2001 SUZUKI GRAND VITARA Fuel system

YH4
GRAND
VITARA
1. Air bleeder plug
2. Weight
3. Attachment2
ªLº
BRAKES 5-13
FLUSHING BRAKE HYDRAULIC SYSTEM
It is recommended that entire hydraulic system be thoroughly
flushed with clean brake fluid whenever new parts are installed in
hydraulic system.
Periodical change of brake fluid is also recommended.
FLUID PRESSURE TEST(if equipped with
LSPV)
Test procedure for LSPV assembly is as follows.
Before testing, confirm the following.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.
1) Stop vehicle on level floor and place approximately about
200 kg (441 lbs) weight on rear housing so that rear axle weight
800 kg (1764 lb).
Rear axle weight ªLº: 800 kg (1764 lb)
2) Install special tool to front and rear brake.
NOTE:
Special tool should be connected to breather of front (driv-
er's side brake) and rear brakes.
Special Tool
Front brake
(A): 09956-02310
(B): 09952-46510 (Attachment for vehicle with SUMITOMO
ELECTRIC brake caliper)
(C): 55473-82030 (Air bleeder plug supplied as a spare part)
Rear brake
(A): 09956-02310
(B): 09952-36310 (Attachment for thread diameter 7 mm of
bleeder plug) or
09952-46510 (Attachment for thread diameter 8 mm of
bleeder plug)
(C): 55473-82030 (Air bleeder plug supplied as a spare part)
NOTE:

Special tool (B) is used instead of thread diameter 10 mm
attachment of special tool (A).
So remove the attachment from (A) and install (B) as
shown in figure.

For vehicle with TOKICO brake caliper, use the attach-
ment included in special tool (A).

For identification of brake caliper type, refer to GENERAL
DESCRIPTION in SECTION 5B.

YH4
GRAND
VITARA
5A-18 BRAKES PIPE / HOSE / MASTER CYLINDER
1. LSPV spring bolt
2. LSPV bolt
3. Brake pipe flare nut
4. Air bleeding plug
1. LSPV lever
2. Stopper bolt (if equipped)
3. Coil spring ªAº: Don't turn(a)
2) Torque each bolt and nut to specification as indicated respec-
tively in figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
(b): 16 N
.m (1.6 kg-m, 11.5 lb-ft) (brake flare nut)
(c): 7.5 N
.m (0.75 kg-m, 9.0 lb-ft) (bleeder plug)
3) Upon completion of installation, fill reservoir tank with specified
fluid and bleed air from brake system.
NOTE:
Make sure to bleed air from LSPV bleeder without failure.
4) After bleeding air, check that LSPV is installed properly, referring
to following INSPECTION & ADJUSTMENT.
INSPECTION & ADJUSTMENT
Confirm the following before inspection and adjustment.

Fuel tank is filled with fuel fully.

Vehicle is equipped with spare tire, tools, jack and jack handle.

Vehicle is free from any other load.
With vehicle in above conditions;
1) Place it on level floor.
2) Push up (for 5 door model) or push down (for 3 door model)
LSPV lever with finger till it stops and measure length ªLº of coil
spring as it is pulled.
3) Spring length ªLº should be the value specified below.
Spring length (between spring end and spring bolt)
ªLº: 103 mm (4.06 in.) (5 door model). . . . .
ªLº: 157 mm (6.18 in.) (3 door model). . . . .
4) If it isn't, adjust it to specification by changing stay positions as
shown in figure. After adjustment, tighten bolt to specified
torque.
For details, refer to left figure.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
NOTE:
Check to make sure that LSPV body and brake pipe joints
are free from fluid leakage. Replace defective parts, if any.

YH4
GRAND
VITARA
7B1-20 AUTOMATIC TRANSMISSION (4 A / T)
PRECAUTION IN DIAGNOSING TROUBLE

Don't disconnect couplers from PCM (ECM), battery cable from battery, PCM ground wire harness from engine
or main fuse before checking the diagnosis information (DTC, freeze frame data, etc.) stored in PCM memory.
Such disconnection will clear memorized information in PCM memory.

Using SUZUKI scan tool (Tech-1), or also generic scan tool for vehicle without monitor connector, the diagnostic
information stored in PCM memory can be checked and cleared as well. Before its use, be sure to read Operator's
(instruction) Manual supplied with it carefully to have good understanding of its functions and usage.

Priorities for diagnosing troubles (Only for vehicle without monitor connector)
If two or more diagnostic trouble codes (DTCs) are stored, proceed to the flow table of the DTC which was de-
tected 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.
1. Diagnostic trouble codes (DTCs) other than DTC P0171 / P0172 (Fuel system too lean / too rich) and DTC
P0400 (EGR flow malfunction)
2. DTC P0171 / P0172 (Fuel system too lean / too rich) and DTC P0400 (EGR flow malfunction)

Be sure to read ªPrecautions for Electrical Circuit Serviceº in Section 0A before inspection and observe what is
written there.

PCM replacement
When substituting a known-good PCM, check for following conditions.
Neglecting this check may result in damage to good PCM.
± All relays and actuators have resistance of specified value.
± MAF sensor, MDP sensor, TP sensor and fuel tank pressure sensor are in good condition. Also, the power
circuit of these sensors is not shorted to the ground.

YH4
GRAND
VITARA
7E-10 DIFFERENTIAL (FRONT)
1. Plugged hose
2. Adjusting screw
3. Pipe (to air pump assembly)
4. Hose (to differential carrier)
5. Differential housing
4 5
INSPECTION
4WD Control System
1) Install special tool to air hose connecting between air pump as-
sembly and differential (actuator) as shown in figure. Tighten ad-
justing screw of special tool as far as it stops. Close air check
side opening by using fuel hose as blind plug.
Special Tool
(A): 09918-18110
(B): 09367-04002
NOTE:
Use care not to bend any part of hose.
2) Turn ON ignition switch and shift transfer lever from 2H to 4H
range.
3) Check that motor starts running (a sound can be heard) within
1 second and it stops when gauge of special tool indicates speci-
fied pressure value.
Check also for air leakage.
Pressure specification:
30.0 ± 45.0 kPa (0.30 ± 0.45 kg / cm
2, 4.25 ± 6.40 psi)
4) Check that pressure value indicated on gauge of special tool
drops as soon as transfer lever is shifted to 2H position.
5) Start motor by shifting transfer lever to 4H position again. Loos-
en adjusting screw to lower pressure value on gauge. Motor
should start to run again and stop in about 4 seconds.
6) With the adjusting screw of special tool loosened, shift transfer
shift lever to N or 2H position and then 4L or 4H position.
Pump motor should stop about 10 seconds after motor starts to
run.

YH4
GRAND
VITARA
8C
INSTRUMENTATION / DRIVER INFORMATION 8C-1
GENERAL DESCRIPTION8C- 2 . . . . . . . . . . . . . .
Cautions in Servicing 8C- 2. . . . . . . . . . . . . . . . .
Symbols and Marks 8C- 2. . . . . . . . . . . . . . . . . . .
Wiring Color Symbols 8C- 2. . . . . . . . . . . . . . . . .
Abbreviations 8C- 2. . . . . . . . . . . . . . . . . . . . . . . .
Joint Connector 8C- 2. . . . . . . . . . . . . . . . . . . . . .
Fuse Box and Relay 8C- 2. . . . . . . . . . . . . . . . . .
Power Supply Diagram 8C- 2. . . . . . . . . . . . . . . .
Combination Meter 8C- 2. . . . . . . . . . . . . . . . . . .
DIAGNOSIS8C- 4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speedometer and VSS 8C- 4. . . . . . . . . . . . . . . .
Fuel Meter / Fuel Gauge Unit 8C- 4. . . . . . . . . . . .
Engine Coolant Temp. (ECT) Meter and
Sensor 8C- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Light 8C- 4. . . . . . . . . . . . . . . . . . . .
Brake and Parking Brake Warning
Light 8C- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light Remainder Warning Buzzer 8C- 5. . . . . . . Seat Belt Warning Light (If Equipped) 8C- 5. . .
Ignition Key Remainder Warning
Buzzer (If Equipped) 8C- 5. . . . . . . . . . . . . . . . .
Cigarette Lighter and Accessory Socket 8C- 5.
ON-VEHICLE SERVICE8C- 6 . . . . . . . . . . . . . . . .
Ignition (Main) Switch 8C- 6. . . . . . . . . . . . . . . . .
Combination Meter 8C- 7. . . . . . . . . . . . . . . . . . .
Speedometer and VSS 8C- 8. . . . . . . . . . . . . . . .
Fuel Meter / Fuel Gauge Unit 8C- 9. . . . . . . . . . . .
Engine Coolant Temp. (ECT) Meter and
Sensor 8C-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Light 8C-11. . . . . . . . . . . . . . . . . . . .
Brake and Parking Brake Warning
Light 8C-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition Key Remainder (If Equipped) /
Light Remainder Warning Buzzer 8C-12. . . . . .
Door Switch 8C-13. . . . . . . . . . . . . . . . . . . . . . . . .
Seat Belt Warning Light (If Equipped) 8C-13. . .
SECTION 8C
INSTRUMENTATION/DRIVER INFORMATION
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 autho-
rized SUZUKI dealer. Refer to ªAir Bag System Components and Wiring Location Viewº under ªGener-
al Descriptionº in air bag system section in order to confirm whether you are performing service on
or near the air bag system components or wiring. Please observe all WARNINGS and ªService Precau-
tionsº under ªOn-Vehicle Serviceº 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
ªLOCKº 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).
CONTENTS

YH4
GRAND
VITARA
0.5TIME (sec.) Ignition switch ON
High Immobilizer
control system
is normal
Immobilizer
control system
is abnormalLow
0.5 0.5 0.5 0.5
High
Low
0.5TIME (sec.) Ignition switch ON
High Immobilizer
control system
is normal
Immobilizer
control system
is abnormalLow
0.5 0.5 0.5 0.5
High
Low
IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED) 8G-5

With the diagnosis switch terminal of monitor coupler for
ECM / PCM not grounded, the ignition switch turned ON (but the en-
gine at stop) and regardless of the condition of the electronic fuel
injection system, ECM / PCM indicates whether a trouble has oc-
curred in the immobilizer control system or not by causing the mal-
function indicator lamp to flash or turn ON.
Malfunction indicator lamp is ON:
No trouble exists in the immobilizer control system.
Malfunction indicator lamp is flashing:
ECM / PCM or Immobilizer Control Module has detected some
trouble in the immobilizer control system.
NOTE:
As soon as the ignition switch is turned ON, ECM / PCM and Im-
mobilizer Control Module diagnose if a trouble has occurred
in the immobilizer control system. While the diagnosis is being
made, the malfunction indicator lamp stays ON and if the diag-
nosis result is ªabnormalº, it immediately changes to flashing
but if the result is ªnormalº, it remains ON. Diagnosis takes
about 3 seconds at maximum.

With the ignition switch turned ON (but the engine at stop) regard-
less of the condition of the electronic fuel injection system,
ECM / PCM indicates whether a trouble has occurred in the immobi-
lizer control system or not by causing the immobilizer indicator lamp
to flash or turn ON.
Immobilizer indicator lamp is ON:
No trouble exists in the immobilizer control system.
Immobilizer indicator lamp is flashing:
ECM / PCM or Immobilizer Control Module has detected some
trouble in the immobilizer control system.
NOTE:
As soon as the ignition switch is turned ON, ECM / PCM and Im-
mobilizer Control Module diagnose if a trouble has occurred
in the immobilizer control system. While the diagnosis is being
made, the Immobilizer indicator lamp stays ON and if the diag-
nosis result is ªabnormalº, it immediately changes to flashing
but if the result is ªnormalº, it remains ON. Diagnosis takes
about 3 seconds at maximum.
When ECM / PCM and Immobilizer Control Module detects a
trouble which has occurred in the above areas, it stores DTC corre-
sponding to the exact trouble area in ECM / PCM and Immobilizer
Control Module memory.
DTCs stored in memory of each controller (Immobilizer Control
Module and ECM / PCM) can be read by using the procedure de-
scribed in ªDIAGNOSTIC TROUBLE CODE CHECK (IMMOBILIZ-
ER CONTROL MODULE)º and ªDIAGNOSTIC TROUBLE CODE
CHECK (ECM / PCM)º in this section.

YH4
GRAND
VITARA
8G-6 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
1. Immobilizer diagnostic coupler
DIAGNOSIS
ECM / PCM and Immobilizer Control Module have on-board diag-
nostic system (a system self-diagnosis function) as described pre-
viously.
Investigate where the trouble is by referring to ªDiagnostic Flow
Tableº and ªDiagnostic Trouble Code Tableº on later pages.
PRECAUTIONS IN DIAGNOSING TROUBLES
[PRECAUTIONS IN IDENTIFYING DIAGNOSTIC TROUBLE CODE]
ECM / PCM


Before identifying diagnostic trouble code indicated by malfunc-
tion indicator lamp, don't disconnect couplers from ECM / PCM,
battery cable from battery, ECM / PCM ground wire harness from
engine.
Such disconnection will clear trouble codes for electronic fuel in-
jection system stored in memory of ECM / PCM.

If abnormality or malfunction lies in two or more areas, malfunc-
tion indicator lamp indicates applicable codes three times each.
And flashing of these codes is repeated as long as diagnosis ter-
minal is grounded and ignition switch is held at ON position.

When ECM / PCM detects a trouble in both electronic fuel injec-
tion system and immobilizer control system, malfunction indicator
lamp indicates trouble codes of both systems alternately while the
ignition switch is turned ON and the diagnosis terminal is
grounded.

Take a note of diagnostic trouble code indicated first.


Before identifying diagnostic trouble code indicated through Su-
zuki scan tool, don't disconnect couplers from ECM / PCM, bat-
tery cable from battery, ECM / PCM ground wire harness from en-
gine.
Such disconnection will clear trouble codes for electronic fuel in-
jection system stored in memory of ECM / PCM.

Take a note of diagnostic trouble code indicated first.
Immobilizer Control Module

Take a note of diagnostic trouble code indicated first.

YH4
GRAND
VITARA
8G-12 IMMOBILIZER CONTROL SYSTEM (IF EQUIPPED)
EXAMPLE: When serial data link wire is defective (Code No.83)
ON
OFFMalfunction
indicator lamp
Code No.83 Code No.83 Code No.83
Time (sec.)
1. Data link connector (DLC)
3) After completing the check, turn ignition switch OFF and discon-
nect service wire from monitor coupler.
[Using SUZUKI scan tool]
1) Turn ignition switch OFF.
2) After setting cartridge to Suzuki scan tool, connect it to data link
connector (DLC) located on underside of instrument panel at
driver's seat side.
Special Tool
(A): 09931-76011 (Suzuki scan tool)
(B): Mass storage cartridge
(C): 09931-76030 (16 / 12 pin DLC adapter)
3) Turn ignition switch ON.
4) Read DTC according to instructions displayed on Suzuki scan
tool and print it or write it down. Refer to Suzuki scan tool opera-
tor's manual for further details.
NOTE:

When reading DTC stored in ECM / PCM using Suzuki scan
tool, select ªECMº from the applications menu and ªSU-
ZUKI modeº from the communication mode menu dis-
played on Suzuki scan tool.

If ECM / PCM detects a trouble in both electric fuel injec-
tion system and immobilizer control system, Suzuki scan
tool indicates trouble codes of both systems using Suzu-
ki mode of ECM application.
If communication between Suzuki scan tool and ECM / PCM is
not possible, check if Suzuki scan tool is communicable by con-
necting it to ECM / PCM in another vehicle. If communication is
possible in this case, Suzuki scan tool is in good condition. Then
check data link connector and serial data line (circuit) in the ve-
hicle with which communication was not possible.
5) After completing the check, turn ignition switch OFF and discon-
nect Suzuki scan tool from data link connector (DLC).