battery SUZUKI GRAND VITARA 2001 2.G Service Manual

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-119
Table B-3 Fuel Pressure Inspection
SYSTEM DIAGRAM
Special tool
(A) : 09912-58441
(B) : 09912-58431
(C) : 09919-58421
INSPECTION
1. Injector 4. Fuel filter
2. Delivery pipe 5. Fuel pump
3. Fuel pressure regulator
NOTE:
Before using the following flow table, check to make sure that battery voltage is higher than 11 V. If
battery voltage is low, pressure becomes lower than specification even if fuel pump and line are in
good condition.
Step Action Yes No
1 1) Install fuel pressure gauge, referring to
“FUEL PRESSURE INSPECTION” in Sec-
tion 6E2.
2) Operate fuel pump.
Is fuel pressure then 270 – 310 kPa
(2.7 – 3.1 kg/cm
2, 38.4 – 44.0 psi)?Go to Step 2. Go to Step 5.
2
Is 200 kPa (2.0 kg/cm
2, 28.4 psi) or higher fuel
pressure retained for 1 minute after fuel pump
is stopped at Step 1?Go to Step 3. Go to Step 4.

ENGINE GENERAL INFORMATION AND DIAGNOSIS (H27 ENGINE) 6-1-125
Special Tool
09912-58441 09912-58431 09912-58490 09912-58421
Pressure gauge Pressure hose 3-way joint & hose Checking tool set
(See NOTE “A”.)
09917-47011 09930-88521 09931-76011
Vacuum pump gauge Injector test lead Tech 1A kit (SUZUKI scan
tool) (See NOTE “B”.)Mass storage cartridge for
Tech 1A
09931-76030
14/16 pin DLC cable for
Tech 1ATech 2 kit (SUZUKI scan
tool) (See NOTE “C”.)
NOTE:
“A”: This kit includes the following items.
1. Tool body & washer, 2. Body plug, 3. Body attachment-1, 4. Holder,
5. Return hose & clamp, 6. Body attachment-2 & washer, 7. Hose attachment-1,
8. Hose attachment-2
“B”: This kit includes the following items and substitutes for the Tech 2 kit.
1. Storage case, 2. Operator’s manual, 3. Tech 1A, 4. DLC cable,
5. Test lead/probe, 6. Power source cable, 7. DLC cable adaptor, 8. Self-test adaptor
“C”: This kit includes the following items and substitutes for the Tech 1A kit.
1. Tech 2, 2. PCMCIA card, 3. DLC cable, 4. SAE 16/19 adapter, 5. Cigarette cable, 6. DLC loopback
adapter, 7. Battery power cable, 8. RS232 cable, 9. RS232 adapter, 10. RS232 loopback connector,
11. Storage case, 12. Power supply

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) 6A2-3
REMOVAL
1) Release fuel pressure in fuel feed line by referring to Section
6.
2) Disconnect negative (–) cable at battery.
3) Drain coolant.
4) Remove strut tower bar (2).
5) Disconnect coupler from intake air temp. sensor, and MAF
sensor.
6) Remove surge tank cover (1).
7) Remove air cleaner upper case, intake air hose, intake air
pipe (1) and surge tank pipe (2) as one component. Do not
disassemble them, when removing and reinstalling. CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
WARNING:
To help avoid danger of being burned, do not remove
drain plug and radiator cap while engine and radiator are
still hot. Scalding fluid and steam can be blown out under
pressure if plug and cap are taken off too soon.
1. Radiator
2. Radiator drain plug
2
1
1
2

6A2-8 ENGINE MECHANICAL (H27 ENGINE)
16) Connect water hoses (3) to throttle body.
17) Connect accelerator cable (1) and A/T throttle cable (2) (for
A/T vehicle) to throttle body.
18) Install surge tank pipe (2) to intake manifold with new gas-
kets and intake air pipe (1) to throttle body.
19) Install surge tank cover (1).
20) Install air cleaner upper case.
21) Connect coupler to intake air temp. sensor and MAF sensor.
22) Install strut tower bar (1).
23) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
24) Refill cooling system referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
25) Connect negative cable at battery.
12
33
1
2
1

ENGINE MECHANICAL (H27 ENGINE) 6A2-9
26) Upon completion of installation, verify that there is no fuel
leakage at each connection according to procedure
described in Section 6.
Exhaust Manifold
REMOVAL
1) Disconnect negative (–) cable at battery.
2) Remove air cleaner upper case and intake air hose if right
side exhaust manifold is removed.
3) Detach couplers from their bracket and disconnect oxygen
sensor lead wires at couplers. WARNING:
To avoid danger of being burned, do not service exhaust
system while it is still hot. Service should be performed
after system has cooled off.
1. Left (No.1) exhaust manifold
Right (No.2) exhaust manifold
2. Exhaust manifold cover
3. Exhaust No.1 pipe
A. Without WU-TWC
B. With WU-TWC
1. HO2S-1 (Green connector)
2. HO2S-2 (Black connector)

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)

6A2-20 ENGINE MECHANICAL (H27 ENGINE)
12) Install oil pan and oil pump strainer.
Refer to “OIL PAN AND OIL PUMP STRAINER” in this sec-
tion.
13) Install cylinder head cover.
Refer to “CYLINDER HEAD COVER” in this section.
14) Install exhaust manifold.
Refer to “EXHAUST MANIFOLD” in this section.
15) Install radiator outlet pipe, radiator, cooling fan and water
hose.
Refer to “COOLING WATER PIPES OR HOSES”, “RADIA-
TOR” and “COOLING FAN AND FAN CLUTCH” in Section
6B.
16) Install throttle body and intake manifold.
Refer to “THROTTLE BODY AND INTAKE MANIFOLD” in
this section.
17) Adjust water pump drive belt tension.
Refer to “COOLING FAN BELT TENSION CHECK AND
ADJUSTMENT” in Section 6B.
18) Adjust power steering pump drive belt tension.
Refer to “POWER STEERING PUMP DRIVE BELT” in Sec-
tion 3B1.
19) Adjust accelerator cable play and A/T throttle cable play.
Refer to “ACCELERATOR CABLE ADJUSTMENT” and “A/T
THROTTLE CABLE ADJUSTMENT (A/T VEHICLE)” in Sec-
tion 6E2.
20) Check to ensure that all removed parts are back in place.
Reinstall any necessary parts which have not been rein-
stalled.
21) Refill engine with engine oil, referring to “ENGINE OIL
CHANGE” in Section 0B.
22) Refill cooling system referring to “COOLING SYSTEM
FLUSH AND REFILL” in Section 6B.
23) Refill front differential housing with gear oil if drained, refer-
ring to “MAINTENANCE SERVICE” in Section 7E.
24) Connect negative cable at battery.
25) Check ignition timing and adjust as necessary, referring to
“IGNITION TIMING CHECK AND ADJUSTMENT” in Section
6F2.
26) Verify that there is no fuel leakage, water leakage, oil leak-
age and exhaust gas leakage at each connection.
27) Check wheel alignment, referring to “STEERING ANGLE” in
Section 3A.

6A2-26 ENGINE MECHANICAL (H27 ENGINE)
Unit Repair Overhaul
Engine Assembly
REMOVAL
1) Release fuel pressure in fuel feed line. Refer to “FUEL
PRESSURE RELIEF PROCEDURE” in Section 6.
2) Disconnect negative (–) cable at battery.
3) Remove engine hood.
4) Drain engine oil.
5) Drain coolant.
6) Remove radiator, radiator fan shroud, cooling fan and radia-
tor reservoir. Refer to “COOLING FAN AND FAN CLUTCH”
and “RADIATOR” in Section 6B.
7) Disconnect accelerator cable (1) and A/T throttle cable (for
A/T vehicle) (2) from throttle body.
8) Remove strut tower bar and surge tank cover.
9) Disconnect IAT sensor coupler and MAF sensor coupler then
remove air cleaner upper case, intake air hose, intake air
pipe and surge tank pipe as a component.
10) Remove engine oil level gauge guide and A/T fluid level
gauge guide (for A/T vehicle).
11) Remove ignition coil covers.
12

6C-2 ENGINE FUEL
On-Vehicle Service
Fuel Tank
REMOVAL
1) Relieve fuel pressure in fuel feed line referring to Section 6
or Section 6-1.
2) Disconnect negative (–) cable at battery.
3) Before disconnecting fuel filler hose, give match marks on
fuel filler hose and fuel filler neck.
4) Disconnect fuel filler hose from fuel filler neck.
5) Insert hose of a hand operated pump into fuel filler hose and
drain fuel in space “A” in the figure (drain fuel through it till
fuel stops).
6) Remove fuel tank filler hose protector.
Disconnect filler hose from fuel tank and breather hose from
fuel filler neck.
7) Remove fuel tank inlet valve. Use care not to damage inlet
valve when removing.
8) Drain fuel tank by pumping fuel out through fuel tank filler.
Use hand operated pump device to drain fuel tank.
9) Disconnect fuel filter inlet hose from filter.CAUTION:
This work must not be done when engine is hot. If done
so, it may cause adverse effect to catalyst.
CAUTION:
Do not force hose of a hand operated pump into fuel
tank. Doing so can damage inlet valve.
1. Fuel filler hose
2. Fuel tank inlet (check) valve
1. Tank
2. Breather hose
3. Filler hose
4. Inlet valve
CAUTION:
Never drain or store fuel in an open container due to pos-
sibility of fire or explosion.
1. Fuel filter
2. Fuel filter outlet hose
3. Fuel filter inlet hose