2001 SUZUKI GRAND VITARA exhaust system

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-95
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Increase vehicle speed to 80 – 90 km/h (50 – 56 mph).
4) Keep above vehicle speed for 5 min. or more (Throttle valve opening is kept constant in this step).
5) Stop vehicle and check if pending DTC exists by using scan tool. If not, check if catalyst monitoring test has
completed by using scan tool. If not in both of above checks (i.e., no pending DTC and catalyst monitoring
test not completed), check vehicle condition (environmental) and repeat Step 3) through 5).
TROUBLESHOOTING
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
NOTE:
Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
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 Exhaust system visual inspection :
1) Check exhaust system for leaks, damage
and loose connection.
Is it in good condition?Go to Step 3. Repair or replace.
3 HO2S-2 output voltage check :
1) Check output voltage of HO2S-2 referring
Step 2 of DTC P0136 Diag. Flow Table.
Is check result satisfactory?Replace warm up three
way catalytic converter.Check “RED/BLK” and
“GRY/YEL” wires for open
and short, and connec-
tions for poor connection.
If wires and connections
are OK, replace HO2S-2.

6-1-96 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P0430 Catalyst System Efficiency Below Threshold (Bank 2)
SYSTEM DIAGRAM
CIRCUIT DESCRIPTION
Exhaust oxygen concentration at the pre-catalyst and the post-catalyst of WU-TWC is detected from HO2S-1
and HO2S-2 respectively and accordingly ECM (PCM) controls the closed loop which then controls the fuel
injection volume. (Refer to Section 6E2.) While the above control is going on and if WU-TWC is in good condi-
tion, the output voltage of HO2S-2 is maintained at specified level. As WU-TWC becomes deteriorated, even
when the above control is going on, the exhaust gas which has passed TWC then passes HO2S-2 at the
exhaust oxygen concentration similar to that of the pre-catalyst without being oxygenated or converted. Thus,
waveforms of HO2S-1 and HO2S-2 output voltages become alike. ECM (PCM) judges deterioration of WU-TWC
by comparing waveforms of HO2S-1 and HO2S-2.
DTC DETECTING CONDITION AND TROUBLE AREA
1. HO2S-1 (Bank-2) 4. TWC
2. HO2S-2 (Bank-2) 5. ECM (PCM)
3. WU-TWC
DTC DETECTING CONDITION TROUBLE AREA
While running under conditions described for DTC CON-
FIRMATION PROCEDURE, output waveform of HO2S-1
becomes similar to that of HO2S-2.
(2 driving cycle detection logic)• Exhaust gas leakage
• Warm up three way catalytic converter
• Heated oxygen sensor – 2 or its circuit
•ECM (PCM)

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-97
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC, pending DTC and freeze frame data by using scan tool.
3) Increase vehicle speed to 80 – 90 km/h (50 – 56 mph).
4) Keep above vehicle speed for 5 min. or more (Throttle valve opening is kept constant in this step).
5) Stop vehicle and check if pending DTC exists by using scan tool. If not, check if catalyst monitoring test has
completed by using scan tool. If not in both of above checks (i.e., no pending DTC and catalyst monitoring
test not completed), check vehicle condition (environmental) and repeat Step 3) through 5).
TROUBLESHOOTING
WARNING:
When performing a road test, select a place where there is no traffic or possibility of a traffic acci-
dent and be very careful during testing to avoid occurrence of an accident.
Road test should be carried out with 2 persons, a driver and a tester, on a level road.
NOTE:
Check to make sure that following conditions are satisfied when using this “DTC CONFIRMATION
PROCEDURE”.
Intake air temp. : – 8°C (18°F) or higher
Engine coolant temp. : – 8 – 110°C (18 – 230°F)
Altitude (barometric pressure) : 2400 m, 8000 ft or less (560 mmHg (75 kPa) or more)
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 Exhaust system visual inspection :
1) Check exhaust system for leaks, damage
and loose connection.
Is it in good condition?Go to Step 3. Repair or replace.
3 HO2S-2 output voltage check :
1) Check output voltage of HO2S-2 referring
Step 2 of DTC P0156 Diag. Flow Table.
Is check result satisfactory?Replace warm up three
way catalytic converter.Check “RED/YEL” and
“GRY/YEL” wires for open
and short, and connec-
tions for poor connection.
If wires and connections
are OK, replace HO2S-2.

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

ENGINE MECHANICAL (H27 ENGINE) 6A2-9
26) Upon completion of installation, verify that there is no fuel
leakage at each connection according to procedure
described in Section 6.
Exhaust Manifold
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Remove air cleaner upper case and intake air hose if right
side exhaust manifold is removed.
3) Detach couplers from their bracket and disconnect oxygen
sensor lead wires at couplers. WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system has cooled off.
1. Left (No.1) exhaust manifold
Right (No.2) exhaust manifold
2. Exhaust manifold cover
3. Exhaust No.1 pipe
A. Without WU-TWC
B. With WU-TWC
1. HO2S-1 (Green connector)
2. HO2S-2 (Black connector)

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.

ENGINE MECHANICAL (H27 ENGINE) 6A2-29
3) Tighten bolts and nuts fastening cylinder block and transmis-
sion to specified torque.
Tightening torque
Transmission to cylinder block bolt and nut (b) :
85 N·m (8.5 kg-m, 61.5 lb-ft)
4) Remove lifting device
5) Tighten torque converter bolts to specified torque (for A/T
vehicle).
Tightening torque
Torque converter bolt (c) :
65 N·m (6.5 kg-m, 47.0 lb-ft)
6) Tighten bolts and nuts of exhaust No.1 pipe (1) to specified
torque.
Tightening torque
Exhaust No.1 pipe bolt and nut (d) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
7) Install front differential housing with differential to chassis if
removed. Refer to “REMOUNTING” in Section 7E.
8) Install steering shaft lower assembly. Refer to “STEERING
LOWER SHAFT ASSEMBLY” in Section 3C1.
9) Install A/C compressor assembly. Refer to “COMPRESSOR
ASSEMBLY” in Section 1B.
10) Install P/S pump assembly. Refer to “POWER STEERING
PUMP” in Section 3B1.
11) Connect hoses, cables and electric wires.
12) Adjust accelerator cable play and A/T throttle cable play (for
A/T vehicle). Refer to “ACCELERATOR CABLE ADJUST-
MENT” and “A/T THROTTLE CABLE ADJUSTMENT (A/T
VEHICLE)” in Section 6E2.
13) Refill engine with engine oil referring to “ENGINE OIL
CHANGE” in Section 0B.
14) Refill cooling system, referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
15) Check to ensure that all fasteners and clamps are tightened.
16) Upon completion of installation, verify that there is no fuel
leakage, coolant leakage, P/S fluid leakage or exhaust gas
leakage at each connection.
1. Bolt (short)
2. Bolt (Long)

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-13
On-Vehicle Service
General
When hoses are disconnected and system components are removed for service, reinstall components properly,
and route and connect hoses correctly after service. Refer to figure on previous page for proper routing of
hoses.
1. Brake booster hose pipe 8. EGR pipe (if equipped) 15. EVAP canister
2. Vacuum hose for fuel pressure regulator 9. Exhaust manifold 16. Tank pressure control valve
3. Fuel pressure regulator 10. Heated oxygen sensor 17. To fuel tank
4. MAP sensor (if equipped) 11. EGR valve (if equipped) 18. Cap
5. Engine coolant hose 12. PCV hose [A]: Vehicle without monitor connector
6. EVAP canister purge valve 13. IAC valve [B]: Vehicle with monitor connector
7. Breather hose 14. IAC hose