2001 SUZUKI GRAND VITARA Cylinder head valves

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-31
Engine Diagnosis Table
Perform troubleshooting referring to following table when ECM (PCM) has detected no DTC and no abnormality
has been found in visual inspection and engine basic inspection previously.
Condition Possible Cause Correction
Hard starting
(Engine cranks OK)Faulty idle air control system “DIAG. FLOW TABLE B-4” in this
section.
Faulty ECT sensor or MAF sensor ECT sensor or MAF sensor in Sec-
tion 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Low compression Compression check in Section
6A2.
Faulty hydraulic valve lash adjuster Valve lash adjuster in Section 6A2.
Compression leak from valve seat Valves inspection in Section 6A2.
Sticky valve stem Valves inspection in Section 6A2.
Weak or damaged valve springs Valves spring inspection in Section
6A2.
Compression leak at cylinder head gasket Cylinder head inspection in Section
6A2.
Sticking or damaged piston ring Piston ring inspection in Section
6A2.
Worn piston, ring or cylinder Cylinders, pistons and piston rings
inspection in Section 6A2.
Malfunctioning PCV valve PCV system inspection in Section
6E2.
Engine has no power
Engine overheating Refer to “OVERHEATING” in this
table.
Defective spark plug Spark plugs in Section 6F2.
Faulty ignition coil with ignitor Ignition coil in Section 6F2.
Fuel pressure out of specification
(dirty fuel filter, dirty or clogged fuel hose or
pipe, malfunctioning fuel pressure regulator,
malfunctioning fuel pump)“DIAG. FLOW TABLE B-3” in this
section.
Maladjusted TP sensor installation angle TP sensor in Section 6E2.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty injector Fuel injector in Section 6E2.
Faulty TP sensor, ECT sensor or MAF sensor TP sensor, ECT sensor or MAF
sensor in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Low compression Refer to the same item in “HARD
STARTING” of this table.
Dragging brakes Diagnosis in Section 5.
Slipping clutch Diagnosis in Section 7C1.

6-1-34 ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE)
Poor gasoline mileage
Faulty spark plug (improper gap, heavy depos-
its, and burned electrodes, etc.)Spark plugs in Section 6F2.
Fuel pressure out of specification “DIAG. FLOW TABLE B-3” in this
section.
Faulty TP sensor, ECT sensor or MAF sensor TP sensor, ECT sensor or MAF
sensor in Section 6E2.
Faulty EGR system “DTC P0400 DIAG. FLOW TABLE”
in this section.
Faulty injector Fuel injector in Section 6E2.
Faulty ECM (PCM) Inspection of ECM (PCM) and its
circuit in this section.
Low compression Refer to the same item in “HARD
STARTING” of this table.
Poor valve seating Valves inspection in Section 6A2.
Dragging brakes Diagnosis in Section 5.
Slipping clutch Diagnosis in Section 7C1.
Thermostat out of order Thermostat in Section 6B.
Improper tire pressure Diagnosis in Section 3.
Excessive engine oil
consumptionSticky piston ring Piston cleaning in Section 6A2.
Worn piston and cylinder Cylinders, pistons and piston rings
inspection in Section 6A2.
Worn piston ring groove and ring Pistons and piston rings inspection
in Section 6A2.
Improper location of piston ring gap Pistons installation in Section 6A2.
Worn or damaged valve stem seal Valves and cylinder head in Sec-
tion 6A2.
Worn valve stem Valves inspection in Section 6A2.
Low oil pressure
Improper oil viscosity Engine oil and oil filter change in
Section 0B.
Malfunctioning oil pressure switch Oil pressure switch inspection in
Section 8.
Clogged oil strainer Oil pan and oil pump strainer clean-
ing in Section 6A2.
Functional deterioration of oil pump Oil pump in Section 6A2.
Worn oil pump relief valve Oil pump in Section 6A2.
Excessive clearance in various sliding parts “INSPECTION” for each parts in
Section 6A2. Condition Possible Cause Correction

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) 6A2-17
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