2001 SUZUKI GRAND VITARA gas

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.
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1
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.
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2. Exhaust No.1 pipe
A. Without WU-TWC
B. With WU-TWC

ENGINE MECHANICAL (H27 ENGINE) 6A2-11
INSTALLATION
1) Install new manifold gaskets to cylinder heads and No.1 pipe
gasket to exhaust No.1 pipe.
2) Install exhaust manifolds.
•Always install new bolts with pre-coated adhesive to the
locations with ✱ mark.
•Tighten both manifold nuts and bolts to specified torque.
Tightening torque
Exhaust manifold bolt and nut (a) :
30 N·m (3.0 kg-m, 21.5 lb-ft)
3) Install stabilizer bar if it was removed. Refer to “STABILIZER
BAR / BUSHINGS” in Section 3D.
4) Install exhaust manifold stiffeners (if removed).
5) Install exhaust No.1 pipe (1).
Tighten exhaust No.1 pipe bolts to specified torque.
Tightening torque
Exhaust No.1 pipe bolt (b) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
6) Tighten exhaust No.1 pipe nuts to specified torque.
Tightening torque
Exhaust No.1 pipe nut (b) :
50 N·m (5.0 kg-m, 36-5 lb-ft)
1. Left (No.1) exhaust manifold
2. Right (No.2) exhaust manifold
2. Exhaust No. 2 pipe
1. Exhaust No.1 pipe
2. Exhaust manifold
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.
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1. HO2S-1 (Green connector)
2. HO2S-2 (Black connector)

ENGINE MECHANICAL (H27 ENGINE) 6A2-17
Valves and Cylinder Heads
1. Cylinder block 6. Exhaust valve 11. Valve stem oil seal 16. Cylinder head bolt
(hex hole bolt)
2. RH bank cylinder head 7. Intake valve 12. Valve spring retainer Tightening Torque
3. LH bank cylinder head 8. Valve spring seat 13. Valve cotter Do not reuse
4. RH bank cylinder head gasket :
Carved lot number on cylinder head
gasket should face up (toward cylinder
head side).9. Outer valve spring :
Be sure to position spring in place with
its bottom end (small-pitch end) facing
the bottom (valve spring seat side).14. Valve guide Apply engine oil to
sliding surface of
each parts.
5. LH bank cylinder head gasket :
Carved lot number on cylinder head
gasket should face up (toward cylinder
head side).10. Inner valve spring :
Be sure to position spring in place with
its bottom end (small-pitch end) facing
the bottom (valve spring seat side).15. Cylinder head bolt

6A2-18 ENGINE MECHANICAL (H27 ENGINE)
INSPECTION
Valve guides
Using a micrometer and bore gauge, take diameter readings on
valve stems and guides to check stem-to-guide clearance. Be
sure to take reading at more than one place along the length of
each stem and guide.
If clearance exceeds limit, replace valve and valve guide.
Valve stem-to-guide clearance :
INSTALLATION
1) Clean mating surface on cylinder head and cylinder block.
Remove oil, old gasket and dust from mating surface.
2) Install knock pin (4) to cylinder block.
3) Apply sealant “A” to cylinder head gasket (1) as shown in the
figure.
“A” : Sealant 99000-31150
Sealant amount (Width “w”) :
4 mm (0.158 in.)
4) Install new cylinder head gasket (1) to cylinder block as
shown in the figure. carved lot number (5) on cylinder head
gasket (1) should face up (toward cylinder head side).Standard Limit
Valve stem
diameterIntake 5.965 – 5.980 mm
(0.2348 – 0.2354 in.)–
Exhaust 5.940 – 5.955 mm
(0.2339 – 0.2344 in.)–
Valve guide
I.D.In & Ex 5.985 – 6.010 mm
(0.2356 – 0.2366 in.)–
Stem-to-guide
clearanceIntake 0.035 – 0.045 mm)
(0.0014 – 0.0018 in.)0.07 mm
(0.0027 in.)
Exhaust 0.060 – 0.070 mm
(0.0024 – 0.0028 in.)0.09 mm
(0.0035 in.)
[A] : RH ( No.2) bank
[B] : LH (No.1) bank
2. Crankshaft pulley side
3. Flywheel side

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)