SUZUKI GRAND VITARA 1987 Service Repair Manual

2) Install valve spring seat to cylinder head.
3) Install new valve stem seal to valve guide.
After applying engine oil to seal and spindle
of valve stem seal installer (special tool), fit
oil seal to spindle, and then install seal to
valve guide by pushing special tool by hand.
After installation, check to be sure that
seal is properly fixed to valve guide.
NOTE:
l Do not reuse oil seal disassembled. Be sure to
install new oil seal.
l When installing, never tap or hit special tool
with a hammer or else. Install seal to guide
only by bushing special tool with hand.
Tapping or hitting special tool may cause
damage on seal.
7 i
1.Valve stem seal installer (Special tool 09917-98210)
2. Valve stem seal
Fig. 3-6-29 Valve stem seal installation
4) Install valve to valve guide.
Before installing valve to valve guide, apply
engine oil to stem seal, valve guide bore,
and valve stem.
Fig. 3-6-30 Valve installation
5) Install valve spring and spring retainer.
Each valve spring has top end (large-pitch
end) and bottom end (small-pitch end)
Be sure to position spring in place with its
bottom end (small-pitch end) down to valve
spring seat side.
41. Large-pitch2. Small-pitch
3.Valve spring retainer side
4. Valve spring seat side
Fig. 3-6-3 1Valve spring installation
3-44

6) Using special tool (Valve lifter), compress
valve spring and fit two valve totters to
groove provided in valve stem.
1. Valve lifter (Special tool)
2.Forceps (Specialtool13.Valve totters4. Valve spring retainer
Fig. 3-6-32 Valve totters installation
7) Be sure that locating pins @ are in place and
then install new head gasket as shown in
Fig. 3-6-33, namely in such a way that
“TOP” mark provided on the gasket comes
on top side (toward cylinder head side)
and on crankshaft pulley side.
1
4
4
1. Cylinder head gasket2. Crankshaft pulley side
3 Flywheel side4. Locating pin
Fig. 3-6-33 Cylinder head gasket installation
8) Install cylinder head onto cylinder block.
Tighten cylinder head bolts gradually with a
torquewrench,following sequence in
Fig. 3-6-34. Finally tighten bolts to specified
torque.
Tightening torque for63-70 N-m
cylinder head bolts6.3-7.0 kg-m
46.0 -50.5 lb-ft
Fig. 3-6-34 Tightening sequence of cylinder
head bolts
Camshaft
1) Apply engine oil to cams and journals on
camshaft, and oil seal on cylinder head.
2) Install to cylinder head from transmission
case side.
Fig. 3-6-35 Camshaft installation
3-35

Rocker-Arm Shafts
1) Apply engine oil to rocker arms and rocker
arm shafts.
2) install rocker arms, springs and rocker arm
shafts.
The two rocker arm shafts are not identical.
To distinguish between the two, dimensions
of their stepped ends differ as shown in
Fig. 36-36. Install intake rocker arm shaft,
facing its stepped end to camshaft pulley
side, and exhaust rocker arm shaft, facing
its stepped end to distributor side (rear side).
56
b01000
/3
I
3
I
o-
“7
1. Intake rocker arm shaft
2.14 mm (0.55 in)
3. Exhaust rocker arm shaft
4.15 mm (0.59 in)
5. Camshaft pulley side
6.Distributor side
Fig. 3-6-36 Rocker arm shafts installation
3) After installing rocker arms, springs, and
rocker arm shafts as shown in Fig. 3-6-37,
tighten rocker arm shaft screws to specified
torque.
Tightening torque9 -12 N.m
for rocker arm shaft0.9 -1.2 kg-m
screws7.0 -8.5 lb-ft
NOTE:
Valve clearance is adjusted after all parts are
assembled. So it is not adjusted at this point
Leave rocker arm adjusting screw as loose as
can be.
1. Intake side
2. Exhaust side
Fig. 3-6-37
Water Inlet Pipe
Install water inlet pipe to cylinder block.
Make sure to fit seal ring @(O-ring) to inlet
pipe before installation.
Fig. 3-6-38
Intake Manifold and Carburetor
1) Install intake manifold gasket to cylinder
head. Use new gasket.
NOTE:
Clean cylinder head mating surface with gasket
before installation.
2) Install intake manifold with carburetor to
cylinder head.
3) Tighten manifold bolts and nuts to specified
torque.
Tightening torque ~.mkg-mlb-ftfor manifold bolts
and nuts18 - 281.8 - 2.8 13.5-20.0
3-46

Fig. 3-6-39
4) Connect water hoses to water inlet pipe and
clamp each hose.
Oil FilterInstall oil filter.
CAUTION:For oil filter installation, refer to P. 1-7 of
this manual.
Exhaust Manifold and Cover
1) Install exhaust manifold gasket to cylinder
head. Use new gasket.
NOTE:
Clean cylinder head mating surface with gasket
before installation.
2) Install exhaust manifold to cylinder head.
3) Tighten bolts and nuts to specified torque.
Tightening torque
N.mkg-mlb-ft
for bolts and nuts18 - 28 1.8 - 2.8 13.5-20.0 Water pump
1) Install water pump gasket to cylinder block.
Use new gasket.
NOTE:
Clean cylinder block mating surface with gasket
before installation.
2) Install water pump to cylinder block.
3) Tighten bolts and nuts to specified torque.
Tightening torque N.m
for water pumpb-mI b-ft
bolts and nuts
8 - 12 0.9 - 1.2 7.0 - 8.5,
Fig. 3-6-40
4) Install rubber seats 0; one between oil
pump and water pump and the other be-
tween water pump and cylinder head.
4) Install exhaust manifold cover.
Fig. 3-6-4 1
3-47

Timing Belt Inside Cover, Belt Pulleys,
Tensioner, Timing Belt and Outside Cover
1) install timing belt inside cover to cylinder
head.
2) Install crankshaft timing belt guide, key and
pulley.
Refer to Fig. 3-6-42 for proper installation
of these parts.
Install timing belt guide in such a way that
its concave side faces oil pump.
Tighten crankshaft timing belt pulley bolt to
specified torque by using flywheel holder
A (Special tool).
1.
2.3.
Timing belt guide
KeyCrank timing belt pulley4. Pulley bolt
(A) Flywheel holder
(09924-I 7810)
Fig. 3-6-42 Installing guide, key and pulley
3) Install camshaft timing belt pulley.
Fit pulley pin on camshaft into slot in
camshaft pulley. Tighten pulley bolt to
specified torque with general rod applied as
shown in Fig. 3-6-44.
inside cover2. Camshaft pulley:
3. Pulley pin4. Slot5. Pulley bolt
Fig. 3-6-43 Pulley pin, slot and pulley bolt
1. Wrench
2. Camshaft timing belt pulley3. Timing belt inside cover
4. General rod
Fig. 3- 6-44
Tightening torque N-mkg-mlb-ft
for pulley bolt56 - 645.6 - 6.4 41.0-46.0
3-48

4) Install timing belt tensioner plate to tensio-
ner.
Insert lug of tensioner plate into hole of
tensioner.
3w1. Tensioner plate42. Tensioner
3. Lug4. Hole
Fig. 3-645 Lug and hole
5) Install timing belt tensioner, tensioner plate
and spring.
Do not tighten tensioner bolt and stud with
wrench yet.
Hand tighten only at this time.
Be sure that plate movement in arrow
direction as shown in Fig. 3-6-46 causes the
same directional movement of tensioner.
If no associated movement between plate
and tensioner occurs, remove tensioner and
plate again and reinsert plate lug into tensio-
ner hole.
1. bolt
2. Tensioner stud3. Tensioner plate
4. Tensioner
5. Spring6. Spring damper
Fig. 3-646 Tensioner installation
6) Before installing timing belt to camshaft
pulley and crankshaft timing belt pulley,
loosen all valve adjusting screws of intake
and exhaust rocker arms fully, or check to
ensure they are loose.
This is to permit free rotation of camshaft
for the following reason; when installing
timing belt to both pulleys, belt should be
correctly tensed by tensioner spring force.
If camshaft does not rotate freely, belt will
not be correctly tensed by tensioner.
1. Valve adjusting screw
2. Locknut
Fig. 3-6-47Valve adjusting screw and lock nut
7) After loosening all valve adjusting screws all
the way, turn camshaft pulley clockwise and
align timing mark on camshaft pulley with
“V” mark on belt inside cover as shown in
Fig. 3-6-48.
1. Camshaft timing pulley
2. Timing mark
3.“V” mark4. Belt inside cover
Fig. 3-648 Timing marks
3-49
Tensioner

8) Turn crankshaft clockwise, fitting 17 mm
wrench to crankshaft timing belt pulley
bolt, and align punch mark on timing belt
pulley with arrow mark on oil pump as
shown in Fig. 3-6-49.
1. Crankshaft timing belt pulley bolt2. Punch mark3. Arrow mark
4. Crankshaft timing belt pulley
Fig. 3-6-49 Timing marks
9) With 4 marks aligned, install timing belt on
two pulleys in such a way that drive side of
belt is free from any slack, and with tensio-
ner plate pushed up by finger.
NOTE:
In this state, No.4 piston is at top dead center
of compression stroke.
NOTE:
When installing timing belt, match arrow mark
(+I on timing belt with rotating direction of
crankshaft.
10)To allow belt to be free of any slack, turn
crankshaft clockwise fully twice after install-
ing belt. After removing belt slack, tighten
tensioner stud first and then tensioner bolt
to 24 - 30 N.m (2.4 - 3.0 kg-m, 17,5 -
21.5 lb-ft).
Then confirm again that 4 marks are match-
ed.9-12 N-m
3. Tensioner plate
Fig. 3-6-51Tensioner bolt and nut
11) Install timing belt outside cover.
Tightening torque
for outside coverN.mkmlb-ft
bolts and nuts9- 120.9 - 1.27.0 - 8.5
Crankshaft Pulley, Water Pump Pulley and
Alternator
1) Install crankshaft pulley.
Fit keyway on pulley to key of crankshaft
timing belt pulley, and tighten 4 bolts to
specification, with flywheel holder (special
tool 09924-17810) hitched to flywheel so
that crankshaft will not turn.
Tightening torque N.mkg-mlb-ft
for pulley boltslo- 13 1.3 7.5-9.0*
Direction of crankshaft1. Drive side of belt
Fig. 3-6-50 Installing timing belt
3-50

-1. Key
‘32. Crankshaft pulley3. Pulley bolt
Fig. 3-6-52 Installing crankshaft pulley
2) Install alternator assembly.
Tighten alternator ass’y securing bolts (3pcs)
only to the extent to allow alternator to be
moved by hand. Don’t torque them tight.
NOTE:
Adjust water pump belt tension to specification
upon completion of installing engine ass’y to
body and then cooling fan and water pump
pulley. Make sure to refer to p. 1-5 of this
manual for adjusting procedure.
Distributor Case
1) Install distributor case O-ring to cylinder
head.
2) Install distributor case.
3) Tighten bolts to specified torque.
Tightening torque N.mkg-mlb-ft
forcasebolts8-120.8-1.26.0-8.5
Fig. 3-6-53
Fuel Pump
Install fuel pump rod, gasket and fuel pump to
cylinder head.
Apply engine oil to rod @ before installation.
Use new gasket.
Fig. 3-6-54 Fuel pump rod installation
case with about 3Occ (1.02/1.05 US/Imp
3-51

Clutch Disc and Cover?
Install clutch disc and cover.
For installation, refer to p. 11-7 of SECTION 11
CLUTCH in this manual and torque each bolt to
specification.
Transmission Assembly
1) Check to make sure that 2 pins @ are
fitted to cylinder block.
Fig. 3-6-55
2) Attach transmission assembly to engine
cylinder block and tighten bolts and nuts to
specified torque.
Tightening torque ~.mkg-mI b-ftfor transmission,.aSe bolts an,-j nutS22 - 352.2 - 3.5 16.0-25.0
Distributor
1) Install distributor to case.
For installation, besure to refer to SECTION
8 IGNITION SYSTEM in this manual.
Valve Lash (Clearance) Adjustment
Adjust valve lash of all intake and exhaust
valves to specification, referring to description
on valve lash on p. 3-53 of this manual.
Cylinder Head Cover
Install cover to cylinder head and tighten
bolts to specified torque.
NOTE:
Check and adjust ignition timing with engine
installed to car body and after installing and
connecting all necessary parts. For procedure,
refer to p. 8-9 of SECTION 8 IGNITION SYS-
TEM in this manual.
3-52

3-7. ENGINE INSTALLATION
1) Lower engine with transmission into vehicle,
but do not remove lifting device.
2) Tighten engine mounting bracket bolts
(right and left) and transmission mounting
bolts to specification. Refer to p. 3-58.
3) Remove lifting device.
4) Reverse removal procedures for installation
of remainder.
5) Adjust accelerator cable play and clutch
cable play.
6) Connect vacuum hoses securely. Refer to
section 5 “EMISSION CONTROL SYSTEM”
for correct connection.
7) Connect wire harnesses and couplers secure-
IY.
8) Tighten bolts and nuts to specified torque.
For individual specification, refer to each
section.
9) Fill specified amount of specified trans-
mission oil and engine oil. For the detail,
refer to SECTION 1 PERIODIC MAINTE-
NANCE SERVICE of this manual.
10) After adjusting water pump belt tension to
specification, fill specified amount of engine
cooling water.
11) Before starting engine, check again to ensure
that all parts once disassembled or discon-
nected are back in place securely.
12)Start engine and check ignition timing. If
it is not to specified timing, adjust it, referr-
ing to SECTION 8 of this manual.
13) After engine is started, check for oil leak,
abnormal noise and other malcondition.
Also, check each part for operation.
3-8. ENGINE MAINTENANCE SERVICE
Fan Belt
Adjust belt tension as outlined in SECTION 6
ENGINE COOLING SYSTEM (p. 6-10).
Ignition Timing
Refer to IGNITION TIMING, Page 8-9.
Carburetor
fidjustments to be made are detailed in SEC-
TION 4 (p. 4-19).
Valve Lash (Clearance)
Valve lash specifications:
Valve lash refers to gap between rocker arm
adjusting screw and valve stem. Use a thickness
gauge to measure this gap @.
When coldWhen hot(Coolant tempe-(Coolant tempa-
Valve lashrature is 15 - 25%rature is 60 - 66’C
(gap A)or 69 - 77’F)or 140 - 154’F)
specif i-0.13 - 0.17 mm0.23 - 0.27 mmcationIntake(0.0051 - 0.0067 in) (0.009 - 0.011 in)
Exhaust0.16 -0.20 mm0.26 - 0.30 mm(0.0063 - 0.0079 in) (0.0102 - 0.0116 in)
Screw lock nut 15 - 19 N.m(1.5 - 1.9 kg-m, 11 .O - 13.5 lb-ft)
Adjusting screw
8
Valve stem
Fig. 3-8-l
Checking and adjusting procedures:
NOTE:
l Refer to Fig. 3-3-11 of SECTION 3 for
cylinder numbers (No. 1, No. 2, No. 3 and
No. 4) mentioned in this section.
l When adjustment becomes necessary in step
4), loosen adjusting screw lock nut and then
make adjustment by turning adjusting screw.
After adjustment, tighten lock nut to specifi-
ed torque while holding adjusting screw
stationary with straight headed screwdriver,
and then make sure again that gap @ is
within specification.
3-53