water pump SUZUKI GRAND VITARA 1987 Service Repair Manual

1-2. ENGINE AND EMISSION CONTROL
1. WATER PUMP BELT INSPECTION
AND REPLACEMENT
[INSPECTION]
1) Disconnect negative battery lead at battery.
2) Inspect belt for cracks, cuts, deformation,
wear and cleanliness. If any defect, replace.
Check belt for tension. The belt is in’ proper
tension if it deflects 6 to 9 mm (0.24 - 0.35
in.) under thumb pressure (about 10 kg or
22 lb.)..
Belt tension6 - 9 mm (0.24 - 0.35 in.)
specificationas deflection
pulley
3) If the belt is too tight or too loose, adjust it
to specification by adjusting alternator
position.
4) Tighten alternator adjusting bolt and pivot
bolts.
5) Connect negative battery lead to battery.
[REPLACEMENT]
1) Disconnect negative battery lead at battery.
2) Loosen alternator adjusting bolt and pivot
bolts.
3) Replace water pump belt.
4) Adjust belt tension to specification and
tighten alternator adjusting bolt and pivot
bolts.
5) Connect negative battery lead to battery.
2. CAMSHAFT TIMING BELT INSPECTION
1) Disconnect negative battery lead at battery.
2) Loosen fan drive belt, and remove 4 bolts
securing radiator shroud panel and 4 nuts
securing engine cooling fan & clutch. Then
remove radiator shroud and cooling fan &
clutch at the same time.
3) Remove water pump belt and pump pulley.
4) Remove crankshaft pulley by removing 4
pulley bolts. The crankshaft timing belt
pulley bolt at the center need not be loosen-
ed.2 1
‘31. Key
2. Crankshaft pulley
3. Pulley bolt
1-5

5) Remove timing belt outside cover. Inspect
the belt for damage or wear. When any
damage or wear is found on the belt, replace
it.
If belt replacement is necessary, be sure to
install the belt properly.
6) Remove cylinder head cover and loosen all
valve adjusting screws all the way to permit
free rotation of camshaft.
7) Turn crankshaft clockwise and align 4 marks
as shown.
Loosen tensioner bolt and nut but do not
remove.
9) Adjust valve lash to specification.
10) Install cylinder head cover and torque bolt
to specification.
11) Install timing belt outside cover and torque
bolts and nut to specification.
12) Install crankshaft pulley and torque bolts to
specification.
13) Install water pump pulley and belt.
14) Install radiator shroud and cooling fan &
clutch.
15) Adjust water pump belt tension to specifica-
tion.
16) Connect negative battery lead to battery.
3. VALVE LASH INSPECTION
1) Remove cylinder head cover.
2) Inspect intake and exhaust valve lash and
adjust as necessary.
1.“V” mark5.Tensioner nut
2.Timing mark6.Tensioner bolt
3.Arrow mark7.Turning direction4.Punch mark
8) To allow belt to be free of any slack, turn
crankshaft clockwise fully twice. After remov-
ing belt slack, tighten tensioner nut to 9 - 12
N-m (0.9- 1.2 kg-m, 7.0 - 8.5 lb-ft) 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.
Valvelash specifi-cation
When coldWhen hot(Coolant tempe-(Coolant tempe---rature is 15 - 25’Crature is 60-68 c or 59 - or 140-154 f)
0.13-0.17mm 0.23-0.27mmIntake(0.0051- 0.0067 in)(0.009 - 0.011 in)
0.16-0.20 mm0.26 -0.30 mm(0.0102- Exhaust (0.0063 - 0.0079 in) 0.0118 in)
Screw lock nut 15 - 19 N.m
Adjusting screw
Valve ste
.5 lb-ft)
3) Install cylinder head cover and tighten bolts
to specification.
l-6

9
Cond it ionPossible causeCorrection
OverheatingAbnormal condition in ignition system
1. Improper ignition timingAdjust
2. Wrong heat value of spark plugsChange heat value
Abnormal condition in fuel systems
1. Float level set too lowAdjust
2. Clogged jets in carburetorClean
3. Loose inlet manifoldRetighten
Abnormal condition in cooling system,,
1. Not enough coolantRefill
2. Loose or broken fan beltAdjust or replace
3. Erratically working thermostatReplace
4. Poor water pump performanceReplace
5. Leaky radiator coresRepair or replace
Abnormal condition in lubrication system
1. Clogged oil filterReplace
2. Clogged oil strainerClean
3. Deteriorated oil pump performanceReplace
4. Oil leakage from oil pan or pumpRepair
5. Improper engine oil gradeReplace with proper grade
oil
6. Not enough oil in oil panReplenish
Others
1. Dragging brakesRepair or replace
2. Slipping clutchAdjust or replace
3. Blown cylinder head gasketReplace
Engine noiseCrankshaft noise
Note: Before check- 1. Worn-down bearings, resulting in excessivelyReplace
ing the mechanicallarge running clearances
noise, make sure that:2. Worn connecting-rod bearingsReplace
0 Ignition timing is3. Distorted connecting rodsRepair or replace
properly adjusted.4. Worn crankshaft journalsRepair by grinding, or re-
l Specified spark plugplace crankshaft
is used.5. Worn crankpins.Repair by grinding, or re-
l Specified fuel is used.place crankshaft
Noise due to pistons, rings, pins or cylinders
1. Abnormally worn cylinder boresRebore to next oversize
or replace
2. Worn pistons, rings or pinsReplace
3. Pistons tending to seizeReplace
4. Broken piston ringsReplace
, Others
1’. Excessively large camshaft thrust playReplace
2. Excessively large crankshaft thrust clearanceAdjust as prescribed
3. Valve clearance too largeAdjust as prescribed
4. Not enough engine oilReplenish
2-7

3-2. ENGINE SERVICES NOT REQUIRING ENGINE REMOVAL
The following parts of components do not require engine removal to receive services (replacement, inspec-
tion or adjustment):
Part or ComponentNature of Service1
1. Spark plug
2. Distributor
Replacement or inspection
Replacement, inspection or adjustment
1 3. Exhaust manifold1 Replacement or inspectionI
I 4. Oil filter1 ReplacementI
1 5. Oil pressure unit( Replacement
6. Cylinder head cover1 ReplacementI
I7. Rocker shaft1 Replacement or inspectionI
8. Rocker-arm
9. Rocker-arm spring
Replacement or inspection
Replacement or inspectionI
10. Cam shaft
11 Cylinder head
I12. Radiator
Replacement or inspection (Cylinder head removal required)
Replacement or inspection
Replacement or inspection (Cooling fan and fan shroud
removal required)I
13. Cooling fan
14. Camshaft timing belt pulley
Replacement
Replacement or inspection
I
15. Crankshaft timing belt pulley
16. Timing beltReplacement or inspection (Cooling fan and fan shroud
1 Replacement or inspection
removal required)
17. Fuel pump
18. Carburetor
Replacement
Replacement, inspection or adiustment
19. Intake manifold1 ReplacementI
20. Alternator
21. Starter motor
Replacement or inspection
22. Fan belt
23. Water pump
Replacement, inspection or tension adjustment
Replacement (Cooling fan and fan shroud removal required)
24.Pulleys (crank, generator, fan)Replacement
25. Timing belt cover)Replacement (Cooling fan and fan shroud removal required)
26. Water hose
27. Oil pan, oil strainer, and oil pump
Replacement or inspection
Replacement or inspection
28. Piston and connecting rodReplacement or inspection (Cylinder head and oil pan
removal required)
Replacement or inspection
3-5

3-3. ENGINE REMOVAL
1) Disconnect negative (-) and positive (+)
cords from battery terminals.
‘)From starter motor terminals, disconnect
black/yellow lead wire and positive (+)
battery cord.
Disconnect coupler and white lead wire
from alternator terminals.
Disconnect lead wires from water tempera-
ture gauge and thermal switch. The gauge
and switch are on intake manifold.
Disconnect earth lead wire from intake
manifold.
5) Disconnect couplers of carburetor fuel cut
solenoid valve, vent solenoid valve and
mixture control solenoid valve, and dis-
connect couplers from TWSVS and VSV.
6) Remove warm air hose.
) Disconnect breather hose from air cleaner
case.
,) Remove air intake case from carburetor
body and air inlet hose.
1) Disconnect accelerator cable from carbure-
tor.
10) Disconnect vacuum hoses of TCAC and
canister from intake manifold.
11) Remove fuel tank filler cap to release fuel
vapor pressure in fuel tank. After releasing,
reinstall it. Disconnect fuel feed and return
hoses from fuel pump.
12) Disconnect lead wire from oil pressure unit
terminal and oxygen sensor lead wire at the
coupler.
13) Disconnect lead wires of back-up light
switch and fifth switch at their couplers.
14) Disconnect distributor lead wire at the
coupler.
15) Pull off high-tension cord from ignition coil.
16) Loosen radiator drain plug to drain cooling
water,
17) Disconnect water hoses from thermostat
cap and water inlet pipe. After removing
cooling fan & clutch and fan shroud, remove
radiator.
Fig. 3-3- 1
Fig. 3-3-2
16) Disconnect heater hoses from heater unit
outlet pipe and intake manifold.
Fig. 3-3-3
3)
4)
3-6

6) Take down alternator and water pump
pulley.
Fig. 3-4,9 (A) Flywheel holder (Special tool
09924-17810)
Fig. 3-4-6
8) Remove outside cover on timing belt.
Fig. 3-4-7
7) Remove crankshaft pulley by removing 49) Loosen tensioner bolt and stud, and remove
pulley bolts, with special tool (A) hitched tobelt from crank timing belt pulley and cam-
flywheel so that crankshaft will not turn.shaft pulley after pushing up tensioner
The crank timing belt pulley bolt at theplate fully by finger as shown in Figure
center needs not to be loosened.3-4-l 1.
1.Crankshaft pulley
Fig. 3-4-8
2. Crankshaft pulley bolt
3.Crank timing belt pulley bolt
Fig. 3-4- 10
1.Timing belt2.Tensioner plate
3.Tensioner boltFig.3-4-114.Tensioner stud
3-10

10) Remove timing belt tensioner, tensioner
plate, and tensioner spring.
11) Remove camshaft timing belt pulley by lock-
ing camshaft (insert general rod into the cam-
shaft hole) as shown below.
13) Remove crankshaft timing belt pulley key.
14) Remove timing belt inside cover.
Fig. 3-4- 14
15) Remove water pump.
1.Wrench2.Camshaft timing belt pulley
3. Timing belt inside cover4.Generalrod
Fig.3412
12) Using flywheel holder (A) (Special tool),
remove crankshaft timing belt pulley bolt,
pulley and timing belt guide with crank-
shaft locked.
Fig. 3-4- 15
16) Remove exhaust manifold cover.
17) Take off exhaust manifold and its gasket.
Fig. 3-4-13
1.Crankshaft timing belt pulley2. Pulley bolt3. Timing belt guide
Fig. 3-4- 16
3-11

18) Using special tool (C), remove oil filter.
NOTE:
Be careful not to spill oil when removing filter.
22) Remove water inlet pipe.
Fig. 3-4- 17 (C) Oil filter wrench (099 15-473 10)
19) Draw water hoses off water pump inlet pipe.
Fig. 3-4-2 1
Fig. 3-4- 18
20) Disconnect PCV (Positive crankcase venti-
lation valve) hose from cylinder head cover.
21) Take down intake manifold with carburetor.
Fig. 3-4120
23) Take off cylinder head cover.
24) Loosen 8 valve adjusting screws fully. Leave
screws in place.
Fig. 3-4-22
3-12

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

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