2001 SUZUKI GRAND VITARA oil

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-81
TROUBLESHOOTING
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 Ignition system inspection :
1) Check spark plug and ignition spark of cylin-
der where misfire occurs, referring to “IGNI-
TION SYSTEM” section.
Is it in good condition?Go to Step 3. Faulty ignition coil, wire
harness, or other system
parts.
3 Fuel injector circuit inspection :
1) Using sound scope, check each injector
operating sound at engine cranking or
idling.
Do all injectors make operating sound?Go to Step 4. Check coupler connec-
tion and wire harness of
injector not making oper-
ating sound and injector
itself.
If OK, substitute a known-
good ECM (PCM) and
recheck.
4 Fuel pressure inspection :
1) Check fuel pressure referring to “TABLE B-
3” in this section.
Is check result satisfactory?Go to Step 5. Repair or replace.
5 Fuel injector inspection :
1) Check fuel injector(s) referring to Section
6E2.
Is check result satisfactory?Go to Step 6. Replace.
6 Ignition timing inspection :
1) Check ignition timing referring to Section
6F2.
Is check result satisfactory?Go to Step 7. Adjust or check system
related parts.
7 EGR system inspection :
1) Check EGR system referring to Section
6E2.
Is check result satisfactory?Go to Step 8. Repair or replace.
8 Fuel level sensor inspection :
1) Check fuel level sensor referring to Section
6E2.
Is check result satisfactory?Go to Step 9. Repair or replace.
9 Check engine mechanical parts or system
which can cause engine rough idle or poor per-
formance.
• Engine compression (See Section 6A2).
• Valve lash or lash adjuster (See Section
6A2).
• Valve timing (Timing belt or chain installa-
tion. See Section 6A2).
Are they in good condition?Check wire harness and
connection of ECM (PCM)
ground, ignition system
and fuel injector for inter-
mittent open and short.Repair or replace.

6-1-88 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Fig. for Step 45 CMP sensor (REF) signal check :
1) With ignition switch OFF, connect CMP sensor
coupler.
2) Disconnect couplers from ignition coil assembly
and fuel injectors.
3) With ignition switch ON and crankshaft turned
slowly, check voltage between C51-1-13 and
C51-3-26 terminal.
Does voltmeter indicator deflect between 0 – 1 V
and 3 – 5.25 V 4 times while crankshaft turned two
revolutions?Go to Step 6. Faulty “YEL/GRN” wire
or CMP sensor.
If OK, substitute a
known-good ECM
(PCM) and recheck.
6 CMP sensor (POS) signal check :
1) With ignition switch ON and crankshaft turned
slowly, check voltage between C51-1-12 and
C51-3-26 terminal.
Does voltmeter indicator deflect between 0 – 1 V
and 3 – 5.25 V 6 times while crankshaft turned two
revolutions?Poor C51-1-12 and/or
C51-3-13 terminal of
ECM (PCM) coupler con-
nection.
If OK, substitute a
known-good ECM (PCM)
and recheck.Faulty “YEL/BLU” wire
or CMP sensor.
If OK, substitute a
known-good ECM
(PCM) and recheck. Step Action Yes No
1. Disconnected CMP sensor coupler
2. “BLU/BLK” wire (C09-2) terminal
3. “GRY/YEL” wire (C09-1) terminal

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-91
TROUBLESHOOTING
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 Is there DTC P0403 (EGR circuit malfunction)? Go to DTC P0403 Diag.
Flow Table.Go to Step 3.
3 Do you have SUZUKI scan tool? Go to Step 4. Go to Step 6.
4 EGR valve operation check :
1) With ignition switch OFF, install SUZUKI
scan tool.
2) Check EGR system referring to Section
6E2.
Is it in good condition?Go to Step 5. Go to Step 6.
5 MAP sensor check :
1) Check MAP sensor for performance refer-
ring to Section 6E2.
Is check result satisfactory?Intermittent trouble or
faulty ECM (PCM). Check
for intermittent referring to
“INTERMITTENT AND
POOR CONNECTION” in
Section 0A.Repair or replace.
6 EGR valve power supply circuit check :
1) With ignition switch OFF, disconnect EGR
valve coupler.
2) With ignition switch ON, check voltage
between C04-2 and ground, C04-5 and
ground.
Is each voltage 10 – 14 V?Go to Step 7. Faulty “BLU/BLK” wire.
7 EGR valve stepper motor coil circuit check :
1) With ignition switch OFF, connect EGR
valve coupler and disconnect ECM (PCM)
couplers.
2) Check resistance between C51-3-4 and
C51-2-12, C51-2-13, C51-2-14, C51-2-15.
Is each resistance 20 – 24 Ω at 20°C (68°F)?Go to Step 8. Faulty EGR valve.
8 MAP sensor check :
1) Check MAP sensor for performance refer-
ring to Section 6E2.
Is check result satisfactory?EGR passage clogged or
EGR valve malfunction.
If all above are OK, inter-
mittent trouble or faulty
ECM (PCM).
Check for intermittent
referring to “INTERMIT-
TENT AND POOR CON-
NECTION” in Section 0A.Repair or replace.

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)

6A2-14 ENGINE MECHANICAL (H27 ENGINE)
Camshaft and Valve Lash Adjuster
1. RH bank 2nd timing chain 6. LH bank intake camshaft 11. Timing chain guide No.5
2. RH bank exhaust camshaft 7. LH bank exhaust camshaft 12. Valve lash adjuster
3. RH bank intake camshaft 8. LH bank intake camshaft holder 13. Camshaft housing bolt
4. RH bank exhaust camshaft holder 9. LH bank exhaust camshaft holder Tightening Torque
5. RH bank intake camshaft holder 10. LH bank camshaft holder Apply engine oil to sliding surface
of each parts.

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