2001 SUZUKI GRAND VITARA service

6-1-44 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Table A-2 Malfunction Indicator Lamp Circuit Check – Lamp Remains “ON”
after Engine Starts
WIRING DIAGRAM/CIRCUIT DESCRIPTION
Refer to TABLE A-1.
INSPECTION
2 ECM power and ground circuit check :
Does engine start?Go to Step 3. Go to “TABLE A-3 ECM
(PCM) POWER AND
GROUND CIRCUIT
CHECK” in this section.
If engine is not cranked,
go to “DIAGNOSIS” in
Section 6G.
3 MIL circuit check :
1) Turn ignition switch OFF and disconnect
connectors from ECM.
2) Check for proper connection to ECM at ter-
minal E61-7.
3) If OK, then using service wire, ground termi-
nal E61-7 in connector disconnected.
Does MIL turn on at ignition switch ON?Substitute a known-good
ECM (PCM) and recheck.Bulb burned out or “PPL/
YEL” wire circuit open. Step Action Yes No
Step Action Yes No
1 DTC check :
1) With ignition switch OFF, install scan tool.
2) Start engine and check DTC.
Is there any malfunction DTC (s).Go to Step 2 of “ENGINE
DIAG. FLOW TABLE” in
this section.Go to Step 2.
2 MIL circuit check :
1) With ignition switch OFF, disconnect cou-
plers from ECM (PCM).
Does MIL turn ON at ignition switch ON?“PPL/YEL” wire shorted to
ground circuit.Substitute a known-good
ECM (PCM) and recheck.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-45
Table A-3 Malfunction Indicator Lamp Check – MIL Flashes at Ignition Switch
ON (Vehicle with Monitor Connector)
WIRING DIAGRAM/CIRCUIT DESCRIPTION
Refer to TABLE A-1.
TROUBLESHOOTING
Table A-4 Malfunction Indicator Lamp Check – MIL Does Not Flash or Just
Remains ON Even with Grounding Diagnosis Switch Terminal (Vehicle with
Monitor Connector)
WIRING DIAGRAM/CIRCUIT DESCRIPTION
Refer to TABLE A-1.
TROUBLESHOOTING
Step Action Yes No
1 MIL Flashing Pattern check:
1) Turn ignition switch ON.
Does lamp flashing pattern indicate diagnostic
trouble code?Go to Step 2. Go to “Diagnosis” in Sec-
tion 8G.
2 Diag. Switch Circuit check:
Is diag. switch terminal connected to ground via
service wire?System is in good condi-
tion.“YEL” circuit shorted to
ground. If circuit is OK
substitute a known-good
ECM (PCM) and recheck.
Step Action Yes No
1 MIL Circuit check:
1) Turn ignition switch OFF and disconnect
connectors from ECM (PCM).
Does MIL turn ON at ignition switch ON?“PPL/YEL” circuit shorted
to ground.Go to Step 2.
2 ECM (PCM) Connection check:
1) Turn ignition switch OFF.
Is connector (E61-29 connection) connected to
ECM (PCM) properly?Go to Step 3. Poor connector connec-
tion.
3 Diag. switch Terminal Circuit check:
1) Connect connectors to ECM (PCM).
2) Using service wire, ground E61-29 terminal
with connectors connected to ECM (PCM).
3) Turn ignition switch ON.
Does MIL flash?“YEL” or “BLK” circuit
open.Substitute a known-good
ECM (PCM) and recheck.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-47
INSPECTION
Step Action Yes No
1 Main relay operating sound check :
Is operating sound of main relay heard at igni-
tion switch ON?Go to Step 5. Go to Step 2.
2 Fuse check :
Is main “FI” fuse in good condition?Go to Step 3. Check for short in circuits
connected to this fuse.
3 Main relay check :
1) Turn OFF ignition switch and remove main
relay.
2) Check for proper connection to main relay
at terminal 3 and 4.
3) If OK, check main relay for resistance and
operation referring to “MAIN RELAY
INSPECTION” in Section 6E2.
Is check result satisfactory?Go to Step 4. Replace main relay.
4 ECM (PCM) power circuit check :
1) Turn OFF ignition switch, disconnect con-
nectors from ECM (PCM) and install main
relay.
2) Check for proper connection to ECM (PCM)
at terminals C51-3-20, E61-9, C51-3-15 and
C51-3-4.
3) If OK, then measure voltage between termi-
nal C51-3-20 and ground, E61-9 and
ground with ignition switch ON.
Is each voltage 10 – 14 V?Go to Step 5. “BLK/WHT”, “BLU” or
“BLK/RED” circuit open.
5 ECM power circuit check :
1) Using service wire, ground terminal E61-9
and measure voltage between terminal
C51-3-15 and ground at ignition switch ON.
Is it 10 – 14 V?Check ground circuits
“BLK/GRN” and “BLK/
ORN” for open.
If OK, then substitute a
known-good ECM (PCM)
and recheck.Go to Step 6.
6 Is operating sound of main relay heard in Step
1?Go to Step 7. “BLK/RED” or “BLU/BLK”
wire open.
7 Main relay check :
1) Check main relay according to procedure in
Step 3.
Is main relay in good condition?“BLK/RED” or “BLU/BLK”
wire open.Replace main relay.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-51
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 Check IAT sensor and its circuit :
1) Connect scan tool with ignition switch OFF.
2) Turn ignition switch ON.
3) Check intake air temp. displayed on scan
tool.
Is – 40°C (– 40°F) or 165°C (329°F) indicated?Go to Step 3. Intermittent trouble.
Check for intermittent
referring to “INTERMIT-
TENT AND POOR CON-
NECTION” in Section 0A.
3 Check wire harness :
1) Disconnect IAT sensor connector with igni-
tion switch OFF.
2) Check for proper connection to IAT sensor
at “LT BLU” and “GRY/YEL” wire terminals.
If OK, then with ignition switch ON, is voltage
applied to “LT BLU” wire terminal about 4 – 6 V?Go to Step 4. “LT BLU” wire open or
short, or poor C51-3-1
connection.
If wire and connection are
OK, substitute a known-
good ECM (PCM) and
recheck.
4 Check wire harness :
1) Using service wire, connect IAT sensor con-
nector terminals.
2) Turn ignition switch ON and check intake air
temp. displayed on scan tool.
Is 165°C (329°F) indicated?Replace IAT sensor. “GRY/YEL” wire open or
poor C51-3-25 connec-
tion.
If wire and connection are
OK, substitute a known-
good ECM (PCM) and
recheck.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-53
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 Check ECT sensor and its circuit :
1) Connect scan tool with ignition switch OFF.
2) Turn ignition switch ON.
3) Check engine coolant temp. displayed on
scan tool.
Is – 40°C (– 40°F) or 164°C (327°F) indicated?Go to Step 3. Intermittent trouble.
Check for intermittent
referring to “INTERMIT-
TENT AND POOR CON-
NECTION” in Section 0A.
3 Check wire harness :
1) Disconnect ECT sensor connector with igni-
tion switch OFF.
2) Check for proper connection to ECT sensor
at “ORN/BLK” and “GRY/YEL” wire termi-
nals.
If OK, then with ignition switch ON, is voltage
applied to “ORN/BLK” wire terminal about 4 – 6
V?Go to Step 4. “ORN/BLK” wire open or
short, or poor C51-3-2
connection.
If wire and connection are
OK, substitute a known-
good ECM (PCM) and
recheck.
4 Check wire harness :
1) Using service wire, connect ECT sensor
connector terminals.
2) Turn ignition switch ON and check engine
coolant temp. displayed on scan tool.
Is 164°C (327°F) indicated?Replace ECT sensor. “GRY/YEL” wire open or
poor C51-3-23 connec-
tion.
If wire and connection are
OK, substitute a known-
good ECM (PCM) and
recheck.

6-1-116 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Table B-1 Fuel Pump Circuit Inspection
WIRING DIAGRAM
INSPECTION
1. To ignition switch 4. Fuel pump relay
2. Main fuse 5. Fuel pump
3. Main relay 6. ECM (PCM)
CAUTION:
Check to make sure that connection is made between correct terminals.
Wrong connection can cause damage to ECM, wire harness etc.
Step Action Yes No
1 Fuel pump operation check :
1) Remove fuel filler cap.
2) Turn ON ignition switch.
Is fuel pump operation sound heard for 3 sec.
after ignition switch ON?Fuel pump circuit is in
good condition.Go to Step 2.
2 Fuel pump circuit check :
1) With ignition switch OFF, remove fuel pump
relay from connector.
2) Check for proper connection to relay at
each terminal.
3) If OK, using service wire, connect terminals
E07-7 and E07-8 of relay connector. (See
Fig.)
Is fuel pump heard to operate at ignition switch
ON?Go to Step 3.“BLU/BLK”, “PNK/BLK” or
“BLK” circuit open or fuel
pump malfunction.

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