2001 SUZUKI GRAND VITARA EGR

6-1-122 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
3 Check IAC valve referring to “IAC VALVE
INSPECTION” in Section 6E2.
Is check result as specified?Go to Step 4. IAC valve malfunction, “BLU/
BLK”, “LT GRN/BLK”, “PPL/
BLK”, “GRY/BLU” or “PPL/
YEL” wire open or short or
poor coupler connection.
If all above are OK, substi-
tute a known-good ECM
(PCM) and recheck.
4 Was idle speed within specification in
Step 1?Check for following :
FIA valve, Vacuum leaks, air inhal-
ing, EVAP canister purge control
system, accessory engine load,
stuck of PCV valve, clog of idle air
passage, MAF sensor, TP sensor,
ECT sensor, EGR valve malfunc-
tion (leakage from valve seat), A/C
signal, transmission range switch
signal and power steering switch
signal.Go to Step 5.
5 Was idle speed higher than specification
in Step 1?Go to Step 6. Go to Step 8.
6 Check A/C (input) signal circuit referring
to Step 1 of “Table B-5”. (A/C signal can
be also checked by using SUZUKI scan
tool.)
Is it in good condition?Go to Step 7. A/C signal circuit open or
short, or A/C system mal-
function.
7 Was IAC duty less than about 2% in Step
1 of this table?
Check FIA valve.
Check abnormal air inhaling from
intake manifold, throttle body, PCV
valve and EVAP canister purge
control system.Check TP sensor (closed
throttle position) and ECT
sensor for performance.
If sensors are OK, substitute
a known-good ECM (PCM)
and recheck.
8 Check transmission range switch signal
referring to “INSPECTION OF ECM
(PCM) AND ITS CIRCUIT” in this section.
Is check result satisfactory?Go to Step 9. Transmission range switch
malfunction or its circuits
open or short.
9 Was IAC duty more than about 30% in
Step 1 of this table?Check parts or system which can
cause engine low idle.
Check FIA valve.
Air inhaling from between throttle
body and MAF sensor, EGR valve
malfunction (leakage from valve
seat), accessory engine load, clog
of idle air passage and etc.Substitute a known-good
ECM (PCM) and recheck. Step Action Yes No

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

6A2-4 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

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

6A2-10 ENGINE MECHANICAL (H27 ENGINE)
4) Disconnect EGR pipe from right (No.2) bank exhaust mani-
fold if right side exhaust manifold is removed.
5) Remove oil level gauge guide (3) if left side exhaust manifold
is removed.
6) Detach P/S pump assembly as following, if left side exhaust
manifold is removed.
a) Loosen P/S pump drive belt by loosening tensioner bolt.
b) Remove P/S pump mounting bolts.
c) Detach P/S pump assembly (4) with its hoses from cylinder
block.
7) Remove exhaust manifold covers (2) from exhaust manifolds
(1).
8) Hoist vehicle.
9) For 4WD vehicle, before disconnecting front propeller shaft,
put match mark (1) on joint flange and propeller shaft to facil-
itate their installation as shown in the figure.
10) For 4WD vehicle, disconnect propeller shaft from front differ-
ential.
11) Remove exhaust manifold stiffeners (1).
12) Remove stabilizer bar mounting bolt and pull down stabilizer
bar if right side exhaust manifold is removed.
13) Remove exhaust manifolds and their gaskets from cylinder
heads.
1
4
32
2. Exhaust No.1 pipe
A. Without WU-TWC
B. With WU-TWC

6A2-12 ENGINE MECHANICAL (H27 ENGINE)
7) Reverse removal procedure to install front propeller shaft if
removed.
When installing propeller shaft, align match mark (1).
Use following specification to torque universal joint flange.
Tightening torque
Universal joint flange bolt (c) :
55 N·m (5.5 kg-m, 40.0 lb-ft)
8) Connect EGR pipe to left (No.1) bank exhaust manifold (1).
9) Install exhaust manifold covers (2).
10) Install oil level gauge guide (3) using new O-ring.
11) Install P/S pump assembly (4) if it was removed. Refer to
“POWER STEERING PUMP” in Section 3B1.
12) Adjust P/S pump drive belt tension, refer to “POWER
STEERING BELT CHECK AND ADJUSTMENT” in Section
3B1.
13) Connect oxygen sensor lead wire couplers.
Be sure to clamp its lead wires.
14) Connect negative (–) cable to battery.
Upon completion of installation, start engine and check that
no exhaust gas leakage exists.
1
4
32
1. HO2S-1 (Green connector)
2. HO2S-2 (Black connector)