2001 SUZUKI GRAND VITARA 001

Foreword
This manual contains only different service information of the following applicable model as compared with
SQ416/SQ420/SQ625 SERVICE MANUAL.
Applicable model: GRAND VITARA XL-7
Therefore, whenever servicing the above applicable model, consult this manual first. And for any section, item
or description not found in this manual, refer to the related manual below.
When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and
service materials (lubricant, sealants, etc.) as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest product infor-
mation available at the time of publication approval. And used as the main subject of description is the vehicle of
standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
RELATED MANUAL:
© COPYRIGHT SUZUKI MOTOR CORPORATION 2001Manual Name Manual No.
SQ416/SQ420/SQ625 Service Manual 99500-65D10-01E
SQ416/SQ420/SQ625 Unit Repair Manual for Manual Transmis-
sion, Automatic Transmission, Transfer and Differential99501-65D01-01E
GRAND VITARA XL-7 Wiring Diagram Manual 99512-52D00-015

GENERAL INFORMATION 0A-7
Engine Identification Number
The number is punched on the cylinder block.
Engine Identification Number Specification
Transmission Identification Number
The A/T manufacture’s identification number is located on the
transmission case as shown. However, the M/T identification
number is not assign.
27 H A 100001
Sequential Number
Engine Displacement
(27 2.7 Liter)
Engine Type

6A2-16 ENGINE MECHANICAL (H27 ENGINE)
6) Remove housing, and using scale (2) on gaging plastic (1)
envelop, measure gaging plastic (1) width at its widest point.
Camshaft journal clearance :
Standard : 0.045 – 0.099 mm (0.0018 – 0.0039 in.)
Limit : 0.12 mm (0.0047 in.)
If measured camshaft journal clearance exceeds limit, measure
journal (housing) bore and outside diameter of camshaft journal.
Replace camshaft or cylinder head assembly whichever the differ-
ence from specification is greater.
Camshaft journal bore dia. (IN & EX) :
Standard : 26.000 – 26.033 mm (1.0236 – 1.0249 in.)
Camshaft journal O.D. (IN & EX) :
Standard : 25.934 – 25.955 mm (1.0210 – 1.0218 in.)
Wear of hydraulic valve lash adjuster
Check adjuster for pitting, scratches, or damage.
If any malcondition is found, replace.
Measure cylinder head bore and adjuster outside diameter to
determine cylinder head-to-adjuster clearance. If clearance
exceeds limit, replace adjuster or cylinder head.
Hydraulic valve lash adjuster O.D. :
Standard : 30.959 – 30.975 mm (1.2188 – 1.2194 in.)
Cylinder head bore :
Standard : 31.000 – 31.025 mm (1.2205 – 1.2214 in.)
Cylinder head to adjuster clearance :
Standard : 0.025 – 0.066 mm (0.0010 – 0.0025 in.)
Limit : 0.15 mm (0.0059 in.)

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

ENGINE MECHANICAL (H27 ENGINE) 6A2-23
•Piston clearance :
Measure cylinder bore diameter and piston diameter to find
their difference which is piston clearance. Piston clearance
should be within specification as given below. If it is out of
specification, rebore cylinder and use oversize piston.
Piston clearance :
0.02 – 0.04 mm (0.0008 – 0.0015 in.)
•Ring groove clearance :
Before checking, piston grooves must be clean, dry and free
of carbon.
Fit new piston ring (1) into piston groove, and measure clear-
ance between ring and ring land by using thickness gauge
(2). If clearance is out of specification, replace piston.
Ring groove clearance :
Top : 0.03 – 0.07 mm (0.0012 – 0.0027 in.)
2nd : 0.02 – 0.06 mm (0.0008 – 0.0023 in.) NOTE:
Cylinder bore diameters used here are measured in
thrust direction at 2 positions.
1. 26.5 mm (1.04 in.)

6A2-24 ENGINE MECHANICAL (H27 ENGINE)
ASSEMBLY
1) 2 sizes of piston are available as standard size spare part so
as to ensure proper piston-to-cylinder clearance. When
installing a standard size piston, make sure to match piston
with cylinder as follows.
a) Each piston has stamped number (1 or 2) on its piston
head. It represents outer diameter of piston.
b) There are also stamped numbers of 1 and 2 on the cylinder
block as shown in the figure.
c) Stamped number on piston and cylinder block must corre-
spond. That is, install number “2” stamped piston to cylinder
which is stamped also number “2” and a number “1” piston
to cylinder with number “1”.
Also, a letter A, B or C is stamped on piston head but ordi-
narily it is not necessary to distinguish each piston by this
letter.
Piston-to-cylinder clearance
Piston :
Cylinder :
Piston-to-cylinder clearance :
0.02 – 0.04 mm (0.0008 – 0.0015 in.)
2) Install piston pin to piston and connecting rod :
After applying engine oil to piston pin and piston pin holes in
piston and connecting rod, fit connecting rod to piston as
shown in the figure and insert piston pin to piston and con-
necting rod, and install piston pin circlips. Number at the top (mark) Outer diameter
187.98 – 87.99 mm
(3.4638 – 3.4642 in.)
287.97 – 87.98 mm
(3.4634 – 3.4638 in.)
Number on cylinder block (mark) Outer diameter
188.01 – 88.02 mm
(3.4650 – 3.4653 in.)
288.00 – 88.01 mm
(3.4646 – 3.4650 in.)
NOTE:
“86F” mark on connecting rod must face toward crank-
shaft pulley side.
1. Piston
2. Arrow mark
3. Connecting rod

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)

ENGINE MECHANICAL (H27 ENGINE) 6A2-35
INSPECTION
Honing or reboring cylinders
1) When any cylinder needs reboring, all other cylinders must
also be rebored at the same time.
2) Select oversized piston according to amount of cylinder
wear.
Oversize piston specification :
3) Using micrometer, measure piston diameter.
4) Calculate cylinder bore diameter to be rebored as follows.
D = A + B – C
Cylinder bore diameter to be rebored
A : Piston diameter as measured
B : Piston clearance = 0.02 – 0.04 mm (0.0008 – 0.0015 in.)
C : Allowance for honing = 0.02 mm (0.0008 in.)
5) Rebore and hone cylinder to calculated dimension.
6) Measure piston clearance after honing.Size Piston diameter
Standard 87.970 – 87.990 mm (3.4634 – 3.4642 in.)
Oversize 0.25 88.220 – 88.240 mm (3.4732 – 3.4740 in.)
Oversize 0.50 88.470 – 88.490 mm (3.4831 – 3.4839 in.)
NOTE:
Before reboring, install all main bearing caps in place
and tighten to specification to avoid distortion of bearing
bores.