2001 SUZUKI GRAND VITARA cranking

Table of Contents
GENERAL INFORMATION TRANSMISSION, CLUTCH AND
DIFFERENTIAL0A7A1
General Information0A
0B7B1
Maintenance and Lubrication0B
Manual Transmission7A1
7C1
HEATING AND AIR CONDITIONING
Automatic Transmission7B1
1A7D
Heater and Ventilation1A
Clutch7C1
1B7E
Air Conditioning1B
Transfer7D7F
STEERING, SUSPENSION, WHEELS
AND TIRESDifferential (Front)7E
3
Differential (Rear)7F
3A8
Steering, Suspension, Wheels and Tires3 ELECTRICAL SYSTEM3B18A
Front End Alignment3A
Electrical System8
3C18B
Power Steering (P/S) System3B1
Wiring Diagram8A3D8C
Air Bag Steering Wheel and Column3C1
Lightening System8B3E8D
Front Suspension3D
Instrumentation / Driver Information8C
3F8E
Rear Suspension3E
Windows, Mirrors, Security and Lock8D
8G
Wheels and Tires3F
Cruise Control System8E
4A2
DRIVE SHAFT AND PROPELLER SHAFT
Immobilizer control system (if equipped)8G4B9
Front Drive Shaft / Shaft Bearing,
Oil Seal4A2BODY SERVICE
Body Service9
510
Propeller Shaft4B RESTRAINT SYSTEM
5A10A
BRAKE SYSTEM
Restraint System10
5B10B
Brakes5
Seat Belt10A
5C
Brake Pipe / Hose / Master Cylinder5A
Air Bag System10B
5E2
Front Brake5B
Parking and Rear Brake5C
6-1
Antilock Brake System (ABS)5E2
6A2
ENGINE
6B
General Information and
Diagnosis (H27 Engine)6-1
6C
6E2
Engine Mechanical (H27 Engine)6A2
6F2
Engine Cooling6B
6G
Engine Fuel6C
6H
Engine and Emission Control System
(SFI For H27 Engine)6E2
6K
Ignition System (H27 Engines)6F2
Cranking System6G
Charging System6H
Exhaust System6K
NOTE:
For the screen toned Sections in the above table, refer to the same section of the Related Manuals
mentioned in FOREWORD of this manual.

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

6-1-20 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
P0174 Fuel system too lean (Bank 2)Short term fuel trim or total fuel trim
(short and long terms added) is larger
than specification for specified time or
longer. (Fuel trim toward rich side is
large.)2 driving
cyclesNot
applicable
P0175 Fuel system too rich (Bank 2)Short term fuel trim or total fuel trim
(short and long terms added) is
smaller than specification for specified
time or longer. (Fuel trim toward lean
side is large.)2 driving
cyclesNot
applicable
P0300
P0301
P0302
P0303
P0304
P0305
P0306Random misfire detected
Cylinder 1 misfire detected
Cylinder 2 misfire detected
Cylinder 3 misfire detected
Cylinder 4 misfire detected
Cylinder 5 misfire detected
Cylinder 6 misfire detectedMisfire of such level as to cause dam-
age to three way catalystMIL flashing
during mis-
fire detec-
tionNot
applicable
Misfire of such level as to deteriorate
emission but not to cause damage to
three way catalyst2 driving
cyclesNot
applicable
P0325
(No.43)Knock sensor circuit malfunc-
tionSensor output too low
1 driving
cycle1 driving
cycle
Sensor output too high
P0335Crankshaft position sensor cir-
cuit malfunctionNo signal during engine running and
CMP sensor signal inputting1 driving
cycleNot
applicable
P0340
(No.42)Camshaft position sensor cir-
cuit malfunctionNo signal for 3 sec. during engine
cranking, REF signal pattern incor-
rect or POS signal voltage too high or
too low1 driving
cycleNot
applicable
P0400Exhaust gas recirculation flow
malfunction detectedExcessive or insufficient EGR flow.2 driving
cyclesNot
applicable
P0403
(No.51)EGR valve circuit malfunctionEGR valve electrical circuit open or
shot to ground1 driving
cycle1 driving
cycle
P0420Catalyst system efficiency
below threshold (Bank 1)Output waveforms of HO2S-1 and
HO2S-2 are similar.
(Time from output voltage change of
HO2S-1 to that of HO2S-2 is shorter
than specification.)2 driving
cyclesNot
applicable
P0430Catalyst system efficiency
below threshold (Bank 2)Output waveforms of HO2S-1 and
HO2S-2 are similar.
(Time from output voltage change of
HO2S-1 to that of HO2S-2 is shorter
than specification.)2 driving
cyclesNot
applicable
P0443Purge control valve circuit
malfunctionPurge control valve circuit is open or
shorted to ground.2 driving
cyclesNot
applicable
P0500
(No.24)Vehicle speed sensor mal-
functionNo signal while running in “D” range
or during fuel cut at decelerating.2 driving
cycles1 driving
cycle DTC NO. DETECTED ITEMDETECTING CONDITION
(DTC will set when detecting : )MIL
(vehicle
without
monitor
connector)MIL
(vehicle
with
monitor
connector)

6-1-40 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
C51-1-10A/T input speed sensor (–)
(A/T vehicle)About 2.5 V Ignition switch ON
C51-1-11A/T input speed sensor (+)
(A/T vehicle)About 2.5 V Ignition switch ON
C51-1-12 Camshaft position sensor 1Deflects between
0 – 1 V and 4 – 6 VIgnition switch ON, crankshaft
turned slowly
C51-1-13 Camshaft position sensor 2Deflects between
0 – 1 V and 4 – 6 VIgnition switch ON, crankshaft
turned slowly
C51-1-14 Vehicle speed sensorDeflects between
0 – 1 V and over 4VIgnition switch ON, Rear right tire
turned slowly with rear left tire
locked
C51-1-15 EVAP canister purge valve 10 – 14 V Ignition switch ON
C51-1-16 IAC valve (stepper motor coil 4) – –
C51-1-17 IAC valve (stepper motor coil 3) – –
C51-1-18Transmission range switch “D”
(A/T vehicle)10 – 14 VIgnition switch ON, selector lever :
“D” range
0 – 1 VIgnition switch ON, selector lever :
Other than “D” range
C51-1-19Transmission range switch “N”
(A/T vehicle)10 – 14 VIgnition switch ON, selector lever :
“N” range
0 – 1 VIgnition switch ON, selector lever :
Other than “N” range
C51-1-20Shield wire ground for A/T output
speed sensor (A/T vehicle)––
C51-1-21Shield wire ground for A/T input
speed sensor (A/T vehicle)––
C51-1-22A/T output speed sensor (–)
(A/T vehicle)About 2.5 V Ignition switch ON
C51-1-23A/T output speed sensor (+)
(A/T vehicle)About 2.5 V Ignition switch ON
C51-1-24 Engine start signal10 – 14 V While engine cranking
0 – 1 V Other than above
C51-1-25 Power steering pressure switch10 – 14 V Ignition switch ON
0 – 1 VWith engine running at idle speed,
turning steering wheel to the right or
left as far as it stops
C51-1-26 4WD low switch0 – 1 VIgnition switch ON, Transfer lever :
4WD low range
10 – 14 VIgnition switch ON, Transfer lever :
4H or 2H range
C51-1-27Transmission range switch “L”
(A/T vehicle)10 – 14 VIgnition switch ON, selector lever :
“L” range
0 – 1 VIgnition switch ON, selector lever :
Other than “L” range
C51-1-28Transmission range switch “2”
(A/T vehicle)10 – 14 VIgnition switch ON, selector lever :
“2” range
0 – 1 VIgnition switch ON, selector lever :
Other than “2” range TERMINAL CIRCUIT NORMAL VOLTAGE CONDITION

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-81
TROUBLESHOOTING
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 Ignition system inspection :
1) Check spark plug and ignition spark of cylin-
der where misfire occurs, referring to “IGNI-
TION SYSTEM” section.
Is it in good condition?Go to Step 3. Faulty ignition coil, wire
harness, or other system
parts.
3 Fuel injector circuit inspection :
1) Using sound scope, check each injector
operating sound at engine cranking or
idling.
Do all injectors make operating sound?Go to Step 4. Check coupler connec-
tion and wire harness of
injector not making oper-
ating sound and injector
itself.
If OK, substitute a known-
good ECM (PCM) and
recheck.
4 Fuel pressure inspection :
1) Check fuel pressure referring to “TABLE B-
3” in this section.
Is check result satisfactory?Go to Step 5. Repair or replace.
5 Fuel injector inspection :
1) Check fuel injector(s) referring to Section
6E2.
Is check result satisfactory?Go to Step 6. Replace.
6 Ignition timing inspection :
1) Check ignition timing referring to Section
6F2.
Is check result satisfactory?Go to Step 7. Adjust or check system
related parts.
7 EGR system inspection :
1) Check EGR system referring to Section
6E2.
Is check result satisfactory?Go to Step 8. Repair or replace.
8 Fuel level sensor inspection :
1) Check fuel level sensor referring to Section
6E2.
Is check result satisfactory?Go to Step 9. Repair or replace.
9 Check engine mechanical parts or system
which can cause engine rough idle or poor per-
formance.
• Engine compression (See Section 6A2).
• Valve lash or lash adjuster (See Section
6A2).
• Valve timing (Timing belt or chain installa-
tion. See Section 6A2).
Are they in good condition?Check wire harness and
connection of ECM (PCM)
ground, ignition system
and fuel injector for inter-
mittent open and short.Repair or replace.

6-1-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P1500 Engine Starter Signal Circuit Malfunction
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC by using scan tool, then start engine and run it for 3 min. or more.
3) Check pending DTC by using scan tool.
TROUBLESHOOTING
1. Engine start switch in ignition (main) switch 2. Starting motor 3. Transmission range sensor (switch) 4. ECM (PCM)
DTC DETECTING CONDITION TROUBLE AREA
•Engine starts even though vehicle is at stop and engine start signal is
not inputted.
or
•Engine start signal is inputted continuously for specified time while
engine is running.
(2 driving cycle detection logic)•Engine start signal circuit
•ECM (PCM)
NOTE:
Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION PRO-
CEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
Step Action Yes No
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”
in this section.
2 Check for voltage at terminal C51-1-24 of
ECM (PCM) connector connected, under fol-
lowing condition.
Engine starter signal specification :
While engine cranking : 6 – 14 V
After starting engine : 0 – 1 V
Is voltage as specified?Poor C51-1-24 connection or
intermittent trouble.
Check for intermittent referring to
“INTERMITTENT AND POOR
CONNECTION” in Section 0A.
If wire and connections are OK,
substitute a known-good ECM
(PCM) and recheck.“BLK/YEL” circuit open.

6-1-118 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
INSPECTION
Step Action Yes No
1 Check injector for operating sound :
Using sound scope, check each injector for
operating sound at engine cranking.
Do all 6 injectors make operating sound?Go to Step 2. Go to Step 3.
2 Wire harness check :
1) Remove ECM (PCM) cover and disconnect
connectors from ECM (PCM).
2) Check for resistance between following ter-
minals of ECM (PCM) connector discon-
nected.
Fuel injector and its circuit resistance (C51-
2-1 – C51-3-4, C51-2-2 – C51-3-4, C51-2-8 –
C51-3-4, C51-2-9 – C51-3-4, C51-2-21 – C51-
3-4 and C51-2-22 – C51-3-4) :
14.2 – 14.8
Ω
ΩΩ Ω at 20°C (68°F)
Is check result as specified?Fuel injector circuit is in
good condition.“PNK”, “PNK/BLK”, “PNK/
GRN”, “PNK/BLU”, “GRY/
GRN” and “GRY/BLK”
shorted each other.
3 Does none of 6 injectors make operating sound
at Step 1?Go to Step 4. Check coupler connec-
tion and wire harness of
injector not making oper-
ating sound and injector
itself (Refer to “FUEL
INJECTOR INSPEC-
TION” in Section 6E2).
4 Check power circuit of injectors for open and
short.
Is it normal?Check all 6 injectors for
resistance respectively.
It resistance is OK, substi-
tute a known-good ECM
(PCM) and recheck.Power circuit open or
short.

6E2-22 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
3) Remove air cleaner outlet hose and remove IAC valve from
throttle body.
4) Connect connector to IAC valve.
5) Check that plunger (1) of IAC valve moves once and then
stops as soon as ignition switch (2) is turned OFF after
cranking engine for 2 sec.
If plunger (1) of IAC valve does not operate at all, check wire
harnesses for open and short. If wire harnesses are in good
condition, replace IAC valve and recheck.
INSTALLATION
1) Install new O-ring to throttle body.
2) Install IAC valve to throttle body.
3) Tighten IAC valve screws to specified torque.
Tightening torque
IAC valve screw (a) : 3.5N·m (0.35 kg-m, 2.5 lb-ft)
4) Connect IAC valve connector securely.
5) Connect negative (–) cable to battery.
Fast idle air valve
1) Disconnect IAC valve coupler with ignition switch OFF.
2) Check that with cold engine started, as cooling water tem-
perature rises, engine idle speed reduces gradually.
If check result is as described above, fast idle air valve is in
good condition.
If not, fast idle air valve, air passage or coolant passage is
faulty. NOTE:
This check should be performed by two people, one per-
son operates ignition switch while the other checks
plunger operation.