2001 SUZUKI GRAND VITARA engine

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-125
Special Tool
09912-58441 09912-58431 09912-58490 09912-58421
Pressure gauge Pressure hose 3-way joint & hose Checking tool set
(See NOTE “A”.)
09917-47011 09930-88521 09931-76011
Vacuum pump gauge Injector test lead Tech 1A kit (SUZUKI scan
tool) (See NOTE “B”.)Mass storage cartridge for
Tech 1A
09931-76030
14/16 pin DLC cable for
Tech 1ATech 2 kit (SUZUKI scan
tool) (See NOTE “C”.)
NOTE:
“A”: This kit includes the following items.
1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder,
5. Return hose & clamp, 6. Body attachment-2 & washer, 7. Hose attachment-1,
8. Hose attachment-2
“B”: This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable,
5. Test lead/probe, 6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
“C”: This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback
adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loopback connector,
11. Storage case, 12. Power supply

6-1-126 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)

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

ENGINE MECHANICAL (H27 ENGINE) 6A2-5
19) Disconnect hoses of heater, EVAP canister, fuel feed and
fuel return.
20) Remove throttle body (1) and intake collector (2) from intake
manifold (3).
21) Disconnect hoses of PCV valve and EVAP canister purge
valve from intake collector.
22) Remove throttle body (1) from intake collector.
23) Remove EGR valve and EVAP canister purge valve from
intake collector.
24) Remove intake manifold bolts (8 pc.) and nuts (4 pc.).
25) Remove intake manifold.
1. Heater hose
2. Fuel feed hose
3. Fuel return hose
4. EVAP canister hose
13
2 4
1
3
2
1

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