Engine removal SUZUKI GRAND VITARA 2001 2.G User Guide

6E2-18 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Air Intake System
Throttle body
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Drain cooling system.
3) Remove strut tower bar.
4) Disconnect accelerator cable (1) and or A/T throttle cable (2)
from throttle body.
5) Disconnect water hoses from throttle body.
1. Throttle body 4. Water hose
2. Intake collector 5. MAF sensor
3. Breather hose 6. TP sensor

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-21
14) Install strut tower bar (1) and tighten bolts.
15) Refill cooling system.
16) Connect negative (–) cable at battery.
17) Adjust accelerator cable and A/T throttle cable, refer to
“ACCELERATOR CABLE ADJUSTMENT” and “A/T THROT-
TLE CABLE ADJUSTMENT” in this section.
Idle air control valve (IAC valve)
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disconnect IAC valve connector.
3) Remove IAC valve (1) from throttle body.
INSPECTION
1) Disconnect connector from IAC valve.
2) Check each coil of IAC valve for resistance.
If resistances is out of specification, replace.
IAC valve resistance:
Terminals Resistance
Between “1” and “2”
25.5 - 33.5 Ω
ΩΩ Ω Between “3” and “2”
Between “4” and “5”
Between “6” and “5”

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-25
REMOVAL
Remove fuel tank from body according to procedure described in
Section 6C and remove fuel pump from fuel tank.
INSPECTION
Check fuel pump filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel tank.
INSTALLATION
Install fuel pump to fuel tank and then install fuel tank to body
according to procedure described in “Section 6C”.
Fuel pressure regulator
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6-1.
2) Disconnect negative (–) cable from battery.
3) Disconnect vacuum hose (1) from fuel pressure regulator.
4) Remove fuel pressure regulator (1) from fuel delivery pipe
(3).
5) Disconnect fuel return hose (2) from fuel pressure regulator.
CAUTION:
A small amount of fuel may be released when it is from
delivery pipe.
Place a shop cloth under delivery pipe so that released
fuel is absorbed in it.
CAUTION:
A small amount of fuel may be released when hose is dis-
connected. Cover hose to be disconnected with a shop
cloth.

6E2-26 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
INSTALLATION
For installation, reverse removal procedure and note the follow-
ings.
•Use new O-ring.
•Apply thin coat of gasoline to O-ring to facilitate installation.
•Tighten fuel pressure regulator (1) bolts to specified torque.
Tightening torque
Fuel pressure regulator bolt
(a) : 10 N·m (1.0 kg-m, 7.5 lb-ft)
•With engine “OFF” and ignition switch “ON”, check for fuel
leaks around fuel line connection.
Fuel injector
ON-VEHICLE INSPECTION
1) Using sound scope (1) or such, check operating sound of
injector when engine is running or cranking.
Cycle of operating sound should vary according to engine
speed.
If no sound or an unusual sound is heard, check injector cir-
cuit (wire or coupler) or injector.
2) Disconnect connector from injector, connect ohmmeter
between terminals of injector and check resistance.
If resistance is out of specification, replace.
Fuel injector resistance:
14.2 – 14.8 Ω
Ω Ω Ω (at 20°C, 68°F)
3) Connect connector to injector securely.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-27
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6-1.
2) Remove throttle body intake collector, refer to “THROTTLE
BODY” in this section.
3) Disconnect fuel feed hose (1) and fuel return hose (2).
4) Disconnect vacuum hose (4) and fuel return hose from fuel
pressure regulator (5).
5) Remove fuel feed pipe (8) and fuel connect pipe (7) from
delivery pipes (6) (right and left).
6) Disconnect connector (3) from each injector.
7) Remove delivery pipes (1) (right and left) from intake mani-
fold.
8) Remove fuel injector(s).
INSPECTION
CAUTION:
A small amount of fuel may be released when it is from
delivery pipe.
Place a shop cloth under delivery pipe so that released
fuel is absorbed in it.
WARNING:
As fuel is injected in this inspection, perform in a well
ventilated area and away from open flames.
Use special care to prevent sparking when connecting
and disconnecting test lead to and from battery.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-31
Electronic Control System
Engine control module (ECM)/powertrain control
module (PCM)
REMOVAL
1) Disconnect negative (–) cable from battery.
2) Disable air bag system (if equipped) referring to “DIS-
ABLING THE AIR BAG SYSTEM” in Section 10B.
3) Remove ECM (PCM) cover (1) from bracket.
4) Disconnect connectors from ECM (PCM) (1).
5) Remove ECM (PCM) (1) with bracket (2).
INSTALLATION
1) Install ECM (PCM) with bracket to vehicle.
2) Connect connectors to ECM (PCM) securely.
3) Install ECM (PCM) cover to bracket.
4) Enable air bag system (if equipped) referring to “ENABLING
AIR BAG SYSTEM” in Section 10B.
5) Connect negative (–) cable to battery. CAUTION:
As ECM (PCM) consists of precision parts, be careful not
to expose it to excessive shock.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-33
REMOVAL
1) Disconnect negative (–) cable at battery and coupler (1) from
MAF sensor (3).
2) Remove air cleaner outlet hose (2) from throttle body and
MAF sensor (3).
3) Remove MAF sensor from air cleaner case.
INSTALLATION
1) Check MAF sensor seal (1) for deterioration and damage.
2) Install MAF sensor to air cleaner case.
3) Install air cleaner outlet hose.
4) Connect MAF sensor coupler securely.
5) Connect negative (–) cable to battery.
CAUTION:
Don’t disassemble MAF sensor.
Do not expose MAF sensor to any shock.
Do not blow compressed air by using air gun or the
like.
Do not put finger or any other object into MAF sensor.
Malfunction may occur.

6E2-34 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Intake air temperature (IAT) sensor
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disconnect IAT sensor coupler.
3) Remove IAT sensor from air cleaner case.
INSPECTION
Immerse temperature sensing part of IAT sensor in water (or ice)
and measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn't show such characteristic as
shown in the figure, replace IAT sensor.
INSTALLATION
1) Clean mating surface of sensor and seal (2) on air cleaner
case.
2) Install IAT sensor (1) into seal.
3) Connect connector to IAT sensor securely.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-35
Throttle position sensor (TP sensor)
INSPECTION
1) Disconnect negative (–) cable at battery and coupler from TP
sensor (4).
2) Using ohmmeter, check resistance between terminals under
each condition given in table below.
If check result is not satisfactory, replace TP sensor.
TP sensor specification:
3) Connect TP sensor coupler securely.
4) Connect negative cable to battery.
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Disconnect coupler from TP sensor.
3) Remove TP sensor from throttle body.
INSTALLATION
1) Install TP sensor (1) to throttle body (2).
Fit TP sensor (1) to throttle body (2) in such way that its
holes are a little away from TP sensor screw holes as shown
in the figure and turn TP sensor (1) clockwise so that those
holes align.
Tightening torque
TP sensor screw
(a) : 3.5 N·m (0.35 kg-m, 2.5 lb-ft)
2) Connect coupler to TP sensor securely.
3) Connect battery negative (–) cable to battery. TERMINALS RESISTANCE
Between 1 and
3 terminals4.0 – 6.0 kΩ
ΩΩ Ω
Between 1 and
2 terminals0.02 – 6.0 kΩ
ΩΩ Ω
varying linearly according to
throttle valve opening
1. Ground terminal
2. Output voltage terminal
3. Reference voltage terminal

6E2-36 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
Engine coolant temperature sensor (ECT sensor)
REMOVAL
1) Disconnect negative (–) cable from battery.
2) Drain cooling system.
3) Disconnect coupler from ECT sensor (1).
4) Remove ECT sensor from water outlet cap (2).
INSPECTION
Immerse temperature sensing part of ECT sensor in water and
measure resistance between sensor terminals while heating
water gradually.
If measured resistance doesn’t shown such characteristic as
shown in the figure, replace ECT sensor.
INSTALLATION
Reverse removal procedure noting the followings.
•Clean mating surfaces of sensor and water outlet cap (1).
•Use new O-ring.
•Tighten ECT sensor to specified torque.
Tightening torque
ECT sensor (a) : 15 N·m (1.5 kg-m, 11.0 lb-ft)
•Connect coupler to sensor securely.
•Refill cooling system.