine Basic Inspection
1) Check and repair according to “ENGINE
BASIC INSPECTION FLOW TABLE” and
“ENGINE DIAGNOSIS TABLE” in this sec-
tion.
Are check and repair complete?Go to Step 11. Check and repair mal-
function part(s).
Go to Step 11.
9 DTC Trouble Shooting
1) Check and repair according to applicable
“DTC Diag. flow table” in this section.
Are check and repair complete?Go to Step 11. Check and repair mal-
function part(s).
Go to Step 11.
10 Intermittent Problems Check
1) Check for intermittent problems referring to
“Check for Intermittent Problem” in “GEN-
ERAL INFORMATION” section.
Is there any faulty condition?Repair or replace mal-
function part.
Go to Step 11.Go to Step 11.
11 Final Confirmation Test
1) Clear DTC if any.
2) Perform final confirmation test referring to
“DTC CONFIRMATION PROCEDURE” in
this section.
Is there any problem symptom, malfunction
DTC or abnormal condition?Go to Step 6. END.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-13
STEP 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK
First, check DTC, referring to “DIAGNOSTIC TROUBLE CODE CHECK” in this section. If DTC is indicated,
record DTC and freeze frame data.
After that clear DTC referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section. DTC indicates
malfunction that occurred in the system but does not indicate whether it exists now or it occurred in the past and
the normal condition has been restored now. To check which case applies, check the symptom in question
according to Step 5 and recheck DTC according to Step 6, 7.
Attempt to diagnose a trouble based on DTC in this step only or failure to clear the DTC (including pending DTC)
in this step will lead to incorrect diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting.
STEP 3. and 4. VISUAL INSPECTION
Be sure to perform visual check of the following items that support proper function of the engine.
STEP 5. TROUBLE SYMPTOM CONFIRMATION
Based on information obtained in Step 1 “CUSTOMER COMPLAINT ANALYSIS” and Step 2 “DTC/FREEZE
FRAME DATA CHECK”, confirm trouble symptoms. Also, reconfirm DTC according to “DTC CONFIRMATION
PROCEDURE” described in each “DTC FLOW TABLE”.NOTE:
For A/T vehicle, if only DTC P0705, P0715, P0720, P0741, P0743, P0751, P0753, P0756, P0758, or P1875
is indicated in this step, proceed to “DIAGNOSIS” in SECTION 7B1.
INSPECTION ITEM REFERRING SECTION
• Engine oil - - - - - level, leakage
• Engine coolant - - - - - level, leakage
• Fuel - - - - - level, leakage
• A/T fluid - - - - - level, leakage
• Air cleaner element - - - - - dirt, clogging
• Battery - - - - - fluid level, corrosion of terminal
• Water pump belt and/or cooling fan belt - - - - - tension, damage
• Accelerator cable - - - - - play, installation
• A/T throttle cable - - - - - play, installation
• Vacuum hoses of air intake system
- - - - - disconnection, looseness, deterioration, bend
• Connectors of electric wire harness - - - - - disconnection, friction
• Fuses - - - - - burning
• Parts - - - - - installation, bolt - - - - - looseness
• Parts - - - - - deformation
• Other parts that can be checked visually
• Also check following items at engine start, if possible
– Malfunction indicator lamp - - - - - operation
– Charge warning lamp - - - - - operation
– Engine oil pressure warning lamp - - - - - operation
– Engine coolant temp. meter - - - - - operation
– Fuel lever meter - - - - - operation
– Abnormal air being inhaled from air intake system
– Exhaust system - - - - - leakage of exhaust gas, noise
– Other parts that can be checked visuallySECTION 0B
SECTION 0B
SECTION 0B
SECTION 0B
SECTION 0B
SECTION 0B
SECTION 6C
SECTION 6E2
SECTION 6E2
SECTION 6A2
SECTION 8
SECTION 6-1
SECTION 6H
SECTION 8/6A2
SECTION 8
SECTION 8

6-1-14 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
STEP 6. AND 7. RECHECKING AND RECORD OF DTC
Refer to “DTC Check” in this section for checking procedure.
STEP 8. ENGINE BASIC INSPECTION AND ENGINE DIAGNOSIS TABLE
Perform basic engine check according to the “ENGINE BASIC INSPECTION FLOW TABLE” first. When the end
of the flow table has been reached, check the parts of the system suspected as a possible cause referring to
“ENGINE DIAGNOSIS TABLE” and based on symptoms appearing on the vehicle (symptoms obtained through
steps of customer complaint analysis, trouble symptom confirmation and/or basic engine check) and repair or
replace faulty parts, if any.
Engine Basic Inspection Flow Table
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 Check battery voltage.
Is it 11 V or more?Go to Step 3. Charge or replace battery.
3 Is engine cranked? Go to Step 4. Go to “DIAGNOSIS” in
Section 6H.
4 Does engine start? Go to Step 5. Go to Step 7.
5 Check engine idle speed/IAC duty referring to
“IDLE SPEED/IAC DUTY INSPECTION” in
Section 6E2.
Is check result as specified?Go to Step 6. Go to “ENGINE DIAGNO-
SIS TABLE” in this sec-
tion.
6 Check ignition timing referring to “IGNITION
TIMING INSPECTION” in Section 6F2.
Is check result as specified?Go to “ENGINE DIAGNO-
SIS TABLE” in this sec-
tion.Adjust ignition timing.
7 Check fuel supply as follows :
1) Check to make sure that enough fuel is
filled in fuel tank.
2) Turn ON ignition switch for 3 seconds and
then OFF.
Repeat this a few times.
Is fuel return pressure (returning sounds) felt
from fuel return hose when ignition switch is
turned ON?Go to Step 9. Go to Step 8.
8 Check fuel pump for operating.
1) Was fuel pump operating sound heard from
fuel filler for about 3 seconds after ignition
switch ON and stop?Go to “DIAG. FLOW
TABLE B-3” in this sec-
tion.Go to “DIAG. FLOW
TABLE B-1” in this sec-
tion.
9 Check ignition spark referring to “IGNITION
SPARK TEST” in Section 6E2.
Is it in good condition?Go to Step 10. Go to “DIAGNOSIS” in
Section 6F2.
10 Check fuel injector referring to “Fuel INJECTOR
INSPECTION” in Section 6E2.
Is it in good condition?Go to “ENGINE DIAGNO-
SIS TABLE” in this sec-
tion.Go to “DIAG. FLOW
TABLE B-2” in this sec-
tion.