2001 SUZUKI GRAND VITARA intake manifold

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

ENGINE MECHANICAL (H27 ENGINE) 6A2-7
6) Connect hoses of heater, EVAP canister, fuel feed and fuel
return.
7) Install EGR pipe with new gaskets.
8) Connect hoses of EVAP canister purge valve and heater.
9) Connect hoses of PCV, breather and water.
10) Connect couplers of manifold absolute pressure (MAP) sen-
sor, EVAP canister purge valve and EGR valve.
Fix wire harness with clamps.
11) Install clamp bracket (4) to intake collector.
12) Connect earth terminal (3) to intake collector.
13) Connect couplers of TP sensor (1) and IAC valve (2).
14) Connect brake booster hose (2) to intake manifold.
15) Connect injector wire (1) coupler.
1. Heater hose
2. Fuel feed hose
3. Fuel return hose
4. EVAP canister hose
13
2 4
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 hose9
4
1 7
6
2
35
8
2
14
3
2
1

6A2-8 ENGINE MECHANICAL (H27 ENGINE)
16) Connect water hoses (3) to throttle body.
17) Connect accelerator cable (1) and A/T throttle cable (2) (for
A/T vehicle) to throttle body.
18) Install surge tank pipe (2) to intake manifold with new gas-
kets and intake air pipe (1) to throttle body.
19) Install surge tank cover (1).
20) Install air cleaner upper case.
21) Connect coupler to intake air temp. sensor and MAF sensor.
22) Install strut tower bar (1).
23) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
24) Refill cooling system referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
25) Connect negative cable at battery.
12
33
1
2
1

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.

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)