1999 SUZUKI GRAND VITARA sensor

6-1-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Table B-6 A/C Condenser Fan Motor Relay Control System Inspection (If
Equipped)
WIRING DIAGRAM
INSPECTION
1. To ignition switch 3. A/C fuse 5. A/C condenser fan motor
2. Main fuse 4. A/C condenser fan motor relay 6. ECM (PCM)
WARNING:
Keep hands, tools, and clothing away from A/C condenser fan to help prevent personal injury. This
fan is electric and can come on whether or not the engine is running. The fan can start automatically
in response to the ECT sensor with the ignition switch in the “ON” position.
Step Action Yes No
1 1) Check DTC referring to “DTC CHECK” in this sec-
tion.
Is there any malfunction DTC?Go to applicable DTC
Diag. Flow Table.Go to Step 2.
2 1) Check A/C condenser fan for operation.
A/C condenser fan should be operated under follow-
ing condition A or B only.
A : When engine is running and A/C is operating.
B : When engine coolant temp. is 113°C (235°F) or
more with ignition switch ON.
Is check result as specified?This system is in
good condition.Go to Step 3.
3 1) Remove ECM (PCM) cover.
2) Check voltage between E61-22 terminal of ECM
(PCM) connected coupler and ground.
Other than conditions A and B in Step 2 :
10 – 14 V
Under condition A or B in Step 2 :
0 – 1 V
Is check result as specified?Fuse blown, “RED”,
“RED/BLK” or “RED/
BLU” circuit open,
malfunction of con-
denser fan motor or
relay.“YEL/GRN” circuit
open, “YEL/BLU” cir-
cuit open or short, or
relay malfunction.
If above are OK, sub-
stitute a known-good
ECM (PCM) and
recheck.

ENGINE MECHANICAL (H27 ENGINE) 6A2-1
6A2
SECTION 6A2
ENGINE MECHANICAL (H27 ENGINE)
CONTENTS
On-Vehicle Service........................................6A2-2
Throttle Body and Intake Manifold .............. 6A2-2
Exhaust Manifold ......................................... 6A2-9
LH (No.1) Bank 2nd Timing Chain
and Chain Tensioner ................................. 6A2-13
Camshaft and Valve Lash Adjuster ........... 6A2-14
Valves and Cylinder Heads ....................... 6A2-17
Piston, Piston Rings, Connecting Rodsand Cylinders ............................................ 6A2-21
Unit Repair Overhaul .................................. 6A2-26
Engine Assembly ...................................... 6A2-26
Main Bearings, Crankshaft
and Cylinder Block .................................... 6A2-30
Special Tool ................................................. 6A2-36

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:
For the descriptions (items) not found in this section, refer to the same section of service manual
mentioned in the FOREWORD of this manual.
Whether following systems (parts) are used in the particular vehicle or not depends on specifica-
tions. Be sure to bear this in mind when performing service work.
–EGR valve
–Warm up three way catalytic converter
–Heated oxygen sensor(s)
–Three way catalytic converter
–CKP sensor
–MAP sensor

6A2-2 ENGINE MECHANICAL (H27 ENGINE)
On-Vehicle Service
Throttle Body and Intake Manifold
1. Air cleaner box 6. Intake manifold 11. Gasket 16. Throttle body bolt
2. Intake air hose 7. Intake manifold gasket 12. IAT sensor Tightening Torque
3. Intake air pipe 8. Throttle body assembly 13. MAF sensor Do not reuse
4. Surge tank pipe 9. Throttle body gasket 14. MAP sensor
5. Gasket 10. Intake collector 15. Throttle body nut

ENGINE MECHANICAL (H27 ENGINE) 6A2-3
REMOVAL
1) Release fuel pressure in fuel feed line by referring to Section
6.
2) Disconnect negative (–) cable at battery.
3) Drain coolant.
4) Remove strut tower bar (2).
5) Disconnect coupler from intake air temp. sensor, and MAF
sensor.
6) Remove surge tank cover (1).
7) Remove air cleaner upper case, intake air hose, intake air
pipe (1) and surge tank pipe (2) as one component. Do not
disassemble them, when removing and reinstalling. CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
WARNING:
To help avoid danger of being burned, do not remove
drain plug and radiator cap while engine and radiator are
still hot. Scalding fluid and steam can be blown out under
pressure if plug and cap are taken off too soon.
1. Radiator
2. Radiator drain plug
2
1
1
2

6A2-4 ENGINE MECHANICAL (H27 ENGINE)
8) Disconnect accelerator cable (1) and A/T throttle cable (2)
(for A/T vehicle) from throttle body.
9) Disconnect water hoses (3) from throttle body.
10) Disconnect injector wire (1) coupler.
11) Disconnect brake booster hose (2) from intake manifold.
12) Disconnect couplers of TP sensor (1) and IAC valve (2).
13) Disconnect earth terminal (3) from intake collector.
14) Remove clamp bracket (4) from intake collector.
15) Disconnect couplers from manifold absolute pressure (MAP)
sensor, EVAP canister purge valve, earth terminal and EGR
valve.
16) Disconnect PCV hose from cylinder head cover.
Disconnect breather hoses from throttle body or cylinder
head cover.
17) Disconnect hoses of EVAP canister purge valve and heater.
18) Remove EGR pipe.
12
33
2
1
2
14
3
1. EVAP canister purge valve 6. PCV hose
2. EGR valve 7. Water hose
3. EGR pipe 8. Breather hose
4. EVAP canister purge valve hose 9. Earth terminal coupler
5. Heater hose
9
4
1 7
6
2
35
8

6A2-6 ENGINE MECHANICAL (H27 ENGINE)
INSTALLATION
1) Install new intake manifold gaskets (1) to cylinder heads.
2) Install intake manifold (1).
Tighten bolts and nuts to specified torque.
Tightening torque
Intake manifold bolt and nut (a) :
23 N·m (2.3 kg-m, 16.5 lb-ft)
3) Install throttle body (2) to intake collector (1) with new throttle
body gasket.
Tighten bolts and nuts to specified torque.
Tightening torque
Throttle body bolt and nut (b) :
23 N·m (2.3 kg-m, 16.5 lb-ft)
4) Install EGR valve (1), EVAP canister purge valve (2), mani-
fold absolute pressure (MAP) sensor and each hoses to
intake collector and throttle body if removed.
Use new gasket, when installing IAC valve and EGR valve.
5) Install throttle body and intake collector assembly to intake
manifold with new intake collector gaskets.
1
(a)
(a)(a)
(a)
2 1
(b)
(b)
3. EVAP canister purge valve hose
2
1
3

ENGINE MECHANICAL (H27 ENGINE) 6A2-7
6) Connect hoses of heater, EVAP canister, fuel feed and fuel
return.
7) Install EGR pipe with new gaskets.
8) Connect hoses of EVAP canister purge valve and heater.
9) Connect hoses of PCV, breather and water.
10) Connect couplers of manifold absolute pressure (MAP) sen-
sor, EVAP canister purge valve and EGR valve.
Fix wire harness with clamps.
11) Install clamp bracket (4) to intake collector.
12) Connect earth terminal (3) to intake collector.
13) Connect couplers of TP sensor (1) and IAC valve (2).
14) Connect brake booster hose (2) to intake manifold.
15) Connect injector wire (1) coupler.
1. Heater hose
2. Fuel feed hose
3. Fuel return hose
4. EVAP canister hose
13
2 4
1. EVAP canister purge valve 6. PCV hose
2. EGR valve 7. Water hose
3. EGR pipe 8. Breather hose
4. EVAP canister purge valve hose 9. Earth terminal coupler
5. Heater hose9
4
1 7
6
2
35
8
2
14
3
2
1

6A2-8 ENGINE MECHANICAL (H27 ENGINE)
16) Connect water hoses (3) to throttle body.
17) Connect accelerator cable (1) and A/T throttle cable (2) (for
A/T vehicle) to throttle body.
18) Install surge tank pipe (2) to intake manifold with new gas-
kets and intake air pipe (1) to throttle body.
19) Install surge tank cover (1).
20) Install air cleaner upper case.
21) Connect coupler to intake air temp. sensor and MAF sensor.
22) Install strut tower bar (1).
23) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
24) Refill cooling system referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
25) Connect negative cable at battery.
12
33
1
2
1