SUZUKI GRAND VITARA 1999 2.G Owners Manual

6A2-14 ENGINE MECHANICAL (H27 ENGINE)
Camshaft and Valve Lash Adjuster
1. RH bank 2nd timing chain 6. LH bank intake camshaft 11. Timing chain guide No.5
2. RH bank exhaust camshaft 7. LH bank exhaust camshaft 12. Valve lash adjuster
3. RH bank intake camshaft 8. LH bank intake camshaft holder 13. Camshaft housing bolt
4. RH bank exhaust camshaft holder 9. LH bank exhaust camshaft holder Tightening Torque
5. RH bank intake camshaft holder 10. LH bank camshaft holder Apply engine oil to sliding surface
of each parts.

ENGINE MECHANICAL (H27 ENGINE) 6A2-15
INSPECTION
Cam wear
Using a micrometer, measure cam height. If measured height is
below its limit, replace camshaft.
Intake cam height :
Standard : 40.402 – 40.562 mm (1.5906 – 1.5969 in.)
Limit : 40.300 mm (1.3581 in.)
Exhaust cam height :
Standard : 39.428 – 39.588 mm (1.5523 – 1.586 in.)
Limit : 39.400 mm (1.5512 in.)
Camshaft runout
Set camshaft between two “V” blocks, and measure its runout by
using a dial gauge.
If measured runout exceeds below specified limit, replace cam-
shaft.
Camshaft runout limit :
0.04 mm (0.002 in.)
Camshaft journal wear
Check camshaft journals and camshaft housings for pitting,
scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder head
with housing. Never replace cylinder head without replacing hous-
ings.
Check clearance by using gaging plastic. The procedure is as fol-
lows.
1) Clean housings and camshaft journals.
2) Make sure that all valve lash adjusters are removed and
install camshaft to cylinder head.
3) Place a piece of gaging plastic the full width of journal of
camshaft (parallel to camshaft).
4) Install camshaft housing.
5) Tighten camshaft housing bolts in such order ([A] : “1” →
“17”, [B] : “1” → “19”) as shown in the figure a little at a time
till they are tightened to specified torque.
NOTE:
Do not rotate camshaft while gaging plastic is installed.
[A] : RH bank
[B] : LH bank

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.)

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

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) 6A2-19
5) Install cylinder head to block.
After applying oil to cylinder head bolts, tighten them gradu-
ally as follows.
a) Tighten all bolts to 53 N·m (5.3 kg-m, 38.5 lb-ft) according
to numerical order in the figure.
b) In the same manner as in a), tighten them to 84 N·m (8.4
kg-m, 61.0 lb-ft).
c) Loosen all bolts until tightening torque is reduced to 0 in
reverse order of tightening.
d) In the same manner as in a), tighten them to 53 N·m (5.3
kg-m, 38.5 lb-ft).
e) In the same manner as in a) again, tighten them to speci-
fied torque.
Tightening torque
Cylinder head bolt (a) : 105 N·m (10.5 kg-m, 76.0 lb-ft)
Cylinder head bolt (hex hole bolt) (b) :
11 N·m (1.1 kg-m, 7.5 lb-ft)
6) Install water outlet cap.
7) Check timing mark on crankshaft as shown in the figure.
8) Install valve lash adjuster, camshaft, CMP sensor and RH
bank 2nd timing chain.
Refer to “CAMSHAFT AND VALVE LASH ADJUSTER” and
“RH (NO.2) BANK 2ND TIMING CHAIN AND CHAIN TEN-
SIONER” in this section. For CMP sensor, refer to “CMP
SENSOR” in Section 6F2.
9) Install 1st timing chain.
Refer to “1ST TIMING CHAIN AND CHAIN TENSIONER” in
this section.
10) Install LH bank 2nd timing chain.
Refer to “LH (NO.1) BANK 2ND TIMING CHAIN AND CHAIN
TENSIONER” in this section.
11) Install timing chain cover.
Refer to “TIMING CHAIN COVER” in this section. NOTE:
Don’t forget to install (b) bolts as shown in the figure.
1. Hex hole bolt
2. Crankshaft pulley side
3. Flywheel side
[A] RH bank
[B] LH bank
1. Crank timing pulley key
2. Oil jet

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.

ENGINE MECHANICAL (H27 ENGINE) 6A2-21
Piston, Piston Rings, Connecting Rods and Cylinders
1. Top ring 5. Connecting rod :
Clean bearing installing surface when install.9. Piston pin circlip Tightening Torque
2. 2nd ring 6. Connecting rod bearing cap :
Clean bearing installing surface when install.10. Cylinder block Do not reuse
3. Oil ring 7. Connecting rod bearing :
Clean outer surface when install.11. Bearing cap nut Apply engine oil to sliding
surface of each parts.
4. Piston 8. Piston pin

6A2-22 ENGINE MECHANICAL (H27 ENGINE)
INSPECTION
Cylinders
•Inspect cylinder walls for scratches, roughness, or ridges
which indicate excessive wear. If cylinder bore is very rough
or deeply scratched, or ridged, rebore cylinder and use over
size piston.
•Using a cylinder gauge, measure cylinder bore in thrust and
axial directions at 2 positions (1, 2) as shown in the figure.
If any of the following conditions is noted, rebore cylinder.
–Cylinder bore dia. exceeds limit.
–Difference of measurements at 2 positions exceeds taper
limit.
–Difference between thrust and axial measurements
exceeds out-of-round limit.
Cylinder bore dia. limit :
88.050 mm (3.4665 in.)
Taper and out-of-round limit :
0.10 mm (0.004 in.)
Pistons
•Inspect piston for faults, cracks or other damages.
Damaged or faulty piston should be replaced.
•Piston diameter :
As shown in the figure, piston diameter should be measured
at a position 26.5 mm (1.04 in.) (1) from piston skirt end in
the direction perpendicular to piston pin.
Piston diameter : NOTE:
If any one of six cylinders has to be rebored, rebore all
six to the same next oversize. This is necessary for the
sake of uniformity and balance.
1. 50 mm (1.96 in.)
2. 95 mm (3.74 in.)
Standard87.970 – 87.990 mm
(3.4634 – 3.4642 in.)
Oversize :
0.50 mm (0.0196 in.)88.470 – 88.490 mm
(3.4831 – 3.4839 in.)

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.)