manual transmission SUZUKI GRAND VITARA 1987 Service Repair Manual

32) Lower vehicle and remove 4 bolts securing
right and left engine mounting brackets(body side).
Fig. 3-3-10
Fig. 3-3-8
CAUTION:Before lifting engine and transmission,
recheck to ascertain all hoses, electric wires
and cables are disconnected from engine
and transmission.
34) Remove clutch lower plate.
35) Separate transmission from engine.
Throughout this MANUAL, 4 cylinders ofengine are identified by numbers: No. 1, No. 2, No. 3 and No. 4 as counted from front end.
33) Take down engine by operating a hoisting
means.
Fig. 3-3-11
Fig. 3-3-9
3-8

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

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

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

Clutch Release Shaft Fork
Apply grease to end of fork.
Fig. I l- 16 @ Grease (SUZUKI SUPER
GREASE “‘A “)
Clutch Release Arm
Align two punch marks when installing clutch
release arm on clutch release shaft.
Fig. 11-17
Clutch Release Shaft Bushes
For reinstallation of bushes, refer to p. 13-5 in
SECTION 13 TRANSMISSION of this manual.
Transmission
For remounting transmission, refer to p. 13-4 in
SECTION 13 TRANSMISSION of this manual
and reverse dismounting procedure.
11-5. MAINTENANCE SERVICES
Clutch Pedal Height
Adjust height of clutch pedal with clutch pedal
stop bolt so that pedal is level with brake pedal.
Tighten lock nut after adjusting.
.
4
I-
I- 18
1. Clutch cable2. Lock nut3. Adjust bolt4. Clutch pedalFig. 1
Clutch Pedal Free Travel
1) Depress clutch pedal, stop the moment
clutch resistance is felt, and measure distance
(clutch pedal free travel). Free travel should
be within the following specification.
!Clutch pedal free travel20-30mm
(0.8 - 1.1 in.)c
Fig. 1
1. Clutch pedalfree travel
Before remounting transmission ass’y, apply
grease (SUZUKI SUPER GREASE I) to input
shaft. Refer to Fig. 13-84.
11-8

151. GENERAL DESCRIPTION
These automobiles, covered in this manual are four-wheel drive machines and, as such, use three propeller
shafts designated as No. 1, No. 2 and No. 3.
No, 1 propeller shaft transmits drive from the transmission to the transfer gear box. No. 2 shaft and No. 3
shaft extend from the transfer gear box, the former driving the front axle and the latter the rear axle.
The cross spider in each universal joint is fitted with four needle roller bearings.
From
TQ transfer
transmission casaTo transfar casa
Propeller shaft No. 2
To rear differential
To front differential
To transfer case
15-2
Fig. 15-1