2001 SUZUKI GRAND VITARA Cylinder head

ENGINE MECHANICAL (H27 ENGINE) 6A2-11
INSTALLATION
1) Install new manifold gaskets to cylinder heads and No.1 pipe
gasket to exhaust No.1 pipe.
2) Install exhaust manifolds.
•Always install new bolts with pre-coated adhesive to the
locations with ✱ mark.
•Tighten both manifold nuts and bolts to specified torque.
Tightening torque
Exhaust manifold bolt and nut (a) :
30 N·m (3.0 kg-m, 21.5 lb-ft)
3) Install stabilizer bar if it was removed. Refer to “STABILIZER
BAR / BUSHINGS” in Section 3D.
4) Install exhaust manifold stiffeners (if removed).
5) Install exhaust No.1 pipe (1).
Tighten exhaust No.1 pipe bolts to specified torque.
Tightening torque
Exhaust No.1 pipe bolt (b) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
6) Tighten exhaust No.1 pipe nuts to specified torque.
Tightening torque
Exhaust No.1 pipe nut (b) :
50 N·m (5.0 kg-m, 36-5 lb-ft)
1. Left (No.1) exhaust manifold
2. Right (No.2) exhaust manifold
2. Exhaust No. 2 pipe
1. Exhaust No.1 pipe
2. Exhaust manifold
A. Without WU-TWC
B. With WU-TWC

ENGINE MECHANICAL (H27 ENGINE) 6A2-15
INSPECTION
Cam wear
Using a micrometer, measure cam height. If measured height is
below its limit, replace camshaft.
Intake cam height :
Standard : 40.402 – 40.562 mm (1.5906 – 1.5969 in.)
Limit : 40.300 mm (1.3581 in.)
Exhaust cam height :
Standard : 39.428 – 39.588 mm (1.5523 – 1.586 in.)
Limit : 39.400 mm (1.5512 in.)
Camshaft runout
Set camshaft between two “V” blocks, and measure its runout by
using a dial gauge.
If measured runout exceeds below specified limit, replace cam-
shaft.
Camshaft runout limit :
0.04 mm (0.002 in.)
Camshaft journal wear
Check camshaft journals and camshaft housings for pitting,
scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head
with housing. Never replace cylinder head without replacing hous-
ings.
Check clearance by using gaging plastic. The procedure is as fol-
lows.
1) Clean housings and camshaft journals.
2) Make sure that all valve lash adjusters are removed and
install camshaft to cylinder head.
3) Place a piece of gaging plastic the full width of journal of
camshaft (parallel to camshaft).
4) Install camshaft housing.
5) Tighten camshaft housing bolts in such order ([A] : “1” →
“17”, [B] : “1” → “19”) as shown in the figure a little at a time
till they are tightened to specified torque.
NOTE:
Do not rotate camshaft while gaging plastic is installed.
[A] : RH bank
[B] : LH bank

6A2-16 ENGINE MECHANICAL (H27 ENGINE)
6) Remove housing, and using scale (2) on gaging plastic (1)
envelop, measure gaging plastic (1) width at its widest point.
Camshaft journal clearance :
Standard : 0.045 – 0.099 mm (0.0018 – 0.0039 in.)
Limit : 0.12 mm (0.0047 in.)
If measured camshaft journal clearance exceeds limit, measure
journal (housing) bore and outside diameter of camshaft journal.
Replace camshaft or cylinder head assembly whichever the differ-
ence from specification is greater.
Camshaft journal bore dia. (IN & EX) :
Standard : 26.000 – 26.033 mm (1.0236 – 1.0249 in.)
Camshaft journal O.D. (IN & EX) :
Standard : 25.934 – 25.955 mm (1.0210 – 1.0218 in.)
Wear of hydraulic valve lash adjuster
Check adjuster for pitting, scratches, or damage.
If any malcondition is found, replace.
Measure cylinder head bore and adjuster outside diameter to
determine cylinder head-to-adjuster clearance. If clearance
exceeds limit, replace adjuster or cylinder head.
Hydraulic valve lash adjuster O.D. :
Standard : 30.959 – 30.975 mm (1.2188 – 1.2194 in.)
Cylinder head bore :
Standard : 31.000 – 31.025 mm (1.2205 – 1.2214 in.)
Cylinder head to adjuster clearance :
Standard : 0.025 – 0.066 mm (0.0010 – 0.0025 in.)
Limit : 0.15 mm (0.0059 in.)

ENGINE MECHANICAL (H27 ENGINE) 6A2-17
Valves and Cylinder Heads
1. Cylinder block 6. Exhaust valve 11. Valve stem oil seal 16. Cylinder head bolt
(hex hole bolt)
2. RH bank cylinder head 7. Intake valve 12. Valve spring retainer Tightening Torque
3. LH bank cylinder head 8. Valve spring seat 13. Valve cotter Do not reuse
4. RH bank cylinder head gasket :
Carved lot number on cylinder head
gasket should face up (toward cylinder
head side).9. Outer valve spring :
Be sure to position spring in place with
its bottom end (small-pitch end) facing
the bottom (valve spring seat side).14. Valve guide Apply engine oil to
sliding surface of
each parts.
5. LH bank cylinder head gasket :
Carved lot number on cylinder head
gasket should face up (toward cylinder
head side).10. Inner valve spring :
Be sure to position spring in place with
its bottom end (small-pitch end) facing
the bottom (valve spring seat side).15. Cylinder head bolt

6A2-18 ENGINE MECHANICAL (H27 ENGINE)
INSPECTION
Valve guides
Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to check stem-to-guide clearance. Be
sure to take reading at more than one place along the length of
each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem-to-guide clearance :
INSTALLATION
1) Clean mating surface on cylinder head and cylinder block.
Remove oil, old gasket and dust from mating surface.
2) Install knock pin (4) to cylinder block.
3) Apply sealant “A” to cylinder head gasket (1) as shown in the
figure.
“A” : Sealant 99000-31150
Sealant amount (Width “w”) :
4 mm (0.158 in.)
4) Install new cylinder head gasket (1) to cylinder block as
shown in the figure. carved lot number (5) on cylinder head
gasket (1) should face up (toward cylinder head side).Standard Limit
Valve stem
diameterIntake 5.965 – 5.980 mm
(0.2348 – 0.2354 in.)–
Exhaust 5.940 – 5.955 mm
(0.2339 – 0.2344 in.)–
Valve guide
I.D.In & Ex 5.985 – 6.010 mm
(0.2356 – 0.2366 in.)–
Stem-to-guide
clearanceIntake 0.035 – 0.045 mm)
(0.0014 – 0.0018 in.)0.07 mm
(0.0027 in.)
Exhaust 0.060 – 0.070 mm
(0.0024 – 0.0028 in.)0.09 mm
(0.0035 in.)
[A] : RH ( No.2) bank
[B] : LH (No.1) bank
2. Crankshaft pulley side
3. Flywheel side

ENGINE MECHANICAL (H27 ENGINE) 6A2-19
5) Install cylinder head to block.
After applying oil to cylinder head bolts, tighten them gradu-
ally as follows.
a) Tighten all bolts to 53 N·m (5.3 kg-m, 38.5 lb-ft) according
to numerical order in the figure.
b) In the same manner as in a), tighten them to 84 N·m (8.4
kg-m, 61.0 lb-ft).
c) Loosen all bolts until tightening torque is reduced to 0 in
reverse order of tightening.
d) In the same manner as in a), tighten them to 53 N·m (5.3
kg-m, 38.5 lb-ft).
e) In the same manner as in a) again, tighten them to speci-
fied torque.
Tightening torque
Cylinder head bolt (a) : 105 N·m (10.5 kg-m, 76.0 lb-ft)
Cylinder head bolt (hex hole bolt) (b) :
11 N·m (1.1 kg-m, 7.5 lb-ft)
6) Install water outlet cap.
7) Check timing mark on crankshaft as shown in the figure.
8) Install valve lash adjuster, camshaft, CMP sensor and RH
bank 2nd timing chain.
Refer to “CAMSHAFT AND VALVE LASH ADJUSTER” and
“RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TEN-
SIONER” in this section. For CMP sensor, refer to “CMP
SENSOR” in Section 6F2.
9) Install 1st timing chain.
Refer to “1ST TIMING CHAIN AND CHAIN TENSIONER” in
this section.
10) Install LH bank 2nd timing chain.
Refer to “LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN
TENSIONER” in this section.
11) Install timing chain cover.
Refer to “TIMING CHAIN COVER” in this section. NOTE:
Don’t forget to install (b) bolts as shown in the figure.
1. Hex hole bolt
2. Crankshaft pulley side
3. Flywheel side
[A] RH bank
[B] LH bank
1. Crank timing pulley key
2. Oil jet

6A2-20 ENGINE MECHANICAL (H27 ENGINE)
12) Install oil pan and oil pump strainer.
Refer to “OIL PAN AND OIL PUMP STRAINER” in this sec-
tion.
13) Install cylinder head cover.
Refer to “CYLINDER HEAD COVER” in this section.
14) Install exhaust manifold.
Refer to “EXHAUST MANIFOLD” in this section.
15) Install radiator outlet pipe, radiator, cooling fan and water
hose.
Refer to “COOLING WATER PIPES OR HOSES”, “RADIA-
TOR” and “COOLING FAN AND FAN CLUTCH” in Section
6B.
16) Install throttle body and intake manifold.
Refer to “THROTTLE BODY AND INTAKE MANIFOLD” in
this section.
17) Adjust water pump drive belt tension.
Refer to “COOLING FAN BELT TENSION CHECK AND
ADJUSTMENT” in Section 6B.
18) Adjust power steering pump drive belt tension.
Refer to “POWER STEERING PUMP DRIVE BELT” in Sec-
tion 3B1.
19) Adjust accelerator cable play and A/T throttle cable play.
Refer to “ACCELERATOR CABLE ADJUSTMENT” and “A/T
THROTTLE CABLE ADJUSTMENT (A/T VEHICLE)” in Sec-
tion 6E2.
20) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
21) Refill engine with engine oil, referring to “ENGINE OIL
CHANGE” in Section 0B.
22) Refill cooling system referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
23) Refill front differential housing with gear oil if drained, refer-
ring to “MAINTENANCE SERVICE” in Section 7E.
24) Connect negative cable at battery.
25) Check ignition timing and adjust as necessary, referring to
“IGNITION TIMING CHECK AND ADJUSTMENT” in Section
6F2.
26) Verify that there is no fuel leakage, water leakage, oil leak-
age and exhaust gas leakage at each connection.
27) Check wheel alignment, referring to “STEERING ANGLE” in
Section 3A.

6A2-24 ENGINE MECHANICAL (H27 ENGINE)
ASSEMBLY
1) 2 sizes of piston are available as standard size spare part so
as to ensure proper piston-to-cylinder clearance. When
installing a standard size piston, make sure to match piston
with cylinder as follows.
a) Each piston has stamped number (1 or 2) on its piston
head. It represents outer diameter of piston.
b) There are also stamped numbers of 1 and 2 on the cylinder
block as shown in the figure.
c) Stamped number on piston and cylinder block must corre-
spond. That is, install number “2” stamped piston to cylinder
which is stamped also number “2” and a number “1” piston
to cylinder with number “1”.
Also, a letter A, B or C is stamped on piston head but ordi-
narily it is not necessary to distinguish each piston by this
letter.
Piston-to-cylinder clearance
Piston :
Cylinder :
Piston-to-cylinder clearance :
0.02 – 0.04 mm (0.0008 – 0.0015 in.)
2) Install piston pin to piston and connecting rod :
After applying engine oil to piston pin and piston pin holes in
piston and connecting rod, fit connecting rod to piston as
shown in the figure and insert piston pin to piston and con-
necting rod, and install piston pin circlips. Number at the top (mark) Outer diameter
187.98 – 87.99 mm
(3.4638 – 3.4642 in.)
287.97 – 87.98 mm
(3.4634 – 3.4638 in.)
Number on cylinder block (mark) Outer diameter
188.01 – 88.02 mm
(3.4650 – 3.4653 in.)
288.00 – 88.01 mm
(3.4646 – 3.4650 in.)
NOTE:
“86F” mark on connecting rod must face toward crank-
shaft pulley side.
1. Piston
2. Arrow mark
3. Connecting rod