2001 SUZUKI GRAND VITARA Page 1

1B-38 AIR CONDITIONING (OPTIONAL)
Compressor Assembly
INSPECTION
1) Install manifold gauge set (1) as shown in the figure.
2) Close Hi (4) and Lo (5) side valves.
3) Run engine at fast idle.
4) Check compressor for the following items.
If any of the above checks indicated a defect, repair com-
pressor.
High pressure gauge reading is not low and low pressure
gauge reading is not higher than normal.
Metallic sound.
Leakage from compressor. CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of
A/C: one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
For identification between these two types, refer to page 66.
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A/C installed in the vehicle being serviced.
Use of incorrect refrigerant or compressor oil will result in leakage of refrigerant, damage in parts or
other faulty condition.
When servicing the compressor, keep dirt or foreign material away from getting on or into the com-
pressor parts and system. Clean tools and a clean work area are important for proper service.
The compressor connection and the outside of the compressor should be cleaned before any “On-
vehicle” repair or before removal of the compressor. The parts must be kept clean at all times and any
parts to be reassembled should be cleaned with Trichloromethane, naphtha, kerosene or equivalent
solvent and dried with dry air. Use only lint free cloths to wipe parts.
The operations described are based on bench overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of accessibility of the components.
When compressor is removed from the vehicle for servicing, the oil remaining in the compressor
should be discarded and new refrigerant oil added to the compressor.
Minor repair procedures may be done on the vehicle without discharging the system. Major repair pro-
cedures require that the system be discharged of refrigerant.
2. High pressure side (Delivery side hose)
3. Low pressure side (Suction side pipe)
1
4 5
2
3

5E2-6 ANTILOCK BRAKE SYSTEM (ABS)
ABS Diagnostic Flow Table
Refer to the following pages for the details of each step.
Step Action Yes No
11)Perform “Customer Complaint Analysis”.
2) Perform “Problem Symptom Confirmation”.
3) Perform “Diagnostic Trouble Code Check, Record and
Clearance”.
Is there any malfunction DTC?Go to Step 2. Go to Step 5.
21)Perform “DRIVING TEST”.
Is trouble symptom identified?Go to Step 3. Go to Step 6.
3 1) Check diagnostic trouble code.
Is it malfunction code?Go to Step 4. Go to Step 5.
4 1) Inspect and repair referring to applicable diagnostic trouble
code table in this section.
2) Perform “FINAL CONFIRMATION TEST” after cleared
DTC.
Does trouble recur?Go to Step 7. End.
5 1) Inspect and repair referring to “DIAGNOSIS” in “BRAKES”
section.
2) Perform “FINAL CONFIRMATION TEST”.––
6 1) Check intermittent troubles referring to “INTERMITTENT
AND POOR CONNECTION” in “GENERAL INFORMA-
TION” section and related circuit of trouble code recorded
in Step 2.
2) Perform “FINAL CONFIRMATION TEST” after cleared
diagnostic trouble code.
Does trouble recur?Go to Step 7. End.
71)Perform “Diagnostic Trouble Code Check, Record and
Clearance”.
Is there any malfunction code?Go to Step 2. Go to Step 5.

5E2-8 ANTILOCK BRAKE SYSTEM (ABS)
b) Problem Symptom Confirmation
Check if what the customer claimed in “CUSTOMER QUESTIONNAIRE” is actually found in the vehicle
and if that symptom is found, whether it is identified as a failure. (This step should be shared with the cus-
tomer if possible.) Check warning lamps related to brake system referring to “EBD WARNING LAMP
(BRAKE WARNING LAMP) CHECK” and “ABS WARNING LAMP CHECK” in this section.
c) Diagnostic Trouble Code (DTC) Check, Record and Clearance
Perform “DIAGNOSTIC TROUBLE CODE CHECK” procedure in this section, record it and then clear it
referring to “DIAGNOSTIC TROUBLE CODE CLEARANCE” in this section.
If the malfunction DTC which was once displayed and then cleared cannot be detected (indicated) again
when the ignition switch is turned ON, attempt to diagnose the trouble based on the DTC recorded in this
step may mislead the diagnosis or make diagnosing difficult. Proceed to Step 2) to check control module for
proper self-diagnosis function.
If the malfunction DTC which was once displayed and then cleared can be detected (indicated) again when
ignition switch is turned ON, proceed to Step 3).
2) DRIVING TEST
Test drive the vehicle at 40 km/h for more than a minute and check if any trouble symptom (such as abnor-
mal lighting of ABS warning light) exists.
If the malfunction DTC is confirmed again at ignition switch ON, driving test as described in above is not nec-
essary. Proceed to Step 3).
3) DIAGNOSTIC TROUBLE CODE CHECK
Recheck diagnostic trouble code referring to “DTC CHECK” as shown in the following page.
4) DIAGNOSTIC TROUBLE CODE FLOW TABLE
According to Diagnostic flow table for the diagnostic trouble code confirmation in Step 3), locate the cause of
the trouble, namely in a sensor, switch, wire harness, connector, actuator assembly or other part and repair
or replace faulty parts.
5)“DIAGNOSIS” IN “BRAKES” SECTION
Check the parts or system suspected as a possible cause referring to “DIAGNOSIS” in “BRAKES” section
and based on symptoms appearing on the vehicle (symptom obtained through Steps 1)-a, 1)-b and 2) and
repair or replace faulty parts, if any).
6) CHECK FOR INTERMITTENT PROBLEM
Check parts where an intermittent trouble is easy to occur (e.g., wire harness, connector, etc.), referring to
“INTERMITTENT TROUBLE” in “GENERAL INFORMATION” section and related circuit of trouble code
recorded in Step 1)-c.
7) FINAL CONFIRMATION TEST
Confirm that the problem symptom has gone and the ABS is free from any abnormal conditions. If what has
been repaired is related to the malfunction DTC, clear the DTC once and perform test driving and confirm
that no DTC is indicated.

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 AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-13
On-Vehicle Service
General
When hoses are disconnected and system components are removed for service, reinstall components properly,
and route and connect hoses correctly after service. Refer to figure on previous page for proper routing of
hoses.
1. Brake booster hose pipe 8. EGR pipe (if equipped) 15. EVAP canister
2. Vacuum hose for fuel pressure regulator 9. Exhaust manifold 16. Tank pressure control valve
3. Fuel pressure regulator 10. Heated oxygen sensor 17. To fuel tank
4. MAP sensor (if equipped) 11. EGR valve (if equipped) 18. Cap
5. Engine coolant hose 12. PCV hose [A]: Vehicle without monitor connector
6. EVAP canister purge valve 13. IAC valve [B]: Vehicle with monitor connector
7. Breather hose 14. IAC hose

7B1-10 AUTOMATIC TRANSMISSION (4 A/T)
Automatic Transmission Diagnostic Flow Table
Refer to the following pages for the details of each step.
Step Action Yes No
1 Customer Complaint Analysis
1) Perform customer complaint analysis refer-
ring to the next page.
Was customer complaint analysis performed
according to instruction?Go to Step 2. Perform customer com-
plaint analysis.
2 Diagnostic Trouble Code (DTC) and Freeze
Frame Data Check, Record and Clearance
1) Check for DTC (including pending DTC)
Is there any DTC(s)?Print DTC and freeze
frame data or write them
down and clear them by
referring to “DTC CLEAR-
ANCE” in this section
Go to Step 3.Go to Step 4.
3 Visual Inspection
1) Perform visual inspection referring to the
next page.
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 referring to the
next page.
Is there any faulty condition?Go to Step 8.
5 Trouble Symptom Confirmation
1) Confirm trouble symptom referring to the
next page.
Is trouble symptom identified?Go to Step 6. Go to Step 7.
6 Rechecking and Record of DTC/Freeze Frame
Data
1) Recheck for DTC and freeze frame data
referring to “DTC Check” in this section.
Is there any DTC(s)?Go to Step 9. Go to Step 8.
7 Rechecking and Record of DTC/Freeze Frame
Data
1) Recheck for DTC and freeze frame data
referring to “DTC Check” in this section.
Is there any DTC(s)?Go to Step 9. Go to Step 10.
8 Automatic Transmission Basic Inspection and
Trouble Diagnosis Table
1) Check and repair according to “A/T Basic
Check” and “Trouble Diagnosis Table” in this
section.
Are check and repair complete?Go to Step 11. Check and repair mal-
function part(s).
Go to Step 11.
9 Troubleshooting for DTC
1) Check and repair according to applicable
DTC diag. flow Table.
Are check and repair complete?
10 Check for Intermittent Problems
1) Check for intermittent problems referring to
the next page.
Is there any faulty condition?Repair or replace mal-
function part(s).
Go to Step 11.Go to Step 11.

AUTOMATIC TRANSMISSION (4 A/T) 7B1-11
STEP 1. CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer.
For this purpose, use of such a inspection form will facilitate collecting information to the point required for
proper analysis and diagnosis.
STEP 2. DIAGNOSTIC TROUBLE CODE (DTC)/FREEZE FRAME DATA CHECK, RECORD AND
CLEARANCE
First, referring to DTC check section, check DTC (including pending DTC). If DTC exists, print or write down
DTC and freeze frame data and then clear them by referring to DTC clearance section. DTC indicates malfunc-
tion in the system but it is not possible to know from it whether the malfunction is occurring now or it occurred in
the past and normal condition has been restored. In order to know that, check symptom in question according to
Step 5 and then recheck DTC according to Step 6.
Diagnosing a trouble based on the DTC in this step only or failure to clear the DTC in this step may result in an
faulty diagnosis, trouble diagnosis of a normal circuit or difficulty in troubleshooting which is otherwise unneces-
sary.
STEP 3 and STEP 4. VISUAL INSPECTION
As a preliminary step, be sure to perform visual check of the items that support proper function of the A/T and
engine referring to Visual Inspection section.
STEP 5. TROUBLE SYMPTOM CONFIRMATION
Check trouble symptoms based on information obtained in Step 1 “CUSTOMER COMPLAINT ANALYSIS” and
Step 2 “DTC/FREEZE FRAME DATA CHECK”.
Also, recheck DTC according to “DTC CONFIRMATION PROCEDURE” described in each “DTC FLOW
TABLE”.
STEP 6 and STEP 7. RECHECKING AND RECORD OF DTC/FREEZE FRAME DATA
Refer to “DTC CHECK” in this section for checking procedure.
STEP 8. A/T BASIC CHECK AND TROUBLE DIAGNOSIS TABLE
Perform A/T basic check according to the “A/T Basic Check 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 “TROUBLE DIAGNO-
SIS TABLE” and based on symptoms appearing on the vehicle (symptoms obtained through steps of customer
complaint analysis, trouble symptom confirmation and/or A/T basic check) and repair or replace faulty parts, if
any.
STEP 9. DIAGNOSTIC TROUBLE CODE FLOW TABLE
Based on the DTC indicated in Step 6 and 7 and referring to “DIAGNOSTIC TROUBLE CODE FLOW TABLE” in
this section, locate the cause of the trouble, namely in a sensor, switch, wire harness, connector, actuator, PCM
or other part and repair or replace faulty parts.11 Final Confirmation Test
1) Clear DTC if any.
2) Perform final confirmation test referring to
the next page.
Is there any problem symptom, DTC or abnor-
mal condition?Go to Step 6. End. Step Action Yes No

AUTOMATIC TRANSMISSION (4 A/T) 7B1-15
Trouble Diagnosis Table 1
Trouble Diagnosis Table 2
TRANSMISSION FLUID
RUNNING CONDITION
4 Perform stall test, time rag test, line pressure test,
engine brake test and “P” range test referring to
“STALL TEST”, “LINE PRESSURE TEST”, “ENGINE
BRAKE TEST” and ““P” RANGE TEST” in this section.
Are the test results satisfactory?Go to Step 5. Proceed to “TROUBLE
DIAGNOSIS TABLE 3” in
this section.
5 Proceed to “TROUBLE DIAGNOSIS TABLE 2” in this
section.
Is trouble identified?Repair or replace
defective parts.Proceed to “TROUBLE
DIAGNOSIS TABLE 3” in
this section. Step Action Yes No
Condition Possible Cause Correction
TCC does not operateBrake pedal (stop lamp) switch or its circuit
faulty (H25 engine only)Refer to “DIAGNOSTIC FLOW
TABLE A-1” in this section.
4WD low switch or its circuit faulty
Engine coolant temp. sensor or its circuit faulty
Cruise control signal circuit faulty (if equipped)
Gear does not change
to 4thO/D off switch or its circuit faulty Refer to “DIAGNOSTIC FLOW
TABLE A-2” in this section.
4WD low switch or its circuit faulty
Engine coolant temp. sensor or its circuit faulty
Cruise control signal circuit faulty (if equipped)
Condition Possible Cause Correction
Low fluid pressureClogged oil pump strainer Wash strainer.
Malfunction of pressure regulator valve Overhaul valve body.
High fluid pressurePressure regulator valve Overhaul valve body.
Condition Possible Cause Correction
Unable to run in all
rangeRegulator valve stick Replace.
Clogged oil strainer Wash strainer.
Seized or broken planetary gear Repair or replace.
Faulty manual valve Replace.
Poor 1st speed run-
ning or excessive slip-
page in “D” or “2”Faulty 1–2 shift valve Replace.