2001 SUZUKI GRAND VITARA crankshaft sensor

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

6A2-30 ENGINE MECHANICAL (H27 ENGINE)
Main Bearings, Crankshaft and Cylinder Block
1. Cylinder block 6. Rear oil seal 11. O-ring [A]: Sealant application amount
2. Lower crankcase :
Apply sealant 99000-31150 to lower
crankcase mating surface.7. Flywheel (M/T) Drive plate
(A/T)12. Clutch housing plate Tightening Torque
3. Crankshaft 8. Water pump 13. Cap bolt Do not reuse
4. Main bearing 9. O-ring 14. Lower crankcase bolt Apply engine oil to sliding
surface of each parts.
5. Thrust bearing :
Set bearing facing grooved side to
crank weds.10. Timing chain oil jet 15. Knock sensor“a”: Width 3 mm (0.12 in.)
“b”: Height 2 mm (0.08 in.)

6E2-2 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Fuel injector.......................................... 6E2-26
Electronic Control System........................ 6E2-31
Engine control module (ECM)/
powertrain control module (PCM) ........ 6E2-31
Mass air flow sensor (MAF sensor)...... 6E2-32
Intake air temperature (IAT) sensor ..... 6E2-34
Throttle position sensor (TP sensor) .... 6E2-35
Engine coolant temperature sensor
(ECT sensor) ........................................ 6E2-36
Heated oxygen sensor (sensor 1) ........ 6E2-37
Heated oxygen sensor (sensor 2) ........ 6E2-38
Vehicle speed sensor (VSS) ................ 6E2-39
Manifold absolute pressure sensor ...... 6E2-39
Fuel level sensor (sender gauge)......... 6E2-41
Crankshaft position sensor................... 6E2-41Main relay ............................................ 6E2-41
Fuel pump relay ................................... 6E2-42
Fuel cut operation ................................ 6E2-43
Emission Control System......................... 6E2-44
EGR system (if equipped) .................... 6E2-44
EVAP canister ...................................... 6E2-45
Vacuum passage ................................. 6E2-46
PCV System ............................................ 6E2-47
PCV hose ............................................. 6E2-47
PCV valve ............................................ 6E2-47
PCV system ......................................... 6E2-48
Tightening Torque Specification.............. 6E2-48
Special Tool ............................................... 6E2-48

General Description
The engine and emission control system has 4 major sub-systems: air intake system, fuel delivery system, elec-
tronic control system and emission control system.
Air intake system includes air cleaner, mass air flow sensor, throttle body, idle air control valve and intake man-
ifold.
Fuel delivery system includes fuel pump, delivery pipe, fuel pressure regulator, fuel injectors, etc.
Electronic control system includes ECM (PCM), various sensors and controlled devices.
Emission control system includes EGR, EVAP and PCV systems.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-5
1. Air cleaner 22. Fuel level sensor 39. A/C controller (if equipped)
2. Intake air temp. sensor 23. Monitor connector (if equipped) 40. Data link connector/Immobilizer control mod-
ule (if equipped)
3. Mass air flow sensor 23-1. Diag. switch terminal 41. ABS control module
4. EVAP canister purge valve 23-2. Test switch terminal 42. Main relay
5. Throttle position sensor 23-3. Output duty select switch terminal 43. Ignition switch
6. Idle air control valve 23-4. Duty output terminal 44. Park/Neutral position switch in TR switch (A/T)
7. Camshaft position sensor 24. Fuel filter 45. Battery
8. EGR valve 25. Fuel pressure regulator 46. Starter magnetic switch
9. Manifold absolute pressure sensor
(if equipped)26. Immobilizer indicator lamp (if equipped) 47.“O/D OFF” lamp (A/T)
10. Fuel injector 27. Tank pressure control valve 48.“POWER” lamp (A/T)
11. PCV valve 28. EVAP canister 49. Lighting switch (A/T)
12. Ignition coil assembly 29. Knock sensor 50. Stop lamp switch (A/T)
13. Engine coolant temperature sensor 30. ECM/PCM (Engine control module/Powertrain con-
trol module)51. O/D cut switch (A/T)
14. Heated oxygen sensor
(bank 1 sensor 1) (if equipped)31. Malfunction indicator lamp 52. POWER/NORMAL change switch (A/T)
15. Heated oxygen sensor
(bank 2 sensor 1) (if equipped)32. Electric loads (rear defogger (if equipped), lighting) 53. 4WD low switch (A/T)
16. Heated oxygen sensor
(bank 1 sensor 2) (if equipped)33. Power steering pressure switch 54. Transmission range switch (A/T)
17. Heated oxygen sensor
(bank 2 sensor 2) (if equipped)34. Heater blower fan switch 55. Solenoid valve A (A/T)
18. Warm-up three way catalytic converter
(if equipped)35. Cruise control module 56. Solenoid valve B (A/T)
19. Three way catalytic converter
(if equipped)36. Vehicle speed sensor 57. TCC solenoid valve (A/T)
20. Crankshaft position sensor
(if equipped)37. Combination meter 58. A/T input speed sensor (A/T)
21. Fuel pump 38. A/C condenser fan relay (if equipped) 59. A/T vehicle (output) speed sensor (A/T)

6E2-8 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Electronic Control System
The electronic control system consists of 1) various sensors which detect the state of engine and driving condi-
tions, 2) ECM (PCM) which controls various devices according to the signals from the sensors and 3) various
controlled devices.
Functionally, it is divided into the following sub systems:
•Fuel injection control system
•Heated oxygen sensor heater control system (if equipped)
•Idle air control system
•Fuel pump control system
•Evaporative emission control system
•Ignition control system
•EGR system (if equipped)
Also, with A/T model, PCM controls A/T.
INFORMATION SENSORS CONTROLLED DEVICES OTHERS
1. IAT sensor a : A/C condenser fan motor relay (if equipped) A : Main fuse box
2. MAP sensor (if equipped) b : Ignition coil assemblies B : ECM (PCM)
3. Heated oxygen sensor (sensor 1) (if equipped) c : EVAP canister purge valve C : Data link connector
4. ECT sensor d : EGR valve (if equipped) D : Combination meter
5. TP sensor e : Idle air control valve E : Fuse box
6. MAF sensor f : Injectors F : EVAP canister
7. Camshaft position sensor (CMP sensor) g : Malfunction indicator lamp
8. ABS control module h : Fuel pump relay
9. Crankshaft position sensor (CKP sensor) (if equipped) i : Main relay
10. Power steering pressure switch (PSP switch) j : Oxygen sensor heater relay (if equipped)
11. CO adjusting resistor (if equipped)
12. Monitor connector (if equipped)
13. Transmission range switch (A/T)
14. Knock sensor
NOTE:
Above figure shows left-hand steering vehicle. For right-hand steering vehicle, parts with (*) are
installed at the side of symmetry.

6E2-10 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
TERMINAL ARRANGEMENT OF ECM (PCM) CONNECTOR (VIEWED FROM HARNESS SIDE)
1. Fuel injector No.1 17.“O/D OFF” lamp (A/T) 34. Power steering pressure switch
2. Fuel injector No.2 18.“POWER” lamp (A/T) 35. Stop lamp switch (Brake pedal switch)
3. Fuel injector No.3 18-1.“4WD” lamp (4WD) 36. Lighting switch
4. Fuel injector No.4 18-2. 4WD air pump assembly (4WD) 37. Rear defogger switch (if equipped)
4-1. Fuel injector No.5 19. 4WD switch (4WD) 38. Heater blower motor (if equipped)
4-2. Fuel injector No.6 20. Power/Normal change switch (A/T) 39. A/C control module (amplifier)
5. EGR valve (if equipped) 21. O/D cut switch (A/T) 40. ABS control module
6. Idle air control 21-1. 4WD low switch (4WD) 41. Heated oxygen sensor-1 (Bank1) (if equipped)
7. EVAP canister purge valve 22. Main relay 41-1. Heated oxygen sensor-1 (Bank2) (if equipped)
8. Ignition coil for No.1 23. Transmission range switch (Park/Neutral
Position Switch) or clutch pedal position switch42. Heater oxygen sensor-2 (Bank1) (if equipped)
8-1. Ignition coil for No.2 24. Starter magnetic switch 42-1. Heater oxygen sensor-2 (Bank2) (if equipped)
9. Ignition coil for No.3 24-1. Cruise control module (if equipped) 43. Intake air temp. sensor
9-1. Ignition coil for No.4 25. Vehicle speed sensor 44. Engine coolant temp. sensor
10. Ignition coil for No.5 26. Combination meter 45. Throttle position sensor
10-1. Ignition coil for No.6 27. Data link connector 46. CO adjusting resistor (if equipped)
11. Fuel pump relay 28. TCC solenoid (A/T) 47. Manifold absolute pressure sensor (if
equipped)
12. Fuel pump 29. Shift solenoid-B (A/T) 48. Mass air flow sensor
13. A/C condenser fan relay (if equipped) 30. Shift solenoid-A (A/T) 49. Camshaft position sensor
14. A/C condenser fan motor (if equipped) 31. Transmission range switch (sensor) (A/T) 50. Crankshaft position sensor (if equipped)
15. Knock sensor 32. A/T input speed sensor (A/T) 51. Monitor connector (if equipped)
16. Malfunction indicator lamp 33. A/T vehicle (output) speed sensor (A/T) 52. Engine control module
(Powertrain control module)
TERMINAL CIRCUIT TERMINAL CIRCUIT TERMINAL CIRCUIT
E61-1 Power source for CO adjusting resistor
(if equipped)E61-13 Data link connector E61-25—
E61-2 Power source for back up E61-14 Test switch terminal (if equipped) E61-26—
E61-3—E61-15 Rear defogger switch (if equipped) E61-27—
E61-4 Cruise control module
(Throttle opening signal)E61-16 Heater blower switch E61-28—
E61-5 Duty output terminal (if equipped) E61-17 A/C signal (if equipped) E61-29 Diag. switch terminal (if equipped)
E61-6 Tachometer E61-18—E61-30 ABS control module (if equipped)
E61-7 MIL (“SERVICE INGINE SOON” lamp) E61-19“4WD” lamp E61-31 Power/Normal change switch (A/T)
E61-8 A/C cut signal (if equipped) E61-20“O/D OFF” lamp (A/T) E61-32 Lighting switch
E61-9 Main relay E61-21“POWER” lamp (A/T) E61-33 O/D cut switch (A/T)
E61-10 CO adjusting resistor (if equipped) E61-22 A/C fan motor relay (if equipped) E61-34 Stop lamp switch (Brake pedal switch)
E61-11—E61-23 Fuel pump relay E61-35 Cruise control module (if equipped)
E61-12—E61-24 Ground for CO adjusting resistor (if
equipped)

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-41
INSTALLATION
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.
Fuel level sensor (sender gauge)
Refer to Section 8C.
Crankshaft position sensor
REMOVAL AND INSTALLATION
Refer to Section 6A4.
INSPECTION
Refer to Section 6-1.
Main relay
INSPECTION
1) Disconnect negative (–) cable at battery.
2) Remove main relay (1) from its connector.
2. Fuel pump relay
3. Fuse box
4. Instrument panel
[A]: Left-hand steering vehicle
[B]: Right-hand steering vehicle

IGNITION SYSTEM (FOR H27 ENGINE) 6F2-7
5) Set timing light to ignition harness for No.1 cylinder.
6) Using timing light, check that timing observed from viewpoint
is within specification.
Initial ignition timing of viewpoint
(when it is fixed by SUZUKI scan tool) :
5 ± 1° BTDC
Ignition order :
1-6-5-4-3-2
Special tool
(A) : 09930-76420
7) If ignition timing is out of specification, loosen flange bolt,
adjust timing by turning CMP sensor (1) while engine is run-
ning, and then tighten bolt (2).
Tightening torque
CMP sensor bolt (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft)
8) After tightening bolt (2), recheck that ignition timing is within
specification.
9) After checking and/or adjusting, end fixed spark mode of
SUZUKI scan tool.
10) With engine idling (closed throttle position and vehicle
stopped), check that ignition timing is about BTDC 12-16°
(shown in the figure). Also, check that increasing engine
speed advances ignition timing.
If above check results are not satisfactory, check input sig-
nals related to this system.
1. Timing mark on crankshaft pulley
NOTE:
In this state, ignition timing may vary more or less of ini-
tial ignition timing but it is nothing abnormal.
1. Timing mark on crankshaft pulley