2001 SUZUKI GRAND VITARA clutch

6-1-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Poor gasoline mileage
Faulty spark plug (improper gap, heavy depos-
its, and burned electrodes, etc.)Spark plugs in Section 6F2.
Fuel pressure out of specification “DIAG. FLOW TABLE B-3” in this
section.
Faulty TP sensor, ECT sensor or MAF sensor TP sensor, ECT sensor or MAF
sensor in Section 6E2.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty injector Fuel injector in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Low compression Refer to the same item in “HARD
STARTING” of this table.
Poor valve seating Valves inspection in Section 6A2.
Dragging brakes Diagnosis in Section 5.
Slipping clutch Diagnosis in Section 7C1.
Thermostat out of order Thermostat in Section 6B.
Improper tire pressure Diagnosis in Section 3.
Excessive engine oil
consumptionSticky piston ring Piston cleaning in Section 6A2.
Worn piston and cylinder Cylinders, pistons and piston rings
inspection in Section 6A2.
Worn piston ring groove and ring Pistons and piston rings inspection
in Section 6A2.
Improper location of piston ring gap Pistons installation in Section 6A2.
Worn or damaged valve stem seal Valves and cylinder head in Sec-
tion 6A2.
Worn valve stem Valves inspection in Section 6A2.
Low oil pressure
Improper oil viscosity Engine oil and oil filter change in
Section 0B.
Malfunctioning oil pressure switch Oil pressure switch inspection in
Section 8.
Clogged oil strainer Oil pan and oil pump strainer clean-
ing in Section 6A2.
Functional deterioration of oil pump Oil pump in Section 6A2.
Worn oil pump relief valve Oil pump in Section 6A2.
Excessive clearance in various sliding parts “INSPECTION” for each parts in
Section 6A2. Condition Possible Cause Correction

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.

6A2-26 ENGINE MECHANICAL (H27 ENGINE)
Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Release fuel pressure in fuel feed line. Refer to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6.
2) Disconnect negative (–) cable at battery.
3) Remove engine hood.
4) Drain engine oil.
5) Drain coolant.
6) Remove radiator, radiator fan shroud, cooling fan and radia-
tor reservoir. Refer to “COOLING FAN AND FAN CLUTCH”
and “RADIATOR” in Section 6B.
7) Disconnect accelerator cable (1) and A/T throttle cable (for
A/T vehicle) (2) from throttle body.
8) Remove strut tower bar and surge tank cover.
9) Disconnect IAT sensor coupler and MAF sensor coupler then
remove air cleaner upper case, intake air hose, intake air
pipe and surge tank pipe as a component.
10) Remove engine oil level gauge guide and A/T fluid level
gauge guide (for A/T vehicle).
11) Remove ignition coil covers.
12

6A2-28 ENGINE MECHANICAL (H27 ENGINE)
24) Remove A/T fluid hose clamps (1) from engine mounting
bracket (2). (for A/T vehicle)
25) Remove clutch housing lower plate.
26) Remove torque converter bolts (for A/T vehicle).
27) Remove starter motor.
28) Lower vehicle.
29) Support transmission. For A/T vehicle, don’t jack under A/T
oil pan to support transmission.
30) Remove bolts and nuts fastening cylinder block and trans-
mission.
31) Install lifting device.
32) Disconnect engine side mounting brackets (1) to engine
mountings.
33) Before lifting engine, check to ensure all hoses, wires and
cables are disconnected from engine.
34) Remove engine assembly from chassis and transmission by
sliding toward front, and then, carefully hoist engine assem-
bly.
INSTALLATION
Reverse removal procedure for installation, noting the following
points.
1) Lower engine assembly into engine compartment. Connect
engine to transmission and engine side mounting brackets to
engine mountings.
2) Tighten nuts fastening engine side mounting brackets and
engine mountings.
Tightening torque
Engine side mounting bracket nut (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)

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.)

6E2-10 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)

7B1-2 AUTOMATIC TRANSMISSION (4 A/T)
Stall Test ................................................... 7B1-38
Line Pressure Test .................................... 7B1-39
Road Test ................................................. 7B1-40
Manual Road Test..................................... 7B1-41
Time Lag Test ........................................... 7B1-41
Engine Brake Test .................................... 7B1-42
“P” Range Test.......................................... 7B1-42
On-Vehicle Service ..................................... 7B1-43
Maintenance Service ................................ 7B1-43
Fluid level .............................................. 7B1-43
Fluid change.......................................... 7B1-44
A/T Throttle Cable ..................................... 7B1-45Solenoid Valves (Shift Solenoid Valves
and TCC Solenoid Valve) ......................... 7B1-45
MANUAL SELECTOR ASSEMBLY .......... 7B1-46
SELECT CABLE ....................................... 7B1-48
Unit Repair .................................................. 7B1-49
Sub-Assembly Repair ............................... 7B1-49
Overdrive (case side) ............................ 7B1-49
Forward clutch ...................................... 7B1-50
Front upper valve body ......................... 7B1-54
Unit Assembly ........................................... 7B1-59
Tightening Torque Specification............... 7B1-60
Special Tool ................................................ 7B1-61

AUTOMATIC TRANSMISSION (4 A/T) 7B1-3
General Description
Item Specifications
Torque
converterType 3-element, 1-step, 2-phase type (with TCC (lock-up) mechanism)
Stall torque ratio 2.0
Oil pump Type Trochoid type oil pump
Drive system Engine driven
Gear
change
deviceType Forward 4-step, reverse 1-step planetary gear type
Shift position“P” range Gear in neutral, output shaft fixed, engine start
“R” range Reverse
“N” range Gear in neutral, engine start
“D” range
(O/D ON)Forward 1st ↔ 2nd ↔ 3rd ↔ 4th (O/D)
automatic gear change
“D” range
(O/D OFF)Forward 1st ↔ 2nd ↔ 3rd
automatic gear change
“2” range (Normal mode) Forward 1st ↔ 2nd ← 3rd auto-
matic gear change
(Power mode) Forward 2nd ← 3rd automatic gear
change and fixed at 2nd gear
“L” range Forward 1st ← 2nd ← 3rd reduction, and fixed at
1st gear
Gear
ratio1st
(low gear)2.826
2nd
(second gear)1.493
3rd
(top gear)1.000
4th
(overdrive gear)0.689
Reverse
(reverse gear2.703
Control elements Wet type multi-disc clutch ... 3 sets
Wet type multi-disc brake ... 4 sets
One-way clutch ... 3 sets
Transfer Hi : 1.000
Lo : 1.816 (4WD model only)
Final gear reduction
ratio (Differential)5.125
Lubrication Lubrication system Force feed system by oil pump
Cooling Cooling system Radiator assisted cooling (water-cooled)
Fluid used
An equivalent of DEXRON
III