ENGINE VACUUM CHECK Suzuki Grand Vitara II

ENGINE VACUUM CHECK

The engine vacuum that develops in the intake line is a good indicator of the condition of the engine. The vacuum checking procedure is as follows

Scheme 7

1. Warm up engine to normal operating temperature and make sure that engine idle speed is within specification.
2. Stop engine and disconnect vacuum hoses from fuel pressure regulator valve (1).
3. Connect special tools (Vacuum gauge and hose joint) and 3-way joint between vacuum hose and valve. Special Tool 09915-67311 09918-08210 09355-35754-600 Hose, SUZUKI genuine parts 09367-04002 3-way joint, SUZUKI genuine parts
4. Start engine and run engine at specified idle speed, and read vacuum gauge. Vacuum should be within specification. Vacuum specifications (sea level) 59-79 kPa (450-600 mm Hg, 17.7-23.7 in. Hg) at specified idle speed
5. After checking, remove, all special tools.
6. Connect vacuum hoses to fuel pressure regulator valve.

Scheme 8

1. Remove negative (-) cable at battery.
2. Remove cylinder head covers referring to «CYLINDER HEAD COVERS REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/mechanical/#engine-mechanical) .
3. Using 19 mm wrench, turn crankshaft pulley (1) clockwise until timing mark "O" position (2) of cylinder block and index (3) of crankshaft pulley (1) are aligned.
4. Check whether cam position (4) of No. 1 cylinder is at the specified position [A] as shown in figure. If cam position is [B], locate cam position to [A] by turning crankshaft one rotation.
5. Check valve lashes with thickness gauge (1) according to the following procedure. Check valve lashes of cylinder No. 1. Turn crankshaft pulley by 120° clockwise. Check valve lashes of cylinder No.6. In the same manner as b) - c), check valve lashes of cylinder No. 5, cylinder No. 4, cylinder No. 3 then cylinder No. 2.

If valve lash is out of specification, record valve lash and adjust it to specification by replacing shim.

Valve clearance specification

VALVE CLEARANCE SPECIFICATION

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

1. Close the valve whose shim (2) is to be replaced by turning crankshaft, then turn tappet (3) till its cut section (1) faces inside as shown in figure.
2. Lift down the valve by turning crankshaft to 360°.
3. Hold tappet at that position using special tool as follows. Remove its housing bolts. Check housing No. and select special tool corresponding to housing No. as below table. Special tool selection table CAMSHAFT HOUSING REFERENCE No. on camshaft housing Embossed mark on special tool I2. I3. I4. IN E2. E3. E4. EX Hold down the tappet so as not to contact the shim by installing special tool on camshaft housing with housing bolt (1) tighten housing bolts to specified torque. Special Tool 09916-66510 Tightening torque Camshaft housing bolts a: 11 N.m (1.1 kgf-m, 7.5 lb-ft) by the specified procedure
4. Turn camshaft by approximately 90° clockwise and remove shim (3). WARNING: Never put in the hand between camshaft and tappet.
5. Using a micrometer (2), measure the thickness of the removed shim (1), and determine replacement shim by calculating the thickness of new shim with the following formula and table. Shim thickness specification Intake side: A = B + C - 0.200 mm (0.008 in.) Exhaust side: A = B + C - 0.300 mm (0.012 in.) A: Thickness of new shim B: Thickness of removed shim C: Measured valve clearance For example of intake side: When thickness of removed shim is 2.400 mm (0.094 in.), and measured valve clearance is 0.450 mm (0.018 in.). A = 2.400 mm (0.094 in.) + 0.450 mm (0.018 in.) - 0.200 mm (0.008 in.) = 2.650 mm (0.104 in.) Calculated thickness of new shim = 2.650 mm (0.104 in.)
6. Select new shim No. (1) with a thickness as close as possible to calculated value. Available new shim No . SHIM THICKNESS SPECIFICATION Thickness mm (in.) Shim No. Thickness mm (in.) Shim No. 2.175 (0.0856) 218 2.600 (0.1024) 260 2.200 (0.0866) 220 2.625 (0.1033) 263 2.225 (0.0876) 223 2.650 (0.1043) 265 2.250 (0.0886) 225 2.675 (0.1053) 268 2.275 (0.0896) 228 2.700 (0.1063) 270 2.300 (0.0906) 230 2.725 (0.1073) 273 2.325 (0.0915) 233 2.750 (0.1083) 275 2.350 (0.0925) 235 2.775 (0.1093) 278 2.375 (0.0935) 238 2.800 (0.1102) 280 2.400 (0.0945) 240 2.825 (0.1112) 283 2.425 (0.0955) 243 2.850 (0.1122) 285 2.450 (0.0965) 245 2.875 (0.1132) 288 2.475 (0.0974) 248 2.900 (0.1142) 290 2.500 (0.0984) 250 2.925 (0.1152) 293 2.525 (0.0994) 253 2.950 (0.1161) 295 2.550 (0.1004) 255 2.975 (0.1171) 298 2.575 (0.1014) 258 3.000 (0.1181) 300
7. Install new shim facing shim No. side (1) with tappet.
8. Lift valve by turning crankshaft counterclockwise (in opposite direction against above Step 4 and remove special tool. Special Tool 09916-66510
9. Install camshaft housing (1) and tighten bolts to specified torque. Tightening torque Camshaft housing bolt a: 11 N.m (1.1 kg-m, 8.0 lb-ft)
10. Turn crankshaft pulley more than 4 rotations.
11. Check valve clearance again after adjusting it.
12. After checking and adjusting all valves.
13. Install cylinder head covers referring to «CYLINDER HEAD COVERS REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2005-2008/remont/mechanical/#engine-mechanical) .

Scheme 18

Scheme 19

1. Disconnect connector from MAF and IAT sensor.
2. Open air cleaner upper case (1) after unhooking its clamps (2).
3. Remove air cleaner filter.