Under engine SUZUKI GRAND VITARA 2001 2.G Owner's Guide

6A2-34 ENGINE MECHANICAL (H27 ENGINE)
•UNDERSIZE BEARING (0.25 mm) :
0.25 mm undersize bearing is available, in 5 kinds varying in
thickness.
To distinguish them, each bearing is painted in the following
colors at such position as shown in the figure.
Each color represents the following thickness at the center of
bearing.
Under size main bearing thickness
•If necessary, regrind crankshaft journal and select undersize
bearing to use with it as follows.
1) Regrind journal to the following finished diameter.
Finished journal diameter :
64.738 – 64.756 mm (2.5487 – 2.5494 in.)
2) Using micrometer, measure reground journal diameter.
Measurement should be taken in 2 directions perpendicular
to each other in order to check for out-of-round.
3) Using journal diameter measured above and alphabets
stamped on lower crankcase, select an undersize bearing by
referring to table given below.
Check bearing clearance with newly selected undersize
bearing.
Under size bearing specification :Color painted Bearing thickness
Black & Red2.621 – 2.625 mm
(0.1032 – 0.1033 in.)
Red2.624 – 2.628 mm
(0.1033 – 0.1034 in.)
Red & Yellow2.627 – 2.631 mm
(0.1034 – 0.1035 in.)
Red & Blue2.630 – 2.634 mm
(0.1035 – 0.1036 in.)
Red & Pink2.633 – 2.637 mm
(0.1036 – 0.1037 in.)
1. Paint
Measured journal diameter
64.750 – 64.756 mm
(2.5492 – 2.5494 in.)64.744 – 64.750 mm
(2.5489 – 2.5492 in.)64.738 – 64.744 mm
(2.5487– 2.5489 in.)
Alphabets stamped on
lower crankcaseA Black & Red Red Red & Yellow
B Red Red & Yellow Red & Blue
C Red & Yellow Red & Blue Red & Pink

ENGINE FUEL 6C-5
Fuel Lines
Due to the fact that fuel feed line is under high pressure, this sys-
tem requires special consideration for service.
The feed pipe uses screw couplings and hose clamps.
INSPECTION
Visually inspect fuel lines for evidence of fuel leakage, hose
cracking and deterioration, or damage. Make sure all clamps are
secure. Replace parts as needed.

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-1
6E2
SECTION 6E2
ENGINE AND EMISSION CONTROL SYSTEM
(SEQUENTIAL MULTIPORT FUEL INJECTION
FOR H27 ENGINE)
CONTENTS
General Description ..................................... 6E2-2
System Flow ............................................... 6E2-3
System Diagram ......................................... 6E2-4
Air Intake System ....................................... 6E2-6
Fuel Delivery System ................................. 6E2-7
Electronic Control System .......................... 6E2-8
Engine and Emission Control Input/Output
Table ........................................................ 6E2-12
Diagnosis .................................................... 6E2-12
On-Vehicle Service..................................... 6E2-13
General .................................................... 6E2-13
Accelerator Cable Adjustment .................. 6E2-14
A/T Throttle Cable Adjustment
(A/T Vehicle) ............................................ 6E2-14Idle Speed/Idle Air Control (IAC) Duty
Inspection................................................. 6E2-15
[Using SUZUKI scan tool] .................... 6E2-15
[Not using SUZUKI scan tool]
(vehicle with monitor connector) .......... 6E2-16
Idle mixture inspection/adjustment
(vehicle without heated oxygen sensor) 6E2-17
Air Intake System ..................................... 6E2-18
Throttle body ........................................ 6E2-18
Idle air control valve (IAC valve) .......... 6E2-21
Fast idle air valve ................................. 6E2-22
Fuel Delivery System ............................... 6E2-23
Fuel pressure inspection ...................... 6E2-23
Fuel pump ............................................ 6E2-24
Fuel pressure regulator ........................ 6E2-25 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:
Whether following systems (parts) are used in the particular vehicle or not depends on specifications.
Be sure to bear this in mind when performing service work.
Monitor connector
CKP sensor
MAP sensor
EGR valve
Heated oxygen sensor or CO adjusting resistor
Three way catalytic converter, Warm-up three way catalytic converter

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-7
Fuel Delivery System
The fuel delivery system consists of the fuel tank, fuel pump, fuel filter, fuel pressure regulator, delivery pipe and
fuel injectors.
The fuel in the fuel tank is pumped up by the fuel pump, filtered by the fuel filter and fed under pressure to each
injector through the delivery pipe.
As the fuel pressure applied to the injector (the fuel pressure in the fuel feed line) is always kept a certain
amount higher than the pressure in the intake manifold by the fuel pressure regulator, the fuel is injected into the
intake port of the cylinder head when the injector opens according to the injection signal from ECM (PCM).
The fuel relieved by the fuel pressure regulator returns through the fuel return line to the fuel tank.
[A] : Fuel 1. Fuel tank 5. Fuel return line 9. Fuel injector
[B] : Air 2. Fuel pump 6. Fuel pressure regulator 10. Fuel delivery pipe
3. Fuel filter 7. Vacuum hose for fuel pressure regulator 11. Throttle valve
4. Fuel feed line 8. Intake manifold surge tank

ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE) 6E2-23
Fuel Delivery System
Fuel pressure inspection
1) Relieve fuel pressure in fuel feed line referring to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6-1.
2) Disconnect fuel feed hose from (3) delivery fuel feed pipe (1).
3) Connect special tools and hose (2) between fuel feed hose
and fuel feed pipe as shown in figure, and clamp hose
securely to ensure no leaks occur during checking.
Special tool
(A) : 09912-58441
(B) : 09912-58431
(C) : 09912-58490
4) Check that battery voltage is above 11 V.
5) Turn ignition switch ON to operate fuel pump and after 3 sec-
onds turn it OFF. Repeat this 3 or 4 times and then check
fuel pressure.
6) Start engine.
7) Measure fuel pressure at idling.
If measure pressure doesn’t satisfy specification, refer to
“Diagnostic Flow Table B-3” in Section 6-1 and check each
possibly defective part. Replace if found defective.
Fuel pressure specification: CAUTION:
A small amount of fuel may be released when fuel feed
hose is removed. Place container under the fuel feed
hose or fuel feed pipe with a shop cloth so that released
fuel is caught in container or absorbed in cloth. Place
that cloth in an approved container.
CONDITION FUEL PRESSURE
With fuel pump operating and
engine stopped270 – 310 kPa
2.7 – 3.1 kg/cm
2
38.4 – 44.0 psi
At specified idle speed 210 – 260 kPa
2.1 – 2.6 kg/cm
2
29.8 – 37.0 psi
With 1 min. after engine (fuel pump)
stop (Pressure reduces as time
passes)over 200 kPa
2.0 kg cm
2
28.4 psi

6E2-24 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
8) After checking fuel pressure, remove fuel pressure gauge
(1).
9) Remove fuel pressure gauge, hose and 3-way joint.
10) Connect fuel feed hose and clamp it securely.
11) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
Fuel pump
ON-VEHICLE INSPECTION
1) Remove filler cap and turn ON ignition switch (2). Then fuel
pump operating sound should be heard from fuel filler (1) for
about 3 seconds and stop. Be sure to reinstall fuel filler cap
after checking.
If above check result is not satisfactory, advance to “DIAG-
NOSTIC FLOW TABLE B-1” in Section 6-1
2) Fuel pressure should be felt at fuel return hose (1) for 3 sec-
onds after ignition switch ON.
If fuel pressure is not felt, advance to “DIAGNOSTIC FLOW
TABLE B-3” in Section 6-1. CAUTION:
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following pro-
cedures.
Place fuel container under joint.
Cover joint with rag and loosen joint nut slowly to
release fuel pressure gradually.
CAUTION:
When fuel filler cap is removed in any procedure, work
must be done in a well-ventilated area, keep away from
any open flames and without smoking.

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.

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.

6E2-28 ENGINE AND EMISSION CONTROL SYSTEM (SEQUENTIAL MULTIPORT FUEL INJECTION FOR H27 ENGINE)
1) Install injector (1) and fuel pressure regulator (2) to special
tool (injector checking tool).
Special tool
(A) : 09912-58421
2) Connect special tools (hoses and attachment) to pipes of
vehicle.
Special tool
(B) : 09912-58431
3) Connect special tool (test lead) to injector.
Special tool
(C) : 09930-88521
4) Install suitable vinyl tube onto injector (3) nozzle to prevent
fuel from splashing out when injecting.
5) Put graduated cylinder under injector as far apart as possi-
ble.
6) Disconnect fuel pump relay.
7) To operate fuel pump and apply fuel pressure to injector,
using wire harness (2) as thick as the one used for fuel pump
circuit, connect two terminals of relay connector (1) as
shown in the figure.
8) Apply battery (4) voltage to injector for 15 seconds and mea-
sure injected fuel volume with graduated cylinder.Test each
injector two or three times.If not within specification, replace
injector.
Injected fuel volume:
56 – 60 cc/15 sec. (1.89/1.97 – 2.02/2.11 US/lmp. oz/15 sec.)
9) Check fuel leakage from injector (1) nozzle. Do not operate
injector for this check (but fuel pump should be at work). If
fuel leaks more than following specifications, replace.
Fuel leakage:
Less than 1 drop/min. NOTE:
Remove grommet from injector, then install injector to
special tool and tighten bolts by hand.
[A]: Left-hand steering vehicle
[B]: Right-hand steering vehicle

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