2001 SUZUKI GRAND VITARA service

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) 6-1-3
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.

6-1-4 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
When disconnecting couplers, don’t pull wire harness but
make sure to hold coupler itself. With lock type coupler, be
sure to unlock before disconnection. Attempt to disconnect
coupler without unlocking may result in damage to coupler.
When connecting lock type coupler, insert it till clicking
sound is heard and connect it securely.
Precaution on Fuel System Service
Work must be done with no smoking, in a well-ventilated area and away from any open flames.
As fuel feed line (between fuel pump and fuel pressure regulator) is still under high fuel pressure even after
engine was stopped, loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to
occur where loosened or disconnected. Before loosening or disconnecting fuel feed line, make sure to
release fuel pressure according to “FUEL PRESSURE RELIEF PROCEDURE” in this section.
A small amount of fuel may be released after the fuel line is disconnected.
In order to reduce the chance of personal injury, cover the fitting to be disconnected with a shop cloth. Put
that cloth in an approved container when disconnection is completed.
Never run engine with fuel pump relay disconnected when engine and exhaust system are hot.
Fuel or fuel vapor hose connection varies with each type of
pipe. When reconnecting fuel or fuel vapor hose, be sure to
connect and clamp each hose correctly referring to left fig-
ure.
After connecting, make sure that the hose has no twist or
kink.
When installing fuel union bolt gasket, always use new gas-
ket and tighten union bolt to specified torque according to
“TIGHTENING TORQUE SPECIFICATION” in Section 6C.
When installing injector, fuel feed pipe or fuel pressure regu-
lator, lubricate its O-ring with gasoline.
When connecting fuel pipe flare nut, first tighten flare nut by
hand and then tighten it to specified torque.
[A] : With short pipe, fit hose as far as it reaches pipe joint as shown.
[B] : With following type pipe, fit hose as far as its peripheral projection as shown.
[C] : With bent pipe, fit hose as far as its bent part as shown or till pipe is about 20
to 30 mm (0.79 – 1.18 in.) into the hose.
[D] : With straight pipe, fit hose till pipe is about 20 to 30 mm (0.79 – 1.18 in.) into
the hose.
1. Hose
2. Pipe
3. Clamp
“a” : Clamp securely at a position 3 to 7 mm (0.12 – 0.27 in.) from hose end.
“b” : 20 to 30 mm (0.79 – 1.18 in.)

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

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-9
On-Board Diagnostic System (Vehicle with
Monitor Connector)
ECM diagnosis troubles which may occur in the area including the
following parts when the ignition switch is ON and the engine is
running, and indicates the result by turning on of flashing mal-
function indicator lamp (1).
• Heated oxygen sensor (if equipped)
•ECT sensor
•TP sensor
• IAT sensor
• CMP sensor
•MAF sensor
• Knock sensor
• EGR (if equipped)
•VSS
• CPU (Central Processing Unit) of ECM
ECM and malfunction indicator lamp (1) operate as follows.
• Malfunction indicator lamp (1) light when the ignition switch
is turned ON (but the engine at stop) with the diagnosis
switch terminal ungrounded regardless of the condition of
Engine and Emission control system. This is only to check
the malfunction indicator lamp (1) bulb and its circuit.
• If the above areas of Engine and Emission control system is
free from any trouble after the engine start (while engine is
running), malfunction indicator lamp (1) turns OFF.
• When ECM detects a trouble which has occurred in the
above areas, it makes malfunction indicator lamp (1) turn ON
while the engine is running to warn the driver of such occur-
rence of trouble and at the same time it stores the trouble
area in ECM back-up memory. (The memory is kept as it is
even if the trouble was only temporary and disappeared
immediately. And it is not erased unless the power to ECM is
shut off for specified time.)
ECM also indicates trouble area in memory by means of
flashing of malfunction indicator lamp (1) at the time of
inspection. (i.e. when diagnosis switch terminal (2) is con-
nected to ground terminal (3) with a service wire and ignition
switch is turned ON.)
NOTE:
When a trouble occurs in the above areas and disappears
soon while the diagnosis switch terminal is ungrounded
and the engine is running, malfunction indicator lamp (1)
lights and remains ON as the trouble exists but it turns
OFF when the normal condition is restored.

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) 6-1-17
[Without Using SUZUKI Scan Tool] (Vehicle with Monitor
Connector)
1) Check malfunction indicator lamp referring to “Malfunction
Indicator Lamp Check” in this section.
2) With the ignition switch OFF position, disconnect SUZUKI
scan tool if connected and using service wire (4), connect
diagnosis switch terminal (1) to ground terminal (2) in moni-
tor connector (3).
3) With the ignition switch ON position and leaving engine OFF,
read DTC from flashing pattern of malfunction indicator
lamp. Refer to “Diagnostic Trouble Code Table”.
If lamp remains ON, go to “Diagnostic Flow Table A-4”.
4) After completing the check, turn the ignition switch OFF posi-
tion and disconnect service wire from monitor coupler.
Diagnostic Trouble Code (DTC) Clearance
[Using scan tool]
1) With ignition switch OFF, connect generic scan tool or
SUZUKI scan tool to data link connector (DLC).
2) Turn ignition switch ON.
3) Erase DTC according to instructions displayed on scan tool.
Freeze frame data is cleared with the DTC. Refer to scan tool
operator’s manual for further details.
4) After completing the clearance, turn ignition switch off and
disconnect scan tool from data link connector. NOTE:
If abnormality or malfunction lies in two or more areas,
malfunction indicator lamp indicates applicable codes
three times each.
And flashing of these codes is repeated as long as
diagnosis terminal is grounded and ignition switch is
held at ON position.
Take a note of diagnostic trouble code indicated first.
NOTE:
DTC and freeze frame data stored in ECM (PCM) memory
are also cleared in following cases. Be careful not to
clear them before keeping their record.
When power to ECM (PCM) is cut off (by disconnecting
battery cable, removing fuse or disconnecting ECM
(PCM) connectors)
When the same malfunction (DTC) is not detected
again during 40 engine warm-up cycles (refer to
“WARM-UP CYCLE” of “ON-BOARD DIAGNOSTIC SYS-
TEM” in this section) (Vehicle without monitor connec-
tor)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-37
TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION
E61-1Power source for CO adjusting
resistor (if equipped)10 – 14 V Ignition switch ON
E61-2 Power source for back up 10 – 14 V Ignition switch ON and OFF
E61-3 – – –
E61-4Cruise control module
(throttle opening signal)
(if equipped)Ignition switch ON, Voltage varies as specified at figure in
cruise control diagnosis of Section 8E while throttle valve is
opened gradually.
E61-5Duty output terminal
(vehicle with monitor connector)0 – 1 V Ignition switch ON
E61-6 Tachometer 0 – 1 V Ignition switch ON, engine stops
E61-7Malfunction indicator lamp
(“SERVICE ENGINE SOON” lamp)0 – 2.5 V Ignition switch ON, engine stops
10 – 14 V Engine running
E61-8 A/C cut signal (if equipped)0 – 1.5 V A/C is not operating
10 – 14 V A/C is operating
E61-9 Main relay10 – 14 V Ignition switch OFF
0 – 2 VIgnition switch ON or for 4 seconds
after ignition switch OFF
E61-10 CO adjusting resistor (if equipped) – –
E61-11 – – –
E61-12Data link connector (5V)
(Vehicle with monitor connector)4 – 6 V Ignition switch ON
E61-13 Data link connector (12V) 10 – 14 V Scan tool not connected to DLC
E61-14Test switch terminal
(Vehicle with monitor connector)10 – 14 V Ignition switch ON
E61-15 Rear defogger switch (if equipped)0 – 1.5 VIgnition switch ON, rear defogger
switch OFF
10 – 14 VIgnition switch ON, rear defogger
switch
E61-16 Heater blower switch10 – 14 VIgnition switch ON, heater blower
switch OFF
0 – 1.5 VIgnition switch ON, heater blower
switch ON
E61-17 A/C signal (if equipped)10 – 14 VIgnition switch ON, A/C switch or
heater blower switch OFF
0 – 1 VIgnition switch ON, A/C switch ON
and heater blower switch ON
E61-18 – – –
E61-19 “4WD” lamp0 – 1 VIgnition switch ON, Transfer lever :
4H or 4L range
10 – 14 VIgnition switch ON, Transfer lever :
2H range
E61-20 “O/D OFF” lamp (A/T vehicle)0 – 1 VFor 4 sec. after ignition switch ON
or overdrive cut switch ON
10 – 14 VAfter 4 sec. from ignition switch ON
and overdrive cut switch OFF
E61-21 “POWER” lamp (A/T vehicle)0 – 1 VIgnition switch ON, P/N change
switch : POWER mode
10 – 14 VIgnition switch ON, P/N change
switch : NORMAL mode