SUZUKI GRAND VITARA 1987 Service Repair Manual

1) Remove cylinder head cover.
2) Remove ignitiontiming check window
rubber plug from clutch housing of trans-
mission case.
3)Turn crankshaft clockwise (viewing from
crankshaft pulley side) to the extent that
line @above “T” mark punched on fly-
wheel is aligned with match mark @ on
transmission case as shown below, i.e. No. 1
cylinder piston reaches TDC position.
Fig. 3-8-2 1. Match mark2. ‘7” (TDC) mark
4) Remove distributor cap and check that rotor
is positioned as shown in figure. If rotor is
out of place, turn crankshaft clockwise
once (360”). In this state, check valve lashes
at valves @,@I, @and 0. Rotate cran kshaft
exactly one turn, and check the same at
valves 8, @, @ and @I.
Fig. 3-8-3
EX
Fig. 3-8-4-
Fig. 3-8-5 Measuring valve lashes
5) Upon completion of check and adjustment,
install cylinder head cover and torque bolts
to specification.
Tightening torque N.,.,.,
for cylinder head Ib-mlb-ft
cover bolts4-50.4 - 0.53.0 - 3.5*
6) Install distributor cap and connect blow-by
gas hose to cylinder head cover.
Camshaft Timing Belt
For checking procedures of damage, wear and
tension of camshaft timing belt, refer to SEC-
TION 1 (p. 1-5) of this manual.
Engine Oil
Refer to SECTION 1 (p. I-7) of this manual.
Engine Oil Filter
For removal and installation of filter, refer to
SECTION 1 (p. I-7) of this manual.
3-54

Engine Coolant
This subject is covered in SECTION 6 ENGINE
COOLING SYSTEM.
Exhaust Line and Muffler
Inspect each exhaust line connection for tight-
ness, and examine muffler and other parts for
evidence of breakage and leakage of gases.
Repair or replace defective parts, if any.
Compression Pressure Measurement
Check compression pressure on all four cylinders
as follows:
1) Warm up engine.
2) Stop engine after warming up.
3) Remove all spark plugs and disconnect
high tension cord from ignition coil.
4) Install compression gauge (special tool) into
spark plug hole.
5) Disengage clutch (to lighten starting load on
engine), and depress accelerator pedal all
the way to make throttle full-open.
6) Crank engine with fully charged battery, and
read the highest pressure on compression
gauge.
Standard
Limit
Max. difference
between any two
cylinders
Compression pressure
14.0 kg/cm2 (199.0 psi)
400 r/min
12.0 kg/cm2 (170.0 psi)
400 r/min
1 .O kg/cm2 (14.2 psi),
400 r/min
3
7) Carry out steps 4) through 6) on each cylin-
der to obtain four readings.
NOTE:
Compression pressure value is measured by using
compression gauge (Special tool 09915-64510).
Oil Pump Discharge Pressure Measurement
NOTE:
Prior to checking oil pressure, check the follow-
ing.
l Oil level in oil pan.
If level is low, add oil up to Full level hole on
oil level gauge.
0 Oil quality.
If oil is discolored, or deteriorated, change oil.
For particular oil to be used, refer to table on
p l-8 of SECTION 1.
l Oil leak.
If leak is found, repair it
1. Compression gauge (Special tool 09915-64510)
Fig. 3-8-7 Installing compression gauge
3-55

1) Disconnect lead wire from oil pressure
switch.
2) Remove oil pressure switch from cylinder
block.
6) After checking oil pressure, stop engine and
remove oil pressure gauge.
7) Before reinstalling oil pressure switch, be
sure to wrap its screw threads with sealing
tape and tighten switch to specified torque.
NOTE:
l If sealing tape edge is bulged out from screw
threads of switch, cut off edge.
8) After installing oil pressure switch, start
engine and check switch for oil leakage.
Fig. 3-8-8 Oil pressure switch
3) Install oil pressure gauge (special tool)
to vacated threaded hole.
Vacuum Measurement
Engine vacuum that develops in intake line is a
good indicator of engine condition. Vacuum
checking procedure is as follows:
1.Oil pressure gauge k+ecial tool O!Xil5-77310)
Fig. 3-8-9 Oil pressure gauge installation
4)Start engine and warm it up to normal
operating temperature.
5) After warming up, raise engine speed to
3,000 r/min and measure oil pressure.
Oil pressure
specification
3.0-4.2 kg/cm2
42.7 59.7 psi-
at 3,000
1) Warm up engine to normal operating tempe-
rature.
2) Install vacuum gauge @ (09915-67310), as
shown in Fig. 3-8-10. Install engine tacho-
meter.
Fig. 3-8- 10
3-56

3) Run engine at specified idling speed and,
under this running condition, read vacuum
gauge. Vacuum should not be lower than
45 cm Hg (17.7 in. Hg).
A low vacuum reading means that any combi-
nation of following malconditions is the cause,
which must be corrected before releasing
machine to customer:
Oil Filler Cap
The cap has a packing. Be sure that packing is in
good condition, free of any damage and signs of
deterioration, and is tight In place: it is replacea-
ble.
(a) Leaky cylinder head gasket
(b) Leaky inlet manifold gasket
(c) Leaky valves
(d) Weakened valve springs
(e) Maladjusted valve clearance
(f) Valve timing out of adjustment
(g) Ignition mistimed
(h) Carburetor improperly adjusted
NOTE:
Should indicating hand of the vacuum gauge
oscillate violently, turn adjusting nut @I to
steady it
4
Standard vacuum45- 55cm Hg
(sea level)(17.7 - 21.6 in. Hg)
Idling speedBOO f 50 r/min (rpm)
specification(Take vacuum reading
at this speed.)L
4) After checking, remove vacuum gauge.
5) Before reinstalling vacuum checking plug,
be sure to wrap its screw threads with
sealing tape and tighten plug.
3-57

3-9. RECOMMENDED TORQUE SPECIFICATIONS
Fastening partsN-m
Tightening torque
kg-mlb-ft
1. Cylinder head bolt1 63-7016.3 - 7.01 46.0 - 50.5
2.Cylinder head cover bolt4-50.4-0.53.0-3.5
3.Spark plug20-302.0-3.014.5-21.5
4.Distributor gear case8-120.8-1.26.0-8.5
5.Rocker arm shaft screwI9- 12I 0.9-1.21 7.0-8.5
6.Valve adjusting screw lock nut
7. Crankshaft main bearing cap bolt
8. Oil filter stand
I15- 191 1.5-1.9I ll.O- 13.5
1 50- 5715.0 - 5.7136.5 - 41 .O
I20-25 -. 12.0 - 2.51 14.5 - 18.0
9.Oilfilter Ass’y12-161.2-1.69.0-11.5
10.Oilpressure switch12-151.2-1.59.0-10.5
11. Oil drain plugI30-40I3.0 - 4.0122.0 - 28.5
12. Oil pan bolt and nutI9- 12I0.9 - 1.2I7.0 - 8.5
13. Oil pump strainer bolt
14. Water pump bolt and nut
I9- 12I0.9 - 1.2I7.0 - 8.5
I9-12I0.9 - 1.2I7.0 - 8.5
15. Cooling fan nutI8- 121 0.8- 1.21 6.0-8.5
16. Flywheel boltI57 - 65I5.7 - 6.5I 41.5-47.0
17. Oil seal housing boltI9- 12I0.9 - 1.2I7.0 - 8.5
18.Connecting rod bearing cap nut1 33-37( 3.3-3.71 24.0 - 26.5
19. Crankshaft pully boltIlo- 13I1.0 - 1.3I7.5 - 9.0
20. Crankshaft timing belt pulley bolt
21.Timing belt cover bolt and nut
I65 - 75I6.5 - 7.51 47.5- 54.0
I9- 12I 0.9- 1.21 7-O-8.5
22. Camshaft timing pully boltI56 - 6415.6 - 6.4141 .O - 46.0III
23.Timingbelttensionbolt24-302.4-3.0117.5-21.5
24. Timing belt tensioner studI9- 12I0.9 - 1.2I7.0 - 8.5
25. Oil pump case boltI‘9- 12I 0.9- 1.21 7.0-8.5
26. Oil pump rotor plate screwI9- 12I 0.9-1.21 7-O-8.5
27.Inlet & exhaust manifold nutI18-281 1.8-2.8I13.5 - 20.0
28. Fuel pump nutIlo- 161 1.0-1.6I 7.0- 11.5
29. Engine mounting bracket frame side bolt 140 - 60I ~~~4.0 - 6.0129.0 - 43.0
30.Engine mounting bracket engine side bolt I50 - 601 5.0-6.0136.5 - 43.0
31. Engine mounting nutI40-50I4.0 - 5.01 29.0 - 36.0I1I
32.Transmissionmountingbracketbolt18-281.8-2.8113.5-20.0
33.Transmission mounting bolt18-281.8-2.813.5 -20.0
34.Transmission mounting and framebolt18-281.8-2.813.5 -20.0
35.Propeller shaft flange bolt and nut23 - 302.3-3.017.0-21.5
NOTE: If specified tightening torque for particular bolt or nut is not included here, refer to p O-12 of
this manual.
3-58

SECTION 4
FUEL SYSTEM
CONTENTS
4-1.CARBURETOR.............................................4-2
GENERAL DESCRIPTION.................................4-2
REMOVAL AND INSTALLATION...........................4-12
UNIT REPAIR OVERHAUL...............................4-13
MAINTENANCE SERVICES...............................4-19
4-2.AIR CLEANER...........................................4-29
GENERAL DESCRIPTION.................................4-29
MAINTENANCE SERVICES...............................4-29
4-3.FUEL PUMP, FILTER AND LINES...........................4-31
GENERAL DESCRIPTION.................................4-31
REMOVAL AND INSTALLATION...........................4-33
MAINTENANCE SERVICES...............................4-35
4-4.ACCELERATOR PEDAL...................................4-36
CAUTION:
THE ENGINE OF THIS VEHICLE REQUIRED THE USE OF UNLEADED FUEL ONLY.
USE OF LEADED AND/OR LOW LEAD FUEL CAN RESULT IN ENGINE DAMAGE AND RE-
DUCE THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEMS.
4-1
4

4-1. CARBURETOR
GENERAL DESCRIPTION
General
This 2-barrel downdraft type carburetor has
primary and secondary systems.
The primary system operates under normal
driving condition,and the secondary system
operates under high speed-high load driving
condition. The choke valve is provided in the
primary system.
The main components and their functions are as
follows.
The primary system has; (1) a mixture control
solenoid valve which is operated by the electri-
cal signals from the Electronic Control
Module (ECM) so as to maintain the optimum
air fuel ratio of the primary slow and the pri-
mary main systems at all times, (2) a fuel cut
solenoid valve which is for the fuel cut under
deceleration and prevention of the dieseling,
and (3) an acceleration pump system.
The secondary system has a secondary diaph-
ragm which is operated by the vacuum from
the primary side and actuates the secondary
throttle valve.
The choke system is a full automatic type
using a thermo-wax.
The switch vent solenoid valve provided on
top of the float chamber is to reduce the
evaporative emissions.
1.Air horn
2.Float chamber
3.Throttle chamber
4.Pump boot5.Pump lever
6.Pump rod
7.Bracket
8.screw
9.Therm0 element holder
10.Seal
11.Therm0 element
12.Choke piston
13.Delay valve
14.Switch vent solenoid
15.Vacuum switching valve
16.3 way joint
17.Vacuum transmitting valve
16.Primary slow air No. 1 bleeder
19.Secondary slow air bleeder
20.Mixture control solenoid valve
21.Solenoid valve seal
22.Needle valve filter
23.Needle valve gasket
24.Needle valve
25.Float
26.Air horn gasket
27.Connector (5 terminal)
28.Connector (4 terminal)
29.Connector (1 terminal)
30. injector weight
31.Injector spring
32.Injector weight
33.
34.Primary slow air No. 2 bleeder
35.Primary slow jet
36.Primary main air bleeder
37.Secondary main air bleeder
38.Spring
39.Secondary slow jet
40.Idle micro switch
41.Wide open micro switch
42.Idle up actuator43.Solenoid valve (Fuel cut)
44.Washer
45.Level gauge seal
46.Level gauge
47.Level gauge gasket
48.Micro switch bracket
49.Primary main jet
60.Secondary main jet
51.Drain plug gasket
52,Drain plug
53. Float pin54. Insulator56. Secondary actuator (diaphragm)
4-2
ball

r-al?
I29
Fig. 4-1-1 Carburetor exploded view
4-3

N
Fig. 4- l-2 Carburetor cross-section
4-4

Float System
The float system consists of a float chamber, a
float, a float needle valve and seat, and needle
valve filter. Fuel from the fuel pump enters the
float chamber, passing through the needle valve
filter and the needle valve.
The float’s function is to maintain a constant
level in the chamber.
As the fuel level in the chamber drops, the float
and the needle valve drops down allowing the
fuel to enter the chamber. As the fuel enters
the chamber, the float and the needle valve
again rise to close the fuel inlet.
A constant fuel level in the chamber is maintain-.ed through the repetition of this cycle.
1. Float
2. From fuel pump3. Needle valve filter
4. Needle valve seat
5. Needle valve
Fig. 4- 1-3 Float system
4-5