2001 SUZUKI GRAND VITARA Under engine

6-1-114 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
DTC P1500 Engine Starter Signal Circuit Malfunction
WIRING DIAGRAM
DTC DETECTING CONDITION AND TROUBLE AREA
DTC CONFIRMATION PROCEDURE
1) Connect scan tool to DLC with ignition switch OFF.
2) Turn ON ignition switch and clear DTC by using scan tool, then start engine and run it for 3 min. or more.
3) Check pending DTC by using scan tool.
TROUBLESHOOTING
1. Engine start switch in ignition (main) switch 2. Starting motor 3. Transmission range sensor (switch) 4. ECM (PCM)
DTC DETECTING CONDITION TROUBLE AREA
•Engine starts even though vehicle is at stop and engine start signal is
not inputted.
or
•Engine start signal is inputted continuously for specified time while
engine is running.
(2 driving cycle detection logic)•Engine start signal circuit
•ECM (PCM)
NOTE:
Check to make sure that following condition is satisfied when using this “DTC CONFIRMATION PRO-
CEDURE”.
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
1Was “ENGINE DIAG. FLOW TABLE” per-
formed?Go to Step 2. Go to “ENGINE DIAG. FLOW TABLE”
in this section.
2 Check for voltage at terminal C51-1-24 of
ECM (PCM) connector connected, under fol-
lowing condition.
Engine starter signal specification :
While engine cranking : 6 – 14 V
After starting engine : 0 – 1 V
Is voltage as specified?Poor C51-1-24 connection or
intermittent trouble.
Check for intermittent referring to
“INTERMITTENT AND POOR
CONNECTION” in Section 0A.
If wire and connections are OK,
substitute a known-good ECM
(PCM) and recheck.“BLK/YEL” circuit open.

6-1-124 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Table B-6 A/C Condenser Fan Motor Relay Control System Inspection (If
Equipped)
WIRING DIAGRAM
INSPECTION
1. To ignition switch 3. A/C fuse 5. A/C condenser fan motor
2. Main fuse 4. A/C condenser fan motor relay 6. ECM (PCM)
WARNING:
Keep hands, tools, and clothing away from A/C condenser fan to help prevent personal injury. This
fan is electric and can come on whether or not the engine is running. The fan can start automatically
in response to the ECT sensor with the ignition switch in the “ON” position.
Step Action Yes No
1 1) Check DTC referring to “DTC CHECK” in this sec-
tion.
Is there any malfunction DTC?Go to applicable DTC
Diag. Flow Table.Go to Step 2.
2 1) Check A/C condenser fan for operation.
A/C condenser fan should be operated under follow-
ing condition A or B only.
A : When engine is running and A/C is operating.
B : When engine coolant temp. is 113°C (235°F) or
more with ignition switch ON.
Is check result as specified?This system is in
good condition.Go to Step 3.
3 1) Remove ECM (PCM) cover.
2) Check voltage between E61-22 terminal of ECM
(PCM) connected coupler and ground.
Other than conditions A and B in Step 2 :
10 – 14 V
Under condition A or B in Step 2 :
0 – 1 V
Is check result as specified?Fuse blown, “RED”,
“RED/BLK” or “RED/
BLU” circuit open,
malfunction of con-
denser fan motor or
relay.“YEL/GRN” circuit
open, “YEL/BLU” cir-
cuit open or short, or
relay malfunction.
If above are OK, sub-
stitute a known-good
ECM (PCM) and
recheck.

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) 6A2-3
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

6A2-28 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)

ENGINE MECHANICAL (H27 ENGINE) 6A2-31
Main bearing clearance
Check clearance by using gaging plastic (1) according to the fol-
lowing procedure.
1) Remove crankcase.
2) Clean bearings and main journals.
3) Place a piece of gaging plastic to full width of bearing (paral-
lel to crankshaft) on journal, avoiding oil hole.
4) Install crankcase to cylinder block.
Tighten crankcase bolts, following sequence in the figure.
Tighten crankcase bolts to specified torque.
Tightening torque
Thrust and journal bearing cap bolt (8 mm thread diame-
ter) (a) :
60 N·m (6.0 kg-m, 43.5 lb-ft)
Thrust and journal bearing cap bolt (10 mm thread diame-
ter) (b) :
27 N·m (2.7 kg-m, 19.5 lb-ft)
5) Remove crankcase and using scale (2) on gaging plastic (1)
envelop, measure gaging plastic (1) width at its widest point.
If clearance exceeds its limit, replace bearing. Always
replace both upper and lower inserts as a unit.
A new standard bearing may produce proper clearance. If
not, it will be necessary to regrind crankshaft journal for use
of 0.25 mm undersize bearing.
After selecting new bearing, recheck clearance.
Main Bearing Clearance
Standard : 0.024 – 0.044 mm (0.0009 – 0.0017 in.)
Limit : 0.060 mm (0.0023 in.)
NOTE:
Tighten 10 mm thread diameter bolts first (following the
order shown in the figure) then tighten 8 mm thread
diameter bolts.
NOTE:
Do not rotate crankshaft while gaging plastic is installed.
1. Lower crankcase
2. Bolt (10 mm thread diameter)
3. Bolt (8 mm thread diameter)
4. Long bolt (8 mm thread diameter)

6A2-34 ENGINE MECHANICAL (H27 ENGINE)
•UNDERSIZE BEARING (0.25 mm) :
0.25 mm undersize bearing is available, in 5 kinds varying in
thickness.
To distinguish them, each bearing is painted in the following
colors at such position as shown in the figure.
Each color represents the following thickness at the center of
bearing.
Under size main bearing thickness
•If necessary, regrind crankshaft journal and select undersize
bearing to use with it as follows.
1) Regrind journal to the following finished diameter.
Finished journal diameter :
64.738 – 64.756 mm (2.5487 – 2.5494 in.)
2) Using micrometer, measure reground journal diameter.
Measurement should be taken in 2 directions perpendicular
to each other in order to check for out-of-round.
3) Using journal diameter measured above and alphabets
stamped on lower crankcase, select an undersize bearing by
referring to table given below.
Check bearing clearance with newly selected undersize
bearing.
Under size bearing specification :Color painted Bearing thickness
Black & Red2.621 – 2.625 mm
(0.1032 – 0.1033 in.)
Red2.624 – 2.628 mm
(0.1033 – 0.1034 in.)
Red & Yellow2.627 – 2.631 mm
(0.1034 – 0.1035 in.)
Red & Blue2.630 – 2.634 mm
(0.1035 – 0.1036 in.)
Red & Pink2.633 – 2.637 mm
(0.1036 – 0.1037 in.)
1. Paint
Measured journal diameter
64.750 – 64.756 mm
(2.5492 – 2.5494 in.)64.744 – 64.750 mm
(2.5489 – 2.5492 in.)64.738 – 64.744 mm
(2.5487– 2.5489 in.)
Alphabets stamped on
lower crankcaseA Black & Red Red Red & Yellow
B Red Red & Yellow Red & Blue
C Red & Yellow Red & Blue Red & Pink

ENGINE FUEL 6C-5
Fuel Lines
Due to the fact that fuel feed line is under high pressure, this sys-
tem requires special consideration for service.
The feed pipe uses screw couplings and hose clamps.
INSPECTION
Visually inspect fuel lines for evidence of fuel leakage, hose
cracking and deterioration, or damage. Make sure all clamps are
secure. Replace parts as needed.