Engine Electrical Devices Suzuki Grand Vitara I рестайлинг

H25 Engine

Note. H25 Engine refers to Grand Vitara, H27 Engine refers to XL-7.

Idle Air Control (IAC) Valve On-Vehicle Inspection

1. Disconnect connector from IAC valve.
2. Check each coil of IAC valve for resistance. If resistances is out of specification, replace. IAC valve resistance at 20 °C (68 °F) Between terminals "a" and "b": 20 - 24 ohm Between terminals "b" and "c": 20 - 24 ohm Between terminals "d" and "e": 20 - 24 ohm Between terminals "e" and "f": 20 - 24 ohm
3. Remove IAC valve from intake collector.
4. Connect connector to IAC valve.
5. Turn ON ignition switch.
6. Check that plunger of IAC valve (1) moves once and then stops as soon as ignition switch is turned OFF.

If plunger 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.

Note. This check should be performed by two people, one person operates ignition switch while the other checks plunger operation.

Scheme 220

Scheme 221

1. Disconnect battery negative cable at battery.
2. Disconnect IAC valve connector.
3. Remove IAC valve (1) from intake collector (2).

Installation

For installation, reverse removal procedure and note the followings.

Scheme 222

1. Use new gaskets (1).

Engine Control Module (ECM)/Powertrain Control Module (PCM) Removal and Installation

Scheme 223

Scheme 224

1. Disconnect battery negative cable from battery.
2. Disable air bag system (if equipped) referring to «DISABLING & ACTIVATING AIR BAG SYSTEM»(/suzuki/grand-vitara/i-2000-2006/remont/airbag/#air-bag-restraint-systems__disabling-activating-air-bag-system) .
3. Remove ECM (PCM) cover (1) from bracket.
4. Disconnect connectors from ECM (PCM) (1).
5. Remove ECM (PCM) (1) with bracket (2).

1. Install ECM (PCM) with bracket to vehicle.
2. Connect connectors to ECM (PCM) securely.
3. Install ECM (PCM) cover to bracket.
4. Enable air bag system (if equipped) referring to «DISABLING & ACTIVATING AIR BAG SYSTEM»(/suzuki/grand-vitara/i-2000-2006/remont/airbag/#air-bag-restraint-systems__disabling-activating-air-bag-system) .
5. Connect negative cable to battery.

Mass Air Flow (MAF) Sensor On-Vehicle Inspection

Note. Use voltmeter with high-impedance (10 kohm/V minimum) or digital type voltmeter.

Scheme 225

1. Remove ECM (PCM) cover from bracket.
2. With ignition switch OFF, disconnect MAF sensor connector (1).
3. Connect voltmeter to C32-3 terminal (2) of MAF sensor connector (1) disconnected and ground.
4. Turn ignition switch ON and check that voltage is battery voltage. If not, check if wire harness is open or connection is poor.
5. Turn ignition switch OFF and connect MAF sensor connector to MAF sensor.
6. Turn ignition switch ON and check voltage between C51-3-23 and C51-3-20 terminal. Voltage between C51-3-23 and C51-3-20 terminal: 0.5 - 1.0 V
7. Start engine and check that voltage is lower than 5 V and it rises as engine speed increases.

(Reference data: 1.5 - 1.8 V at specified idle speed)

If check result is not as specified above, cause may lie in wire harness, coupler connection, MAF sensor or ECM (PCM).

Scheme 226

Removal

1. Disconnect negative cable at battery and coupler from MAF sensor (2).
2. Remove throttle body (1) referring to «THROTTLE BODY»(/suzuki/grand-vitara/i-2000-2006/remont/removal-installation/#removal-installation__throttle-body) .

Scheme 227

1. Install throttle body, referring to «THROTTLE BODY»(/suzuki/grand-vitara/i-2000-2006/remont/removal-installation/#removal-installation__throttle-body) .

Scheme 228

1. Warm up engine and stop it when its temperature has reached normal operating temperature (Check to make sure that they have some clearance between fast idle cam and cam follow lever.)
2. Disconnect negative cable at battery and coupler from TP sensor.
3. Using ohmmeter, check resistance between terminals under each condition given in table below. If check result is not satisfactory, replace TP sensor. TP sensor resistance Between "1" and "3" terminals: 4 - 6 kohm Between "2" and "3" terminals: 0 - 4.6 kohm (varying linearly according to throttle valve opening)
4. Connect TP sensor coupler securely.
5. Connect negative cable to battery.

1. Disconnect battery negative cable at battery.
2. Disconnect connector from TP sensor.
3. Remove TP sensor from throttle body.

Scheme 229

1. To install sensor, place it onto throttle body so that sensor pickup lever (2) can engage with throttle body lever (1). "A" should engage with "B".
2. Hand-tighten TP sensor screws.
3. Connect connector to TP sensor securely.
4. Connect battery negative cable to battery.
5. Adjust installation angle of TP sensor according to procedure described in «Throttle Position (TP) Sensor Adjustment»(/suzuki/grand-vitara/i-2000-2006/remont/testing-diagnostics/#engine-electrical-devices) .

Scheme 230

1. Warm up engine to normal operating temperature.
2. Check to make sure that fast idle cam and cam follower lever are not in contact with each other. If they are, check fast idle control system.
3. Loosen TP sensor screws.
4. Remove ECM (PCM) cover from bracket.
5. Turn TP sensor (1) clockwise or counterclockwise and tighten TP sensor screw at a position where voltage as specified below is obtained at coupler terminal C51-3-12. NOTE: If SUZUKI scan tool and cartridge are available, make an adjustment by using SUZUKI scan tool while observing TP sensor voltage. TP sensor voltage when throttle is fully close: 0.35 - 0.65 V Tightening torque TP sensor screw (a): 2.5 N.m (0.25 kg-m, 1.8 lb-ft)
6. Check to make sure that when throttle is fully open TP sensor voltage is as shown below. TP sensor voltage when throttle is fully open: 3.5 - 4.5 V
7. Install ECM (PCM) cover.
8. Disconnect negative cable at battery for 30 seconds or more and connect negative cable at battery.

1. Disconnect negative cable from battery.
2. Disconnect IAT sensor coupler.
3. Remove IAT sensor (1) from air cleaner case.

Scheme 231

1. Clean mating surface of sensor and seal on air cleaner case.
2. Install IAT sensor (1) into seal (2).
3. Connect connector to IAT sensor (1) securely.

Intake Air Temperature (IAT) Sensor Inspection

Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals while heating water gradually.

If measured resistance doesn't show such characteristic as shown in the figure, replace IAT sensor.

Scheme 232

Scheme 233

1. Disconnect negative cable from battery.
2. Drain cooling system.
3. Disconnect coupler from ECT sensor (1).
4. Remove ECT sensor (1) from water outlet cap (2).

Reverse removal procedure noting the followings.

Scheme 234

1. Clean mating surfaces of sensor and water outlet cap (1).
2. Use new O-ring.
3. Tighten ECT sensor to specified torque. Tightening torque ECT sensor (a): 15 N.m (1.5 kg-m, 11.0 lb-ft)
4. Connect coupler to sensor securely
5. Refill cooling system.

Engine Coolant Temperature (ECT) Sensor Inspection

Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating water gradually.

If measured resistance doesn't shown such characteristic as shown, replace ECT sensor.

Scheme 235

1. Disconnect negative cable at battery.
2. Disconnect connector from manifold absolute pressure sensor (1).
3. Remove manifold absolute pressure sensor (1) from intake manifold (2).

Scheme 236

1. Confirm that vacuum passage on intake manifold is free from clog.
2. Apply engine oil to O-ring of manifold absolute pressure sensor.
3. Install manifold absolute pressure sensor (1) to intake manifold (2).
4. Connect connector to manifold absolute pressure sensor (1) securely.

Scheme 237

1. Check sensor O-ring (1) for damage and deterioration. Replace as necessary.
2. Arrange 3 new 1.5 V batteries (2) in series and connect its positive terminal to "Vin" terminal and negative terminal to "Ground" terminal. Then check voltage between "Vout" and "Ground".

Also, check if voltage reduces when vacuum is slowly applied up to 400 mmHg by using vacuum pump (3).

If check result is not satisfactory, replace manifold absolute pressure sensor (1).

1. Manifold absolute pressure output voltage ("Vin" voltage: 4.5 - 5.5 V, ambient temp. 20 - 30 °C (68 - 86 °F))

Scheme 238

Scheme 239

1. Disconnect negative cable from battery.
2. Disconnect coupler of oxygen sensor(s) (1).
3. Remove oxygen sensor(s) (1) from exhaust manifold(s).

Note. Be careful not to expose it to excessive shock.

Scheme 240

Reverse removal procedure noting the followings.

Scheme 241

1. Tighten oxygen sensor(s) to specified torque. Tightening torque Heated oxygen sensor 1 (a): 45 N.m (4.5 kg-m, 32.5 lb-ft)
2. Connect connector of oxygen sensor(s) and clamp wire harness securely.
3. After installing oxygen sensor(s), start engine and check that no exhaust gas leakage exists.

1. Disconnect negative cable from battery.
2. Disconnect coupler (3) of oxygen sensor(s) (2).
3. Remove oxygen sensor(s) (2) from exhaust manifold(s) (1).

Note. Be careful not to expose it to excessive shock.

Scheme 242

Reverse removal procedure noting the followings.

Scheme 243

1. Tighten oxygen sensor(s) to specified torque. Tightening torque Heated oxygen sensor 2 (a): 45 N.m (4.5 kg-m, 32.5 lb-ft)
2. Connect connector of oxygen sensor(s) and clamp wire harness securely.
3. After installing oxygen sensor(s), start engine and check that no exhaust gas leakage exists.

Vehicle Speed Sensor (VSS) On-Vehicle Inspection

1. Hoist vehicle.
2. Release parking brake lever, set transmission in neutral and transfer in "2H".
3. Remove ECM (PCM) cover.
4. Connector voltmeter between VSS terminal C51-3-1 of ECM (PCM) connector and body ground.
5. Turn ignition switch ON and turn rear right tire slowly with rear left tire locked.

Voltmeter should indicate deflection between 0 - 1 V and 8 - 14 V a few times while tire is turned one revolution. If check result is not satisfactory, proceed to DTC P0500: VEHICLE SPEED SENSOR MALFUNCTION .

Scheme 244

Camshaft Position (CMP) Sensor Removal and Installation

Scheme 245

1. Disconnect CMP sensor coupler (2).
2. Remove CMP sensor (1) by removing bolt (3).

Scheme 246

Scheme 247

Scheme 248

1. Install a new O-ring (2) with engine oil applied to CMP sensor (1).
2. Install CMP sensor (1) to camshaft (3). Fit the dog of CMP sensor coupling (2) into the slots of camshaft (3), when installing. The dogs of CMP sensor coupling are offset. Therefore, if the dogs can not be fitted into the slots, turn the CMP sensor shaft by 180 degree and try again.
3. Tighten CMP sensor bolt (3). Tightening torque CMP sensor bolt (a): 15 N.m (1.5 kg-m, 11.0 lb-ft)
4. Connect CMP sensor coupler (2) to CMP sensor (1).

Scheme 249

Scheme 250

Scheme 251

1. Disconnect negative cable at battery.
2. Remove main relay (1) from relay box (2).
3. Check resistance between each two terminals as in table below. If check results are as specified, proceed to next operation check. If not, replace. Main relay resistance Between "A" and "B": Infinity Between "C" and "D": 79 - 95 ohm at 20 °C (68 °F)
4. Check that there is continuity between terminals "A" and "B" when battery is connected to terminals "C" and "D". If malfunction is found, replace.

Scheme 252

H27 Engine

Note. H25 Engine refers to Grand Vitara, H27 Engine refers to XL-7.

Scheme 253

1. Disconnect connector from IAC valve.
2. Check each coil of IAC valve for resistance. If resistances is out of specification, replace. IAC valve resistance Between terminals "1" and "2": 25.5 - 33.5ohm Between terminals "3" and "2": 25.5 - 33.5ohm Between terminals "4" and "5": 25.5 - 33.5ohm Between terminals "6" and "5": 25.5 - 33.5ohm
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.

Note. This check should be performed by two people, one person operates ignition switch while the other checks plunger operation.

Scheme 254

Fast Idle Air Valve

1. Disconnect IAC valve coupler with ignition switch OFF.
2. Check that with cold engine started, as cooling water temperature 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.

Scheme 255

1. Disconnect battery negative cable at battery.
2. Disconnect IAC valve connector.
3. Remove IAC valve (1) from throttle body.

Scheme 256

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): 3.5 N.m (0.35 kg-m, 2.5 lb-ft)
4. Connect IAC valve connector securely.
5. Connect negative cable (-) to battery.

Scheme 257

Scheme 258

1. Disconnect negative (-) cable at battery.
2. Disable air bag system (if equipped) referring to «DISABLING & ACTIVATING AIR BAG SYSTEM»(/suzuki/grand-vitara/i-2000-2006/remont/airbag/#air-bag-restraint-systems__disabling-activating-air-bag-system) .
3. Remove ECM (PCM) cover (1) from bracket.
4. Disconnect connectors from ECM (PCM) (1).
5. Remove ECM (PCM) (1) with bracket (2).

1. Install ECM (PCM) with bracket to vehicle.
2. Connect connectors to ECM (PCM) securely.
3. Install ECM (PCM) cover to bracket.
4. Enable air bag system (if equipped) referring to «DISABLING & ACTIVATING AIR BAG SYSTEM»(/suzuki/grand-vitara/i-2000-2006/remont/airbag/#air-bag-restraint-systems__disabling-activating-air-bag-system) .
5. Connect negative (-) cable to battery.

Note. Use voltmeter with high-impedance (10 kohm/V minimum) or digital type voltmeter.

Scheme 259

Scheme 260

1. Connect voltmeter (1) to "B+" terminal of MAF sensor (2) coupler disconnected and ground (3).
2. Turn ignition switch ON and check that voltage is battery voltage. If not, check if wire harness is open or connection is poor.
3. Turn ignition switch OFF and remove ECM (PCM) cover (1) from bracket.
4. Connect MAF sensor coupler to MAF sensor.
5. Turn ignition switch ON and check voltage at MAF sensor output terminal of ECM (PCM) connector (1). MAF sensor output voltage Voltage: 1.0 - 1.6V
6. Start engine and check that voltage is lower than 5 V and it rises as engine speed increases.

(Reference data: 1.7 - 2.0 V at specified idle speed)

If check result is not as specified above, cause may lie in wire harness, coupler connection, MAF sensor or ECM (PCM).

Scheme 261

1. Disconnect negative cable (-) at battery and coupler (1) from MAF sensor (3).
2. Remove air cleaner outlet hose (2) from throttle body and MAF sensor (3).
3. Remove MAF sensor from air cleaner case.

Scheme 262

Scheme 263

1. Check MAF sensor seal (1) for deterioration and damage.
2. Install MAF sensor to air cleaner case.
3. Install air cleaner outlet hose.
4. Connect MAF sensor coupler securely.
5. Connect negative cable (-) to battery.

Scheme 264

1. Disconnect negative cable (-) at battery and coupler from TP sensor (4).
2. Using ohmmeter, check resistance between terminals under each condition. If check result is not satisfactory, replace TP sensor. TP sensor specifications Between "1" and "3" terminals: 4.0 - 6.0 kohm Between "1" and "2" terminals: 0.02 - 6.0 kohm (Varying linearly according to throttle valve opening)
3. Connect TP sensor coupler securely.
4. Connect negative cable to battery.

1. Disconnect negative cable (-) at battery.
2. Disconnect coupler from TP sensor.
3. Remove TP sensor from throttle body.

Scheme 265

1. Install TP sensor (1) to throttle body (2). Fit TP sensor (1) to throttle body (2) in such way that its holes are a little away from TP sensor screw holes as shown in the figure and turn TP sensor (1) clockwise so that those holes align. Tightening torque TP sensor screw (a): 3.5 N.m (0.35 kg-m, 2.5 lb-ft)
2. Connect coupler to TP sensor (1) securely.
3. Connect battery negative cable (-) to battery.

1. Disconnect negative cable (-) at battery.
2. Disconnect IAT sensor coupler.
3. Remove IAT sensor from air cleaner case.

Scheme 266

1. Clean mating surface of sensor and seal (2) on air cleaner case.
2. Install IAT sensor (1) into seal.
3. Connect connector to IAT sensor securely.

Immerse temperature sensing part of IAT sensor in water (or ice) and measure resistance between sensor terminals, while heating water gradually.

If measured resistance doesn't show such characteristic as shown in the figure, replace IAT sensor.

Scheme 267

Scheme 268

1. Disconnect negative cable from battery.
2. Drain cooling system.
3. Disconnect coupler from ECT sensor (1).
4. Remove ECT sensor from water outlet cap (2).

Reverse removal procedure noting the followings.

1. Clean mating surfaces of sensor and water outlet cap (1).
2. Use new O-ring.
3. Tighten ECT sensor to specified torque.

Tightening torque

1. ECT sensor (a): 15 N-m (1.5 kg-m, 11.0 lb-ft)

Scheme 269

1. Connect coupler to sensor securely.
2. Refill cooling system.

Immerse temperature sensing part of ECT sensor in water and measure resistance between sensor terminals while heating water gradually.

If measured resistance doesn't shown such characteristic as shown in the figure, replace ECT sensor.

Scheme 270

1. Disconnect negative cable (-) at battery.
2. Disconnect connector from manifold absolute pressure sensor.
3. Remove manifold absolute pressure sensor from intake manifold.

Scheme 271

1. Confirm that vacuum passage on intake manifold is free from clog.
2. Apply engine oil to O-ring of sensor.
3. Install sensor (1) to intake manifold (2).
4. Connect connector to sensor (1) securely.

Scheme 272

1. Check sensor O-ring (1) for damage and deterioration. Replace as necessary.
2. Arrange 3 new 1.5 V batteries (2) in series and connect its positive terminal to "Vin" terminal of MAP sensor (1) and negative terminal to "Ground" terminal. Then check voltage between "Vout and "Ground". Also, check if voltage reduces when vacuum is slowly applied up to 400 mmHg by using vacuum pump (3). If check result is not satisfactory, replace manifold absolute pressure sensor.

1. MAP sensor output voltage ("Vin" voltage): 4.5 - 5.5 V, ambient temp. 20 - 30°C (68 - 86°F)

Scheme 273

Scheme 274

1. Disconnect negative (-) cable from battery.
2. Disconnect coupler of oxygen sensor(s).
3. Remove oxygen sensor(s) from exhaust manifold(s).

Note. Be careful not to expose it to excessive shock.

Scheme 275

Reverse removal procedure noting the followings.

Scheme 276

1. Tighten oxygen sensor (s) to specified torque. Tightening torque Heated oxygen sensor 1 (a): 45 N-m (4.5 kg-m, 32.5 lb-ft)
2. Connect connector of oxygen sensor(s) and clamp wire harness securely.
3. After installing oxygen sensor(s), start engine and check that no exhaust gas leakage exists.

Heated Oxygen Sensor (Sensor 1) Inspection

Inspect HO2S-1 and its circuit referring to DTCS P0131 OR P0132: HO2S BANK 1, SENSOR 1 CIRCUIT LOW VOLTAGE/HIGH VOLTAGE and/or DTCS P0151 OR P0152: HO2S BANK 2, SENSOR 1 - LOW VOLTAGE/HIGH VOLTAGE . If malfunction is found, replace.

Scheme 277

1. Disconnect negative (-) cable from battery.
2. Disconnect coupler (3) of oxygen sensor(s).
3. Remove oxygen sensor(s) (2) from exhaust manifold(s) (1). NOTE: Be careful not to expose it to excessive shock.

Reverse removal procedure noting the followings.

Scheme 278

1. Tighten oxygen sensor{s) to specified torque. Tightening torque Heated oxygen sensor 2 (a): 45 N.m (4.5 kg-m, 32.5 lb-ft)
2. Connect connector of oxygen sensor(s) and clamp wire harness securely.
3. After installing oxygen sensor(s), start engine and check that no exhaust gas leakage exists.

Scheme 279

1. Disconnect HO2S-1 or HO2S-2 coupler.
2. Using ohmmeter, measure resistance between terminals "VB" and "GND" of HO2S coupler (1). If found faulty, replace HO2S. NOTE: Temperature of HO2S affects resistance value largely. Make sure that HO2S heater is at correct temperature. Resistance of HO2S heater HO2S-1: 5.0 - 6.4 ohm at 20°C (68°F) HO2S-2: 11.7 - 14.3 ohm at 20°C (68°F)
3. Connect HO2S coupler securely.

1. Hoist vehicle.
2. Release parking brake lever, set transmission in neutral and transfer in "2H".
3. Remove ECM (PCM) cover.
4. Connector voltmeter between VSS terminal "C51-3-1" of ECM (PCM) connector and body ground.
5. Turn ignition switch ON and turn rear right tire slowly with rear left tire locked. Voltmeter should indicate deflection between 0-1 V and 8- 14 V a few times while tire (1) is turned one revolution. If check result is not satisfactory, proceed to «DTC P0500: VEHICLE SPEED SENSOR MALFUNCTION»(ref-159350-S36011463302003120100000) .

Scheme 280

Crankshaft Position (CKP) Sensor Removal and Installation

Refer to OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION .

Crankshaft Position (CKP) Sensor inspection

Refer to DTC P0335: CRANKSHAFT POSITION SENSOR - CIRCUIT MALFUNCTION .

Scheme 281

1. Disconnect CMP sensor coupler (2).
2. Remove A/T fluid level gauge and filler tube.
3. Remove CMP sensor (1) by removing bolt (3).

Scheme 282

Scheme 283

Scheme 284

1. Install a new O-ring (2) with engine oil applied to CMP sensor (1).
2. Install CMP sensor (1) to camshaft (3). Fit the dog of CMP sensor coupling (2) into the slots of camshaft, when installing. The dogs of CMP sensor coupling are offset. Therefore, if the dogs can not be fitted into the slots, turn the CMP sensor shaft by 180 degree and try again.
3. Tighten CMP sensor bolt (3). Tightening torque CMP sensor bolt (a): 15 N-m (1.5 kg-m, 11.0 lb-ft)
4. Connect CMP sensor coupler (2) to CMP sensor (1).
5. Install A/T fluid level gauge and filler tube.

Tightening torque

1. A/T filler tube bolt (a): 85 N.m (8.5 kg-m, 61.5 lb-ft)

Scheme 285

Scheme 286

Scheme 287

Scheme 288

1. Disconnect negative (-) cable at battery.
2. Remove main relay (1} from its connector.
3. Check resistance between each two terminals. If check results are as specified, proceed to next operation check. If not, replace. Main relay resistance Between terminals "A" and "B": Infinity Between terminals "C" and "D": 79 - 95 Q (at 20°C (68°F))
4. Check that there is continuity between terminals "A" and "B" when battery is connected to terminals "C" and "D". If malfunction is found, replace.

Scheme 289

See also:
• DISABLING & ACTIVATING AIR BAG SYSTEM
• THROTTLE BODY
• DTC P0500: VEHICLE SPEED SENSOR MALFUNCTION
• OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
• H27 Engine
• Throttle Position (TP) Sensor Adjustment
• H25 Engine