Engine Mechanical (j24b) Suzuki Grand Vitara II рестайлинг

Engine Construction Description

The engine is water-cooled, in-line 4 cylinders, 4-stroke-cycle gasoline unit with its DOHC (Double Over Head Camshaft) valve mechanism arranged for "V" type valve configuration and has 16 valves (4 valves/one cylinder). The intake camshaft and exhaust camshaft are mounted over the cylinder head; They are driven by crankshaft through timing chain, and no push rod is provided in the valve train system.

IMT (Intake Manifold Tuning) System Description

The IMT (Intake manifold tuning) system consists of the following items.

1. IMT valve (1) included in the intake manifold (2)
2. IMT valve actuator (3) fixed on the intake manifold
3. IMT vacuum solenoid valve (4)
4. Vacuum tank (5)

The vacuum tank contains the one way check valve (6) to maintain negative pressure constantly regardless of variation in the intake manifold pressure.

There fore, the vacuum tank, supplies the IMT vacuum solenoid valve actuator with stable negative pressure in the whole of engine speed ranges.

Scheme 1

The IMT system varies effective length of the intake pipe by opening and closing the IMT valve (1) in order to improve air volumetric efficiency.

As the intake valve in the cylinder head is opened and closed repeatedly, intake air pulsation always exists. If the intake valve is opened when the air pressure is momentarily maximum in the intake manifold, the intake air volumetric efficiency is increased. This momentary maximum air pressure depends on the effective intake pipe length.

When the IMT valve is totally closed [A]

The effective intake pipe length is longer. The engine torque in the low engine speed range and the high engine speed range drops, however it is improved in the middle engine speed range.

When the IMT valve is fully open [B]

The effective intake pipe length is shorter. The engine torque in the low engine speed range and the high engine speed range are improved, however it drops in the middle engine speed range.

The IMT system utilizes above-mentioned characteristic of the engine torque. The IMT valve is closed in the middle engine speed range, and opened in the low engine speed range and the high engine speed range.

In this way, the engine torque is improved in the whole of engine speed range.

Scheme 2

Scheme 3

Cross-reference table between valve operation and intake pipe length

SOLENOID VALVE SPECIFICATION

Scheme 4

1. The IMRC (Intake Manifold Runner Control) system reduces fuel consumption and exhaust emission by producing the tumble air flow which makes A/F leaner when the engine is idling at low temperature.
2. The tumble air flow is generated by opening/closing the IMRC valve located between the intake manifold and the cylinder head.
3. The IMRC system consists of the following items. IMRC valve (1) IMRC valve actuator (2) (including in the IMRC valve motor and the IMRC valve position sensor)
4. The ECM drives the IMRC valve motor which is included in the IMRC valve actuator according to a vehicle speed, an engine speed, a coolant temperature and an accelerator pedal position.
5. When the IMRC valve (1) driving conditions are met, the ECM sends "closing" signal to the IMRC valve motor. The IMRC valve motor closes the IMRC valve to create the tumble air flow (2).
6. When the IMRC valve driving conditions are not met, The ECM sends "opening" signal to the IMRC valve motor. The IMRC valve motor opens the IMRC valve.
7. The ECM detects an IMRC valve position by a non-contact type IMRC valve position sensor.

IMRC valve closing condition

1. Vehicle speed: Stop
2. Engine speed: Idling speed
3. Engine coolant temperature: Low
4. Accelerator position: Fully released

Scheme 5

Scheme 6

1. Warm up engine to normal operating temperature.
2. Stop engine after warm-up.
3. For 4 A/T model, place select lever in "P" and apply parking brake. For 5 M/T model, place gear shift lever in "Neutral" and apply parking brake.
4. Remove engine cover.
5. Remove all ignition coils and spark plugs. See «SPARK PLUG REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-j24b) .
6. Disconnect all fuel injector connectors.
7. Install special tools into spark plug hole. Special Tool (A): 09915-64512 (B): 09915-64530 (C): 09915-67010
8. Depress accelerator pedal all the way to fully open throttle. NOTE: For 5 M/T model, disengage clutch to lighten starting load on engine, and depress accelerator pedal all the way to fully open throttle.
9. Crank engine with fully charged battery, and read the highest pressure on compression gauge. NOTE: For measuring compression pressure, crank engine at least 200 RPM by using fully charged battery. If measured compression pressure is lower than limit value, check installation condition of special tool. If the measured compression pressure of particular cylinder is lower than limit, add a bit of engine oil into the cylinder through the spark plug hole, and then repeat the compression check. If the compression pressure increases after adding engine oil, there is possibility of the following cause. The pressure leakage is caused by worn piston rings or worn cylinder. If the compression pressure does not increase significantly, there is possibility of the following causes. Incorrect valve timing. The pressure leakage is at the valves and the valve seats. The pressure leakage is at the cylinder head gasket. Compression pressure Standard: 1,400 kPa (14.3 kgf/cm 2 , 203 psi) Limit: 1,100 kPa (11.2 kgf/cm 2 , 160 psi) Max. difference between any two cylinders: 100 kPa (1.02 kgf/cm 2 , 14.5 psi)
10. Carry out Steps 7) through 9) on each cylinder.
11. Install spark plugs and ignition coil assemblies. See «SPARK PLUG REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-j24b) .
12. Connect fuel injector connectors.
13. Install engine cover.

Scheme 7

1. Warm up engine to normal operating temperature.
2. For 4 A/T model, place select lever in "P" and apply parking brake. For 5 M/T model, place gear shift lever in "Neutral" and apply parking brake.
3. Remove engine cover.
4. Remove PCV hose (1) from PCV valve (2).
5. Connect special tool to PCV hose (1). Special Tool (A): 09915-67311
6. Close PCV valve (2) using tape (3) or the like.
7. Start engine and turn off all electric loads.
8. Read vacuum gauge at specified idle speed. See «IDLE SPEED AND IAC THROTTLE VALVE OPENING INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/testing-diagnostics/#engine-general-information-and-diagnosis-j24b) . Vacuum specification (at sea level) Standard: -65 kPa (-0.66kgf/cm 2 , -9.43 psi, -0.65 bar) or less at specified idle speed
9. After checking, disconnect special tool from PCV valve.
10. Peel off tape from PCV hose.
11. Connect PCV hose to PCV valve.
12. Install engine cover.

Valve Clearance Inspection and Adjustment

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

Scheme 8

Scheme 9

1. Disconnect negative (-) cable from battery.
2. Remove cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__cylinder-head-cover-removal-and-installation) .
3. Remove engine under cover.
4. Align timing mark (3) on exhaust camshaft timing sprocket with match mark (2) on camshaft housing No. 1, by turning crankshaft pulley (1) clockwise with 19 mm wrench.
5. Measure valve clearances with thickness gauge according to the following procedures. Measure valve clearances of indicated valves "A" in figure. Turn crankshaft pulley 360° clockwise with 19 mm wrench. Measure valve clearances of indicated valves "B" in figure.

Scheme 10

If valve clearance is out of specification, record valve clearance and adjust it to specification.

Valve clearance specification

When cold (ECT: 15 - 25 °C (59 - 77 °F))

1. Intake: 0.16 - 0.24 mm (0.0063 - 0.0094 in.)
2. Exhaust: 0.31 - 0.39 mm (0.0123 - 0.0153 in.)

Scheme 11

1. Remove tappet to be replaced. See «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__camshaft-and-tappet-removal-and-installation) .
2. Select proper size of tappet as follows. Using a micrometer, measure the thickness of the removed tappet (1). Calculate the thickness of new tappet by formula below. NOTE: If the number at second places of decimal point A is odd number, use (A - 0.01) tappet. Intake side: A = B + C - 0.20 mm (0.0079 in.) Exhaust side: A = B + C - 0.35 mm (0.0138 in.) A: Thickness "a" of new tappet B: Thickness "a" of removed tappet C: Measured valve clearance Select new tappet closest to calculated value from available size as a spare part.
3. Install tappets and camshafts. See «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__camshaft-and-tappet-removal-and-installation) .
4. Recheck valve clearance.

Scheme 12

Air Cleaner Filter Removal and Installation

Reference: AIR CLEANER COMPONENTS

Scheme 13

1. Open air cleaner case (1) by unhooking its clamps (2).
2. Remove air cleaner filter from case.

Installation

Reference: AIR CLEANER FILTER INSPECTION AND CLEANING

Reverse removal procedure for installation.

Air Cleaner Filter Inspection and Cleaning

Reference: AIR CLEANER FILTER REMOVAL AND INSTALLATION

Inspection

Check air cleaner filter for dirt.

Replace excessively dirty filter.

Cleaning

Blow off dust by compressed air from air outlet side of filter.

Scheme 14

Air Cleaner Assembly Removal and Installation

Reference: AIR CLEANER COMPONENTS

Scheme 15

1. Disconnect negative (-) cable from battery.
2. Disconnect MAF and IAT sensor connector (1).
3. Remove water bypass pipe bolt (2).
4. Remove air cleaner outlet hose (3).
5. Remove air cleaner assembly (4).

Reverse removal procedure for installation.

Scheme 16

Throttle Body Assembly Removal and Installation

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Scheme 17

Scheme 18

1. Disconnect negative (-) cable from battery.
2. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-draining) .
3. Remove water bypass pipe bolt (2).
4. Remove air cleaner outlet hose (1).
5. Disconnect engine coolant hoses (2) and connector (3) from throttle body assembly (1).
6. Remove throttle body assembly and its gasket from intake manifold.

Reference: THROTTLE BODY CLEANING

Scheme 19

Scheme 20

1. Clean mating surfaces and install new throttle body gasket (1) to intake manifold.
2. Install throttle body assembly (1) to intake manifold.
3. Connect connector (3) and coolant hoses (2) to throttle body assembly (1).
4. Install air cleaner outlet hose. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation) .
5. Refill cooling system. See «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
6. Connect negative (-) cable to battery.
7. Check for coolant leaks. See «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Throttle Body Cleaning

Reference: THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION

Clean throttle body assembly according to "Throttle Valve Visual Check" under THROTTLE BODY ASSEMBLY ON-VEHICLE INSPECTION .

Intake Manifold Removal and Installation

Reference: THROTTLE BODY AND INTAKE MANIFOLD COMPONENTS

Scheme 21

Scheme 22

Scheme 23

1. Disconnect negative (-) cable from battery.
2. Remove engine cover.
3. Remove air cleaner outlet hose and air cleaner upper case. See «AIR CLEANER FILTER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-filter-removal-and-installation) .
4. Remove throttle body assembly. See «THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__throttle-body-assembly-removal-and-installation) .
5. Disconnect the following connectors and hoses. EVAP canister purge valve connector (1) IMT vacuum solenoid valve connector (2) Brake booster hose (3) PCV valve hose (4) Breather hose (5) Engine coolant hoses (6) Purge hose (7) IMRC valve actuator connector (8) A/T oil filler tube (4 A/T model): See «OIL COOLER HOSE AND PIPE COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) . Engine harness clamps Brake vacuum pipe. See «BRAKE BOOSTER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical-hydraulic/#brake-control-system-and-diagnosis) .
6. Remove intake manifold (1), intake manifold gasket (2), IMRC valve (3) and IMRC valve gasket (4) from cylinder head.

Reverse removal procedure for installation noting the following.

Scheme 24

1. Use new Intake manifold bolt for position (1) in figure, because it is not reusable.
2. Use New gaskets
3. Refill cooling system. See «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
4. Check for coolant leaks. See «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Scheme 25

Scheme 26

Scheme 27

1. When the engine is not running, make sure the IMT valve actuator (1) is at fully open position (2).
2. Check IMT valve actuator (1) according to the following procedure. Connect special tool to IMT valve actuator (1) and then vacuum it. CAUTION: Never apply excessive vacuum more than standard value. Special Tool (A): 09917-47011 Actuation vacuum specification Standard value: -33 kPa (-0.3 kgf/cm 2 , -4.79 psi, -0.33 bar) Check that IMT valve actuator sets valve to fully closed position, and keeps fully closed. With actuating valve to fully opened and closed positions several times, check that IMT valve actuator moves smoothly and properly. If any abnormality is found, replace intake manifold assembly. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__intake-manifold-removal-and-installation) .

Vacuum Tank and One-Way Check Valve Inspection

Check vacuum tank and one-way check valve according to the following procedure.

Scheme 28

1. Disconnect vacuum hose (1) from IMT vacuum solenoid valve and connect special tool to vacuum hose (1). Special Tool (A): 09915-67311
2. Run engine at specified idle speed and check that engine vacuum is standard value. See «ENGINE VACUUM CHECK»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
3. Stop engine and check that engine vacuum is held for longer than one minute.

If any abnormality is found, replace intake manifold assembly. See INTAKE MANIFOLD REMOVAL AND INSTALLATION .

Scheme 29

1. Disconnect negative (-) cable from battery.
2. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-draining) .
3. Remove exhaust manifold cover.
4. Remove engine block heater (1).

Reference: CYLINDER BLOCK HEATER INSPECTION (IF EQUIPPED)

Reverse removal procedure for installation noting the following.

Scheme 30

1. Use new cylinder block heater bolts.
2. Tighten cylinder block heater bolts (1) to specified torque. Tightening torque Cylinder block heater bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
3. Refill coolant. See «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
4. Check for coolant leaks. See «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Cylinder Block Heater Inspection (If equipped)

Reference: CYLINDER HEAD COVER REMOVAL AND INSTALLATION

Scheme 31

1. Check continuity between terminals "a" and "c". If there is no continuity, replace cylinder block heater. See «CYLINDER BLOCK HEATER REMOVAL AND INSTALLATION (IF EQUIPPED)»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
2. Check that there is no continuity between terminal "a" and "b". If there is continuity, replace engine block heater. See «CYLINDER BLOCK HEATER REMOVAL AND INSTALLATION (IF EQUIPPED)»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
3. Check continuity between terminal "b" and engine block heater body. If there is no continuity, replace engine block heater. See «CYLINDER BLOCK HEATER REMOVAL AND INSTALLATION (IF EQUIPPED)»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Scheme 32

Tightening Order/Removal and Installation figure callout references

CYLINDER HEAD COVER REMOVAL AND INSTALLATION

Cylinder Head Cover Removal and Installation

Reference: CYLINDER HEAD COVER COMPONENTS

Scheme 33

1. Disconnect negative (-) cable from battery.
2. Remove engine cover.
3. Remove ignition coil assemblies from cylinder head cover. See «IGNITION COIL ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-j24b) .
4. Disconnect PCV valve hose (1) and breather hose (2).
5. Detach engine harness clamps.
6. Loosen cylinder head cover bolts in numerical order ("1" - "16") evenly and gradually.
7. Remove cylinder head cover with its gasket.
8. Remove PCV valve if necessary.

Scheme 34

Scheme 35

Scheme 36

1. Install new cylinder head cover gasket (1) to cylinder head cover (2) as shown in figure.
2. Remove oil, old sealant, and dust from sealing surfaces on cylinder head and cover. After cleaning, apply sealant "A" to the designated area in figure. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G)
3. Install cylinder head cover to cylinder head. NOTE: When installing cylinder head cover, use care so that cylinder head cover gasket does not get out of place or fall off.
4. Tighten cylinder head cover bolts according to the following procedure. Tighten cylinder head cover bolts to 3.0 N.m (0.31 kgf-m, 2.5 lbf-ft) in numerical order ("1" - "16") evenly and gradually. In the same manner as Step a), retighten them to 5.0 N.m (0.51 kgf-m, 4.0 lbf-ft). In the same manner as Step a), retighten them to 7.5 N.m (0.76 kgf-m, 5.5 lbf-ft). Tightening torque Cylinder head cover bolt* (a): 3.0 N.m --> 5.0 N.m --> 7.5 N.m (0.31 kgf-m --> 0.51 kgf-m --> 0.76 kgf-m, 2.5 lbf-ft --> 4.0 lbf-ft --> 5.5 lbf-ft)
5. Connect PCV valve hose (1) to PCV valve and breather hose (2) to cylinder head cover.
6. Install ignition coil assemblies. See «IGNITION COIL ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-j24b) .
7. Install engine cover.
8. Connect negative (-) cable to battery.

Scheme 37

Tightening Order/Removal and Installation figure callout references

CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION

Camshaft and Tappet Removal and Installation

Reference: CAMSHAFT AND TAPPET COMPONENTS

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. Remove cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__cylinder-head-cover-removal-and-installation) .
2. Remove accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
3. Turn crankshaft clockwise with 19 mm wrench, and position piston No. 1 at TDC on the compression stroke according to the following procedure. Align the timing mark (1) on the CMP actuator and the timing mark (2) on the exhaust camshaft timing sprocket with the match marks (3) on the camshaft housing No. 1. Align notch (1) on the crankshaft pulley with "0" (2) on the timing chain cover.
4. Fix timing chain tensioner according to the following procedure. Remove timing chain cover plug (1) and gasket (2). Insert fore-end of special tool into timing chain tensioner hole (1) from timing chain cover plug hole. NOTE: Make sure that special tool is inserted in timing chain tensioner hole, with mirrors or the like. Special Tool (A): 09917-16510 Fix special tool by tightening bolt (2) to 8 N.m (0.82 kgf-m, 6.0 lbf-ft). CAUTION: Failure to observe the following cautions result it engine damage or incorrect installing of timing chain. Use bolt (2) of M6 size and 1.00 mm (0.039 in.) pitch. Be sure to tighten bolt (2) to 8 N.m (0.82 kgf-m, 6.0 lbf-ft). If bolt becomes loose, plunger of timing chain tensioner adjuster may extend, making it difficult to reinstall timing chain properly. Do not turn crankshaft after timing chain is fixed with special tool.
5. Apply a dab of paint to two timing chain links (2) which meet timing marks (1) on CMP actuator and exhaust camshaft timing sprocket.
6. Remove exhaust camshaft timing sprocket according to the following procedure. Hold hexagonal section of exhaust camshaft using wrench or the like. Loosen exhaust camshaft timing sprocket bolt and remove exhaust camshaft timing sprocket (1). CAUTION: Be careful not to drop dowel pin into the space between timing chain cover and cylinder block. It is not needed to remove CMP actuator at this procedure.
7. Remove dowel pin from exhaust camshaft.
8. Loosen camshaft housing bolts in numerical order ("1" - "21") evenly and gradually.
9. Remove intake camshaft and exhaust camshaft.
10. Remove camshaft bearings and tappets as necessary.
11. Remove CMP actuator from intake camshaft according to the following procedure if necessary. Hold hexagonal section of intake camshaft using vice. Loosen CMP actuator bolt and remove CMP actuator (1). CAUTION: Do not disassemble CMP actuator.

Reference: CAMSHAFT AND TAPPET INSPECTION

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

1. Install CMP actuator (1) to intake camshaft. Tightening torque CMP actuator bolt (a): 60 N.m (6.1 kg-m, 44.5 lbf-ft)
2. Apply engine oil to contact surface of tappets (arrow), and then Install tappets (1) to cylinder head.
3. Install camshaft bearings according to the following procedure. CAUTION: Camshaft upper bearing half (1) is different in shape from lower bearing half (2). Distinguish upper and lower bearing halves certainly when installing. Fit tab (1) of camshaft bearing to groove (2) of cylinder head or camshaft housing. Press camshaft bearing end (3) until it fully seats in cylinder head or camshaft housing. Apply engine oil to sliding surface (4) of camshaft bearing halves. CAUTION: Do not apply engine oil between bearing halves (5) and camshaft housing or cylinder head (5).
4. Apply engine oil to sliding surfaces of camshafts, and then install camshafts to cylinder head according to the following procedure. Align the timing chain link (2), which is painted in removal procedure under this information, with timing mark (1) on CMP actuator and install intake camshaft. Install exhaust camshaft and position dowel pin hole (3) of exhaust camshaft downward.
5. Install camshaft housings (1) to proper places distinguished by character (2), number (3) and arrow direction (4) on each camshaft housing.
6. Tighten camshaft housing bolts according to the following procedure. Apply engine oil to bolt thread and seat of camshaft housing bolts. Install camshaft housing No. 1 (1). Install camshaft housing bolts, and tighten them by hand. Tighten camshaft housing bolts in numerical order ("1" - "21") evenly and gradually. Tightening torque Camshaft housing bolt*: 11 N.m (1.1 kg-m, 8.5 lbf-ft)
7. Install dowel pin to exhaust camshaft. CAUTION: Be careful not to drop dowel pin into the space between timing chain cover and cylinder block.
8. Install exhaust camshaft timing sprocket (3) to exhaust camshaft according to the following procedure. Align timing chain link (1), which is painted in "removal" under this information, with timing mark (2) on exhaust camshaft timing sprocket (3), and loop timing chain up over exhaust camshaft timing sprocket. Install exhaust camshaft timing sprocket (3) with timing chain to the exhaust camshaft.
9. Tighten exhaust camshaft timing sprocket bolt (1) using special tool. Special Tool (A): 09911-05120 Tightening torque Exhaust camshaft timing sprocket bolt (a): 60 N.m (6.1 kg-m, 44.5 lbf-ft) CAUTION: In case of using extension special tool combined with torque wrench, reading value of torque wrench is smaller than actual value. When using extension special tool, reading value should be calculated according to formula below. Formula for reading value of torque wrench . M = T X L/(L + "a") M: Reading value using extension special tool T: Specified torque L: Torque wench length "a": Dimension of special tool
10. Confirm that painted timing chain links (1) are aligned with timing marks (2) on CMP actuator and exhaust camshaft timing sprocket.
11. Remove special tool from timing chain cover.
12. Install timing chain cover plug (1) with new gasket (2), and tighten it to specified torque. Tightening torque Timing chain cover plug (a): 27 N.m (2.8 kg-m, 20.0 lbf-ft)
13. Check that camshaft and timing chain are installed properly as follows. Check that timing mark (1) on CMP actuator and timing mark (2) on exhaust camshaft timing sprocket are aligned with match marks (3) on camshaft housing No. 1. Check that notch (1) on crankshaft pulley is aligned with "0" (2) on timing chain cover. Turn crankshaft clockwise twice and repeat Step a) and b). NOTE: Be sure to turn crankshaft fully twice. If it is once, timing marks on CMP actuator and exhaust camshaft timing sprockets do not meet match marks on camshaft housing No. 1. After turning crankshaft twice, the painted timing chain links are not aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but it is normal.
14. Check valve clearance. See «VALVE CLEARANCE INSPECTION AND ADJUSTMENT»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__valve-clearance-inspection-and-adjustment) .
15. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__cylinder-head-cover-removal-and-installation) .

Camshaft and Tappet Inspection

Reference: CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION

Cam Height

Using a micrometer, measure cam height "a". If measured height is out of standard values, replace camshaft.

Cam Height (IN)

Standard: 47.023 - 47.183 mm (1.8513 - 1.8576 in.)

Limit: 46.890 mm (1.8461 in.)

Cam Height (EX)

Standard: 46.543 - 46.703 mm (1.8324 - 1.8387 in.)

Limit: 46.420 mm (1.8276 in.)

Scheme 59

Camshaft Runout

Set camshaft between two "V" blocks and measure its runout using a dial gauge.

If measured camshaft runout exceeds limit, replace camshaft.

Camshaft runout limit

0.015 mm (0.00050 in.)

Scheme 60

Scheme 61

1. Check camshaft journals and camshaft housings for pitting, scratches, wear or damage. If any defective is found, replace camshaft or cylinder head with camshaft housings. CAUTION: Do not attempt to fix malcondition of camshaft journal and camshaft housing for reuse.

Scheme 62

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Scheme 65

Scheme 66

1. Clean camshaft housings and camshaft journals.
2. Remove all tappets.
3. Install camshafts and lower bearing half to cylinder head.
4. Place a piece of gauging plastic to full width of camshaft journal (parallel to camshaft).
5. Install camshaft housing referring to steps 2) to 5) in "Installation" under «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__camshaft-and-tappet-removal-and-installation) . CAUTION: Do not rotate camshaft while gauging plastic is installed.
6. Remove housings, and using scale (2) on gauging plastic envelop, measure gauging plastic (1) width at its widest point. Camshaft journal clearance (intake side of camshaft housing No. 1) Standard: 0.020 - 0.072 mm (0.00079 - 0.00244 in.) Limit: 0.10 mm (0.0039 in.) Camshaft journal clearance (except intake side of camshaft housing No. 1) Standard: 0.020 - 0.062 mm (0.00079 - 0.0024 in.) Limit: 0.095 mm (0.00374 in.) If measured camshaft journal clearance exceeds limit, recheck camshaft journal clearance according to the following procedure. Install camshaft upper bearing half and camshaft housings without camshafts to cylinder head. Tighten camshaft housing bolts referring to Step 6) in "Installation" under «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__camshaft-and-tappet-removal-and-installation) . For intake camshaft journal No. 1, measure journal outside diameter at positions shown in figure. If measured diameter is out of standard values, replace camshaft and recheck camshaft journal clearance. If measured diameter is within standard values, replace camshaft bearings and recheck camshaft journal clearance. For all other camshaft journals, measure camshaft journal outside diameters and camshaft housing inside diameters. If measured diameters are out of standard values, replace corresponding camshaft or cylinder head and camshaft housings. Camshaft journal outside diameter CAMSHAFT JOURNAL OUTSIDE DIAMETER SPECIFICATIONS Item Standard Intake camshaft journal No. 1 "a" 28.959 - 28.980 mm (1.1402 - 1.1409 in.) Exhaust camshaft journal No. 1 26.959 - 26.980 mm (1.0614 - 1.0622 in.) Others 25.959 - 25.980 mm (1.0220 - 1.0228 in.) Camshaft housing inside diameter CAMSHAFT HOUSING INSIDE DIAMETER SPECIFICATIONS Item Camshaft housing No. 1 (intake) 32.000 - 32.025 mm (1.2599 - 1.2608 in.) Camshaft housing No. 1 (exhaust) 27.000 - 27.021 mm (1.0630 - 1.0638 in.) Others 26.000 - 26.021 mm (1.0237 - 1.0244 in.)
7. Install intake and exhaust camshaft without tappet, and then measure intake and exhaust camshaft housing thrust clearance using a dial gauge. If measured clearance exceeds limit, replace camshaft or cylinder head and camshaft housings. Camshaft housing thrust clearance Standard: 0.10 - 0.35 mm (0.0040 - 0.0137 in.) Limit: 0.50 mm (0.020 in.)

Wear of Tappet

Check tappet for pitting, scratches, or damage.

If any defective condition is found, replace tappet.

Scheme 67

Measure tappet bore of cylinder head inside diameter, and tappet outside diameter, and then determine cylinder head-to-tappet clearance. If clearance exceeds limit, replace tappet or cylinder head.

Cylinder head to tappet clearance

Standard: 0.025 - 0.066 mm (0.0010 - 0.0025 in.)

Limit: 0.10 mm (0.0039 in.)

Tappet outside diameter

Standard: 32.459 - 32.475 mm (1.2780 - 1.2785 in.)

Cylinder head tappet bore

Standard: 32.500 - 32.525 mm (1.2796 - 1.2805 in.)

Scheme 68

Scheme 69

Exhaust Camshaft Timing Sprocket

Check exhaust camshaft timing sprocket for wear and damage.

If any defective condition is found, replace exhaust camshaft timing sprocket.

Scheme 70

1. Check CMP actuator for wear or damage. If any defective condition is found, replace CMP actuator.
2. Install CMP actuator to intake camshaft and hold hexagonal section of intake camshaft stationary using wrench or the like. Check that CMP actuator (1) cannot be turned by hand. If it can be turned by hand, replace CMP actuator.

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF PROCEDURE»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-j24b__fuel-pressure-relief-procedure) .
2. Remove battery. See «BATTERY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system__battery-removal-and-installation) .
3. Remove battery tray (1) and battery bracket (2).
4. Remove engine cover.
5. Drain the following oils and fluids if necessary. Engine oil: See «ENGINE OIL AND FILTER CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-j24b__engine-oil-and-filter-change) . Manual transmission oil (5M/T model): See «MANUAL TRANSMISSION OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/manual-trans/#manual-transmissiontransaxle) . A/T fluid (4 A/T model): «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) . P/S fluid: See «P/S FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/accessory-drive-belts/#power-assisted-steering-system__ps-fluid-change) . Transfer oil (4WD model): Motor shift type: See «TRANSFER OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/transfer-case/#transfer-motor-shift-type) . Non-shift type: See «TRANSFER OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/transfer-case/#transfer-non-motor-shift-type__transfer-oil-change) . Front differential oil (4WD model): See «FRONT DIFFERENTIAL OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/differentials-drive-axles/#differential-front) .
6. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-draining) .
7. Remove air cleaner suction pipe. See «AIR CLEANER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
8. Remove air cleaner assembly and air cleaner outlet hose. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation) .
9. Remove accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
10. Remove front bumper. See «FRONT BUMPER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exterior-body-panels/#body-structure) .
11. Disconnect the following electric wires and connectors. ECM connector (1) Radiator cooling fan motor connector (2) Ground cable (3) and (4) Connector (5) and terminal (6) in fuse box No. 1 Connectors (7) in fuse box No. 2 Front height sensor connector (8) A/C compressor magnet clutch connector (9) Engine harness connector (10)
12. Disconnect the following hoses. Brake booster hose (11) Heater inlet and outlet hoses (12) Fuel hose (13) EVAP canister purge hose (14) Radiator lower hose (15)
13. Remove engine harness clamps
14. With hose connected, remove A/C compressor from its bracket. See «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system__compressor-assembly-removal-and-installation) . CAUTION: Suspend removed A/C compressor (1) with rope (2) or the like, at a place where no damage will be caused during removal and installation of engine assembly.
15. For 5 M/T model, disconnect clutch fluid hose from clutch fluid pipe joint. See «CLUTCH FLUID PIPE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/clutches-manual-hydraulic/#clutch) .
16. For 4 A/T model, disconnect A/T select cable from A/T. See «SELECT CABLE COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) .
17. For 5 M/T model, remove transmission shift control lever from transmission. See «TRANSMISSION SHIFT CONTROL LEVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/manual-trans/#manual-transmissiontransaxle) .
18. Remove exhaust pipe No. 2. See «EXHAUST SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-system-components) .
19. Remove rear propeller shaft. See «PROPELLER SHAFT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/driveshaft-universal-joints/#propeller-shaft) .
20. With hose connected, remove A/C condenser assembly from radiator. See «A/C CONDENSER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system__ac-condenser-assembly-removal-and-installation) . CAUTION: Suspend removed A/C condenser (1) with rope (2) or the like, at a place where no damage will be caused during removal and installation of engine assembly.
21. Remove radiator with radiator support bracket (1) and filler neck bracket (2) from vehicle body.
22. With hose connected, remove P/S fluid reservoir (3) from vehicle body.
23. Remove stabilizer bar joints from stabilizer bar. See «FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/wheel-hubs/#front-suspension) .
24. Remove tie-rod ends, front drive shafts (4WD model) and ball joints from steering knuckles referring to Step 1) through 9) in "Removal" under «SUSPENSION CONTROL ARM REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/wheel-hubs/#front-suspension) .
25. Remove steering lower shaft assembly from P/S gear case assembly. See «STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-switchsteering-lock/#steering-wheel-and-column__steering-lower-shaft-assembly-removal-and) .
26. Support front suspension frame (1) and engine rear mounting member (2) using jack.
27. Remove front suspension frame bolts (3).
28. Remove engine rear mounting member bolts (4).
29. Before lowering engine, make sure that all hoses, electric wires and cables are disconnected from engine.
30. Lower engine assembly with transmission and transfer (4WD model) from engine compartment. NOTE: Lower engine assembly, transmission, transfer (4WD model), front suspension frame, drive shafts (4WD model), radiator, P/S gear case and engine rear mounting member all together. Before lowering engine assembly, make clearance by raising A/C compressor and A/C condenser in order to avoid damage to them.
31. Disconnect transmission if necessary. 5 M/T model: See «MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING»(/suzuki/grand-vitara/ii-2008-2012/remont/manual-trans/#manual-transmissiontransaxle) . 4 A/T model: See «AUTOMATIC TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) .
32. For 4 A/T model, remove oil cooler pipe if necessary. See «OIL COOLER HOSE AND PIPE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) .
33. Remove engine harness from engine assembly if necessary.
34. Remove engine mounting from engine front mounting bracket if necessary.
35. For 5 M/T model, remove clutch cover and clutch disc if necessary. See «CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/clutches-manual-hydraulic/#clutch) .
36. For 5 M/T model, remove flywheel if necessary. See «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) . For 4 A/T model, remove drive plate if necessary. See «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

1. For 5 M/T model, install flywheel if removed. See «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) . For 4 A/T model, install drive plate if removed. See «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
2. For 5 M/T model, install clutch cover and clutch disc if removed. See «CLUTCH COVER, CLUTCH DISC AND FLYWHEEL REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/clutches-manual-hydraulic/#clutch) .
3. Install engine harness to engine assembly if removed. Tighten engine harness ground bolts with engine harness ground cables to specified torque. Tightening torque Engine harness ground bolt (M6) (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft) Engine harness ground bolt (M8) (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
4. Connect transmission to engine if removed. For 5 M/T model: See «MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING»(/suzuki/grand-vitara/ii-2008-2012/remont/manual-trans/#manual-transmissiontransaxle) . For 4 A/T model: See «AUTOMATIC TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) .
5. Lift engine assembly with transmission and transfer (4WD model) into engine compartment using jack. NOTE: Lift engine assembly, transmission, transfer (4WD model), front suspension frame, drive shafts (4WD model), radiator, P/S gear case and engine rear mounting member all together. Before lifting engine assembly, make clearance by raising A/C compressor and A/C condenser in order to avoid damage to them.
6. Tighten engine rear mounting member bolts (2) to specified torque. Tightening torque Engine rear mounting member bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft)
7. Tighten front suspension frame bolts to specified torque. See «FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/wheel-hubs/#front-suspension) .
8. Install steering lower shaft assembly to P/S gear case assembly. See «STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-switchsteering-lock/#steering-wheel-and-column__steering-lower-shaft-assembly-removal-and) .
9. Install tie-rod ends, front drive shafts (4WD model) and ball joints to steering knuckles referring to "Removal" under «SUSPENSION CONTROL ARM REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/wheel-hubs/#front-suspension) .
10. Install stabilizer bar joints to stabilizer bar. See «FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/wheel-hubs/#front-suspension) .
11. Install P/S fluid reservoir to vehicle body.
12. Install radiator with radiator support bracket and filler neck bracket to vehicle body.
13. Install A/C condenser assembly to radiator. See «A/C CONDENSER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system__ac-condenser-assembly-removal-and-installation) .
14. Install rear propeller shaft. See «PROPELLER SHAFT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/driveshaft-universal-joints/#propeller-shaft) .
15. Install exhaust pipe No. 2. See «EXHAUST SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-system-components) .
16. For 5 M/T model, install transmission shift control lever to transmission. See «TRANSMISSION SHIFT CONTROL LEVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/manual-trans/#manual-transmissiontransaxle) .
17. For 5 M/T model, connect clutch fluid hose and clutch fluid pipe joint. See «CLUTCH FLUID PIPE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/clutches-manual-hydraulic/#clutch) .
18. For 4 A/T model, connect A/T select cable to A/T. See «SELECT CABLE COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) .
19. Install A/C compressor to engine assembly. See «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system__compressor-assembly-removal-and-installation) .
20. Install engine harness clamps.
21. Install all other removed electric wires, connectors and hoses to original locations.
22. Connect battery ground cable to vehicle body. Tightening torque Battery ground terminal bolt (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
23. Install front bumper and radiator grille. See «FRONT BUMPER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exterior-body-panels/#body-structure) .
24. Install accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
25. Install air cleaner assembly and air cleaner outlet hose. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__air-cleaner-assembly-removal-and-installation) .
26. Install air cleaner suction pipe. See «AIR CLEANER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
27. Make sure that all electric wires, connectors and hoses are installed at original locations.
28. Make sure that all removed components are installed at original locations.
29. Fill all drained oils and fluids. Engine oil: See «ENGINE OIL AND FILTER CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-j24b__engine-oil-and-filter-change) . Manual transmission oil (5M/T model): See «MANUAL TRANSMISSION OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/manual-trans/#manual-transmissiontransaxle) . A/T fluid (4 A/T model): «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) . P/S fluid: See «P/S FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/accessory-drive-belts/#power-assisted-steering-system__ps-fluid-change) . Transfer oil (4WD model): Motor shift type: See «TRANSFER OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/transfer-case/#transfer-motor-shift-type) . Non-shift type: See «TRANSFER OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/transfer-case/#transfer-non-motor-shift-type__transfer-oil-change) . Front differential oil (4WD model): See «FRONT DIFFERENTIAL OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/differentials-drive-axles/#differential-front) .
30. Install front tires.
31. Install engine cover.
32. Install battery tray and battery bracket.
33. Install battery. See «BATTERY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system__battery-removal-and-installation) .
34. Refill cooling system with coolant. See «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__cooling-system-refilling) .
35. Check any leakage of coolant, oil, fuel and exhaust. Fuel leak: See «FUEL LEAKAGE CHECK PROCEDURE»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-j24b__fuel-leakage-check-procedure) . Coolant leak: See «ENGINE COOLING SYSTEM INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b__engine-cooling-system-inspection) .

Scheme 83

Tightening Order/Removal and Installation figure callout references

TIMING CHAIN COVER REMOVAL AND INSTALLATION

Timing Chain Cover Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

Scheme 84

Scheme 85

Scheme 86

1. Remove engine assembly from vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
2. Remove crankshaft pulley bolt. To lock crankshaft pulley (1), use special tool as shown in figure. CAUTION: Use special tool to avoid applying unnecessary load to timing chain, sprockets and any other related parts. Use specified bolts (2) to install special tool to crankshaft pulley. Bolt size: M8 Pitch: 1.25 mm Length: 25 mm (0.98 in.) Strength: 7T Special Tool (A): 09917-68221
3. Remove crankshaft pulley (1). If it is hard to remove, use special tools as shown in figure. Special Tool (A): 09944-36011 (B): 09926-58010
4. Remove cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__cylinder-head-cover-removal-and-installation) .
5. Remove oil pan. See «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-j24b__oil-pan-and-oil-pump-strainer) .
6. Remove tensioner pulley and idler pulley. See «TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
7. Remove timing chain cover by loosing timing chain cover bolts in numerical order ("1" - "17") evenly and gradually.
8. Remove crankshaft oil seal from timing chain cover using flat-head screwdriver or the like, if necessary.
9. Remove oil seal from timing chain cover if necessary.

Reference: TIMING CHAIN COVER INSPECTION

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

1. Clean mating surface of timing chain cover, cylinder block and cylinder head. Remove oil, old sealant and dust from mating surface.
2. Check oil seal (1) for any damage. If abnormality is found, replace oil seal. NOTE: When installing new oil seal, press it into timing chain cover (2) using special tool as shown in figure. Special Tool (A): 09913-75510
3. Install dowel pins (1) to cylinder block.
4. Apply sealant "A" to mating surface of cylinder, cylinder head and timing chain cover as shown in figure. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) Sealant bead size for timing chain cover Width "a": 3 mm (0.12 in.) Height "b": 2 mm (0.08 in.)
5. Apply engine oil to oil seal lip, then install timing chain cover (1). Tighten timing chain cover bolts to specified torque in numerical order ("1" - "17") evenly and gradually. NOTE: Before installing timing chain cover, check that dowel pins are securely fitted. Tightening torque Timing chain cover bolt* (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
6. Install tensioner pulley and idler pulley. See «TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
7. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__cylinder-head-cover-removal-and-installation) .
8. Install oil pan. See «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-j24b__oil-pan-and-oil-pump-strainer) .
9. Install crankshaft pulley (1) and tighten crankshaft pulley bolt to specified torque. To lock crankshaft pulley, use special tool as shown in figure. CAUTION: Use special tool to avoid being applying unnecessary load to timing chain, sprockets and any other related parts. Use specified bolts (2) to install special tool to crankshaft pulley. Bolt size: M8 Pitch: 1.25 mm Length: 25 mm (0.98 in.) Strength: 7T Special Tool (A): 09917-68221 Tightening torque Crankshaft pulley bolt (a): 150 N.m (15.3 kg-m, 111.0 lbf-ft)
10. Install engine assembly to vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Timing Chain Cover Inspection

Reference: TIMING CHAIN COVER REMOVAL AND INSTALLATION

Oil Seal

Check oil seal lip for any damage. If abnormality is found, replace oil seal.

Timing Chain Cover

Inspect oil passage (1) for driving CMP actuator and strainer (2).

If clog or foreign matter exists, clean strainer.

Scheme 92

OCV (Oil Control Valve) Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

Removal

Remove OCV (2) and O-ring (3) from timing chain cover (1).

Scheme 93

Reverse removal procedure noting the following.

1. Install new O-ring.
2. Tighten OCV bolt to specified torque. Tightening torque OCV bolt: 11 N.m (1.1 kg-m, 8.5 lbf-ft)

Scheme 94

1. Remove transmission assembly. 5 M/T model: See «MANUAL TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING»(/suzuki/grand-vitara/ii-2008-2012/remont/manual-trans/#manual-transmissiontransaxle) . 4 A/T model: See «AUTOMATIC TRANSMISSION ASSEMBLY DISMOUNTING AND REMOUNTING»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-4at) .
2. Wedge a special tool in ring gear teeth to lock flywheel or drive plate as shown in figure. Special Tool (A): 09924-17811
3. Remove flywheel or drive plate from engine assembly.

Reverse removal procedure noting the following.

Scheme 95

1. Install new drive plate bolts or flywheel bolts.
2. Wedge a special tool in ring gear teeth to lock flywheel or drive plate as shown in figure. Special Tool (A): 09924-17811
3. Tighten flywheel bolts or drive plate bolts to specified torque. Tightening torque Flywheel bolt (a): 70 N.m (7.1 kg-m, 52.0 lbf-ft) Drive plate bolt (a): 70 N.m (7.1 kg-m, 52.0 lbf-ft)

Scheme 96

Timing Chain and Chain Tensioner Removal and Installation

Reference: TIMING CHAIN AND CHAIN TENSIONER COMPONENTS

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

Scheme 97

Note. If it is necessary to rotate the camshaft after removing timing chain, turn crankshaft counterclockwise and position key (1) within specified range (30 - 90°) as shown in figure before rotating camshaft.

Scheme 98

Scheme 99

Scheme 100

1. Remove timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__timing-chain-cover-removal-and-installation) .
2. By turning crankshaft, align camshafts and crankshaft at specific position as follows. Align timing marks on CMP actuator (1) and timing mark (2) on exhaust camshaft timing sprocket with match marks (3) on camshaft housing No. 1. Align timing mark (1) on crankshaft timing sprocket with match mark (2) on lower crank case.
3. Remove timing chain tensioner adjuster (3).
4. Remove timing chain tensioner (4).
5. Remove timing chain guide (5).
6. Remove timing chain (6) and crankshaft timing sprocket (7).

Reference: TIMING CHAIN AND CHAIN TENSIONER INSPECTION

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

1. Turn camshaft position key slot (1) within specified range (30 - 90°) (2) in counterclockwise direction from top as shown in figure.
2. Align timing mark (3) on CMP actuator with match marks (4) on camshaft housing No. 1.
3. Align timing mark (5) on exhaust camshaft timing sprocket with match marks (4) on camshaft housing No. 1.
4. Install key (6) to key slot (1) of crankshaft. Align key slot of crankshaft timing sprocket (7) with key, and then Install crankshaft timing sprocket to crankshaft. Align timing mark (8) on crankshaft timing sprocket with match mark (9) on lower crank case.
5. Install timing chain while aligning two blue plates (2) with timing marks (1) on CMP actuator and exhaust camshaft timing sprockets.
6. Install timing chain while aligning blue plate (2) with timing mark (1) on crankshaft timing sprocket.
7. Install timing chain guide (1) and tighten timing chain guide bolts (2) to specified torque. Tightening torque Timing chain guide bolt (a): 9 N.m (0.92 kg-m, 7.0 lbf-ft)
8. Apply engine oil to sliding surface of timing chain guide.
9. Attach spacer (4) to timing chain tensioner (3).
10. Install timing chain tensioner (3) and tighten timing chain tensioner bolt (5) to specified torque. Tightening torque Timing chain tensioner bolt (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
11. Apply engine oil to sliding surface of timing chain tensioner.
12. Make sure that all blue plated (6) are aligned with timing marks (7) on corresponding timing sprockets.
13. Screw in plunger (2) of timing chain tensioner adjuster (1) clockwise and install a retainer (3) (1.4 mm-diameter wire or the like) to hold plunger in place.
14. Install timing chain tensioner adjuster (1) with a retainer. Tighten timing chain tensioner adjuster bolts (2) to specified torque, and then remove a retainer from timing chain tensioner adjuster. Tightening torque Timing chain tensioner adjuster bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
15. Apply engine oil to timing chain, and then turn crankshaft clockwise fully twice, and make sure the following items. Timing mark (4) on CMP actuator is aligned with match mark (3) on camshaft housing No. 1. Timing mark (5) on exhaust camshaft timing sprocket is aligned with match mark (3) on camshaft housing No. 1. Timing mark (6) on crankshaft timing sprocket is aligned with match mark (7) on lower crank case. NOTE: Be sure to turn crankshaft fully twice. If it is once, timing marks on CMP actuator and exhaust camshaft timing sprocket do not meet match marks on camshaft housing No. 1. After turning crankshaft twice, the discrimination links of timing chain are not aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but it is normal.
16. Install timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__timing-chain-cover-removal-and-installation) .
17. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__cylinder-head-cover-removal-and-installation) .
18. Install oil pan. See «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-j24b__oil-pan-and-oil-pump-strainer) .
19. Install engine assembly. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Timing Chain and Chain Tensioner Inspection

Reference: TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION

Timing Chain Guide

Check sliding surface of timing chain guide (1) for wear or damage.

If abnormality is found, replace timing chain guide.

Scheme 107

Timing Chain Tensioner

Check sliding surface of timing chain tensioner (1) for wear or damage.

If abnormality is found, replace timing chain tensioner.

Scheme 108

Crankshaft Timing Sprocket

Check sprocket teeth for wear or damage.

If abnormality is found, replace crankshaft timing sprocket.

Scheme 109

Timing Chain

Check timing chain for wear or damage.

If abnormality is found, replace timing chain.

Scheme 110

Timing Chain Tensioner Adjuster

Check that tooth surface (1) are free from damage.

If abnormality is found, replace timing chain tensioner adjuster.

Scheme 111

Scheme 112

Tightening Order figure callout reference

VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION

Valve and Cylinder Head Removal and Installation

Reference: VALVE AND CYLINDER HEAD COMPONENTS

Scheme 113

Scheme 114

Scheme 115

1. Remove timing chain. See «TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__timing-chain-and-chain-tensioner-removal) .
2. Remove spark plugs. See «SPARK PLUG REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-j24b) .
3. Remove CMP actuator and exhaust camshaft timing sprocket according to the following procedure. Hold hexagonal section of camshaft stationary using wrench or the like. Loosen bolts and remove CMP actuator (1) and exhaust camshaft timing sprocket (2). NOTE: Do not hold CMP actuator to loosen bolt. Doing so may result in damaged lock pin. Do not use impact wrench to loosen bolt. Do not disassemble CMP actuator (1).
4. Remove intake camshaft and exhaust camshaft. See «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__camshaft-and-tappet-removal-and-installation) .
5. Remove camshaft bearings.
6. Remove water outlet pipe from cylinder head. See «COOLING SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) .
7. Remove heater outlet pipe bolt (1) from cylinder head (2).
8. Loosen cylinder head bolts in numerical order ("1" - "10") evenly and gradually. NOTE: Use 12-point socket wrench to cylinder head bolts.
9. Remove cylinder head with its gasket, intake manifold and exhaust manifold from cylinder block.
10. Remove the following components cylinder head if necessary. Intake manifold: See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__intake-manifold-removal-and-installation) . Exhaust manifold: See «EXHAUST MANIFOLD REMOVAL AND INSTALLATION (J24B)»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-manifold-removal-and-installation-j24b) . Fuel injector: See «FUEL INJECTOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-j24b__fuel-injector-removal-and-installation) . Water outlet cap: See «COOLING SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) . Oil venture plug: See «VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Reference: VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Reference: CYLINDER HEAD INSPECTION

Reference: CYLINDER HEAD BOLT INSPECTION

Scheme 116

Scheme 117

Scheme 118

Scheme 119

1. Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface.
2. Install dowel pins (1) to cylinder block.
3. Install new cylinder head gasket (2) to cylinder block.
4. Install cylinder head to cylinder block as follows. NOTE: Before Installing cylinder head to cylinder block, turn crankshaft and position key (1) within specified range (30 - 90°) in counterclockwise direction from top as shown in figure. Install cylinder head to cylinder block. Apply engine oil to cylinder head bolts threads. Tighten cylinder head bolts to 20 N.m (2.0 kgf-m, 15.0 lbf-ft) in numerical order ("1" - "10") evenly and gradually. NOTE: Use 12-point socket wrench to cylinder head bolts. In the same manner as in Step c), retighten them to 40 N.m (4.1 kgf-m, 29.5 lbf-ft). In the same manner as Step c), retighten them to 60°. In the same manner as Step c), retighten them to 80°. Tightening torque Cylinder head bolt * (a): 20 N.m --> 40 N.m --> +60° --> +80° (2.0 kgf-m --> 4.1 kgf-m --> +60° --> +80°, 15.0 lbf-ft --> 29.5 lbf-ft --> +60° --> +80°)
5. Install intake camshaft and exhaust camshaft. See «CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__camshaft-and-tappet-removal-and-installation) .
6. Install timing chain. See «TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__timing-chain-and-chain-tensioner-removal) .
7. Install timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__timing-chain-cover-removal-and-installation) .
8. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__cylinder-head-cover-removal-and-installation) .
9. Install oil pan. See «OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-j24b__oil-pan-and-oil-pump-strainer) .
10. Install water outlet cap if removed. See «COOLING SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) .
11. Install heater outlet pipe bolt to cylinder head. See «COOLING SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) .
12. Install water outlet pipe to cylinder head. See «COOLING SYSTEM COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) .
13. Install spark plugs. See «SPARK PLUG REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-j24b) .
14. Install exhaust manifold if removed. See «EXHAUST MANIFOLD REMOVAL AND INSTALLATION (J24B)»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-manifold-removal-and-installation-j24b) .
15. Install intake manifold if removed. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__intake-manifold-removal-and-installation) .
16. Install fuel injectors if removed. See «FUEL INJECTOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-j24b__fuel-injector-removal-and-installation) .
17. Install engine assembly. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Disassembly

Reference: VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION

Note. If following parts are removed, keep them in order. They must go back in the position from which they were removed. Valve cotter Valve spring retainer Valve spring Valve spring seat Intake valve Exhaust valve Tappet

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

1. Remove oil venturi plugs (1).
2. Remove tappets from cylinder head.
3. Using special tools (A) and (B), compress valve spring and then remove valve cotters (1) also by using special tool (C). CAUTION: When compressing the valve spring, be careful not to damage in inside surface of tappet installing hole. Special Tool (A): 09916-14510 (B): 09916-14522 (C): 09916-84511
4. Release special tools (A) and (B), and remove spring retainer and valve spring.
5. Remove valve from combustion chamber side.
6. Remove valve stem seal (1) and valve spring seat (2).
7. Using special tool, drive out valve guide from combustion chamber side to valve spring side. NOTE: Heat cylinder head to remove valve guide, if necessary. Special Tool (A): 09916-44910

Reassembly

Reference: VALVE AND VALVE GUIDE INSPECTION

Reference: CYLINDER HEAD INSPECTION

Reference: VALVE SPRING INSPECTION

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

1. Before installing valve guide into cylinder head, ream guide hole with special tool (10.5 mm reamer) so as to remove burrs and make it truly round. CAUTION: Clean away shavings from reamed hole. Special Tool (A): 09916-37320 (B): 09916-34542
2. Using special tools, install valve guide to cylinder head as follows. Special Tool (A): 09916-58210 (B): 09916-56510 NOTE: Never reuse valve guide. Install new oversized valve guide. Intake and exhaust valve guides are identical. Heat cylinder head uniformly to a temperature of 80 to 100 °C (176 to 212 °F) so that it will not be distorted, and drive new valve guide into guide hole with special tools. Drive in new valve guide until special tool contacts cylinder head. After installation, make sure that valve guide protrudes by specified dimension "a" from cylinder head. CAUTION: For installing intake valve guide and exhaust valve guide, the same special tool (B) is used, but its application direction is different. Use it in proper direction. For intake valve guide The side (2) should be directed to valve guide. For exhaust valve guide The side (1) should be directed to valve guide. Valve guide protrusion "a" IN: 16.3 - 16.7 mm (0.642 - 0.657 in.) EX: 12.3 - 12.7 mm (0.485 - 0.500 in.)
3. Ream valve guide bore with special tool. CAUTION: Clean away shavings from reamed hole. Special Tool (A): 09916-34550 (B): 09916-34542
4. Install valve spring seat to cylinder head.
5. Install new valve stem seal (1) to valve guide. After applying engine oil to valve stem seal and spindle of special tool (A), fit valve stem seal to spindle, and then install valve stem seal to valve guide pushing special tool by hand. After installation, check that valve stem seal is properly fixed to valve guide. CAUTION: When installing, never tap or hit special tool with a hammer or else. Install seal to guide only pushing special tool by hand. Tapping or hitting special tool may cause damage to seal. Special Tool (A): 09917-98221 (B): 09916-58210
6. Apply engine oil to valve stem seal, valve guide bore and valve stem.
7. Install valve to valve guide.
8. Install valve spring and valve spring retainer. NOTE: Valve spring does not have specific direction for installation.
9. Using special tools, compress valve spring and fit two valve cotters (1) into groove in valve stem. CAUTION: When compressing the valve spring, be careful not to damage inside surface of tappet installing hole. Special Tool (A): 09916-14510 (B): 09916-14522 (C): 09916-84511
10. Install venturi plugs (1). Tightening torque Venturi plug (a): 3.5 N.m (0.36 kg-m, 2.5 lbf-ft)

Valve and Valve Guide Inspection

Reference: VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Valve stem-to-guide clearance

1. Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance.
2. Be sure to take reading at more than one place along the length of each stem and guide.
3. If clearance exceeds limit, replace valve and valve guide.

Valve stem outside diameter

IN: 5.465 - 5.480 mm (0.2152 - 0.2157 in.)

EX: 5.440 - 5.455 mm (0.2142 - 0.2147 in.)

Valve guide inside diameter

IN & EX: 5.500 - 5.512 mm (0.2166 - 0.2170 in.)

Stem-to-guide clearance

Standard

IN: 0.020 - 0.047 mm (0.0008 - 0.0018 in.)

EX: 0.045 - 0.072 mm (0.0018 - 0.0028 in.)

Limit

IN: 0.070 mm (0.0027 in.)

EX: 0.090 mm (0.0035 in.)

Scheme 132

Scheme 133

Valve stem end deflection

Check valve stem end deflection using a dial gauge.

Move stem end in directions (1) and (2) to measure end deflection.

If deflection exceeds its limit, replace valve and valve guide.

Valve stem end deflection limit

In: 0.14 mm (0.0055 in.)

Ex: 0.18 mm (0.0070 in.)

Scheme 134

Scheme 135

1. Remove all carbon deposits from all valves (1).
2. Check each valve for wear, burn or distortion at its face and stem end. Replace it if necessary.
3. Measure valve protrusion length "a". If measured length is out of standard value, replace valve. Valve protrusion length "a" Standard IN: 44.00 - 44.60 mm (1.733 - 1.755 in.) EX: 42.85 - 43.45 mm (1.687 - 1.710 in.)

Valve head radial runout

Check each valve for radial runout using a dial gauge and "V" block.

To check runout, rotate valve slowly.

If runout exceeds its limit, replace valve.

Valve head radial runout

Standard

IN: 0.000 - 0.045 mm (0.0000 - 0.0017 in.)

EX: 0.000 - 0.030 mm (0.0000 - 0.0011 in.)

Limit

IN: 0.090 mm (0.0035 in.)

EX: 0.060 mm (0.0023 in.)

Scheme 136

Seating contact width

Create contact pattern on each valve in the usual manner, i.e., by giving uniform coat of marking compound to valve seat and by rotating tapping seat with valve head. Valve lapper (tool used in valve lapping) must be used.

Pattern produced on seating surface of valve must be a continuous ring without any break, and the width of pattern must be within specified range.

Standard seating width "a" revealed by contact pattern on valve face

IN: 1.05 - 1.35 mm (0.0414 - 0.531 in.)

EX: 1.12 - 1.42 mm (0.0441 - 0.0559 in.)

Scheme 137

Valve seat repair

A valve seat not producing a uniform contact with its valve or showing width of seating contact that is out of specified range must be repaired by regrinding or by cutting and regrinding and finished by lapping.

Scheme 138

1. Intake valve seat: Use valve seat cutters to make three cuts as illustrated in figure. Three cutters must be used: the 1st for making 22° angle, the 2nd for making 60° angle, and 3rd for making 45° angle. The 3rd cut (45°) must be made to produce desired seat width. Seat width for intake valve seat "a": 1.05 - 1.35 mm (0.0414 - 0.0531 in.)
2. Exhaust valve seat: Use valve seat cutters to make three cuts as illustrated in the figure. Three cutters must be used: the 1st for making 22° angle, the 2nd for making 65° angle, and 3rd for making 45° angle. The 3rd cut must be made to produce desired seat width. Seat width for exhaust valve seat "b": 1.12 - 1.42 mm (0.0441 - 0.559 in.)
3. Valve lapping: Lap valve on seat in two steps, first with coarse size lapping compound applied to face and the second with fine-size compound, each time using valve lapper according to usual lapping method.

Venturi Plug Inspection

Check that venturi plug passage is not clogged.

If venturi plug passage is clogged, clean or replace venturi plug.

Scheme 139

Cylinder Head Inspection

Reference: VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Combustion Chamber

1. Remove all carbon deposits from all combustion chambers. NOTE: Do not use any sharp-edged tool to scrape off carbon deposits. Be careful not to scuff or nick metal surfaces when removing carbon deposits. The same applies to valves and valve seats, too.
2. Check cylinder head for cracks on intake and exhaust ports, combustion chambers, and head surface.

Cylinder Head Flatness

Using a straightedge (1) and thickness gauge (2), check flatness of gasket surface at a total of 6 locations.

If any measure value exceeds its limit, correct gasket surface with a surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place abrasive paper on and over surface plate, and rub gasket surface against paper to grind off high spots.

If it is impossible to correct cylinder head distortion, replace cylinder head.

Note. Distorted mating surface of cylinder head and cylinder head gasket causes combustion gas leakage, overheating and reduced power output.

Distortion of mating surface of cylinder head and cylinder head gasket

Limit: 0.03 mm (0.0011 in.)

Scheme 140

Scheme 141

Manifold Seating Surface Flatness

Using straightedge (1) and thickness gauge (2), check flatness of manifold seating surface.

If measured value exceeds its limit, correct seating surface or replace cylinder head.

Distortion of seating face of intake manifold and exhaust manifold on cylinder head

Limit: 0.05 mm (0.0019 in.)

Scheme 142

Scheme 143

Cylinder Head Bolt Inspection

Reference: VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Note. If they are reused, check thread diameter of cylinder head bolt (1) for deformation as follows and replace it with new one if thread diameter difference exceeds its limit.

Measure each thread diameter of cylinder head bolt "A" at "a" and "B" at "b" using micrometer (3).

Then calculate difference in diameters (A - B).

If it exceeds limit, replace cylinder head bolt with new bolt.

Cylinder head bolt diameter measurement points

"a": 95.0 mm (3.74 in.)

"b": 130.0 mm (5.12 in.)

Cylinder head bolt diameter difference (deformation)

Limit (A - B): 0.25 mm (0.0098 in.)

Scheme 144

Scheme 145

Valve Spring Inspection

Reference: VALVE AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Valve Spring Free Length and Preload

1. Check each valve springs for breakage or weakening.
2. Measure valve spring free length and preload. If measured value is less than limit, replace valve spring. NOTE: Weakened valve springs can cause chatter, not to mention possibility of reducing power output due to gas leakage caused by decreased seating pressure.

Valve spring free length "a"

Standard: 51.34 mm (2.021 in.)

Limit: 50.34 mm (1.981 in.)

Valve spring preload when compressed to 41 mm (1.61 in.)

Standard: 170 - 196 N (17.4 kgf - 19.9 kgf, 38.3 lbf - 44.0 lbf)

Limit: 165 N (16.9 kgf, 37.1 lbf)

Valve spring preload when compressed to 31.2 mm (1.23 in.)

Standard: 379 - 437 N (38.7 - 44.5 kgf, 85.2 - 98.2 lbf)

Limit: 375 N (38.3 kgf, 84.3 lbf)

Scheme 146

Scheme 147

Spring Squareness

Use a square and surface plate to check each spring for squareness in terms of clearance between end of valve spring and square. Valve springs found to exhibit a larger clearance than limit must be replaced.

Valve spring squareness

Limit: 2.2 mm (0.086 in.)

Scheme 148

Scheme 149

Tightening Order/Removal and Installation figure callout references

PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION

Piston, Piston Ring and Connecting Rod Removal and Installation

Reference: PISTON, PISTON RING AND CONNECTING ROD COMPONENTS

1. Remove engine assembly from vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
2. Remove cylinder head. See «VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__valve-and-cylinder-head-removal-and) .
3. Remove oil pump. See «OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-j24b__oil-pump-assembly-removal-and-installation) .
4. Mark cylinder number on all pistons, connecting rods and connecting rod bearing caps using silver pencil or quick drying paint.
5. Remove connecting rod bearing caps.
6. Remove carbon deposits from tops of cylinder bores before removing pistons from cylinder.
7. Push piston and connecting rod assembly out through the top of cylinder bore.
8. Remove connecting rod bearings from connecting rod and connecting rod bearing cap, if necessary.

Reference: PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY

Reference: CRANKSHAFT PIN AND CONNECTING ROD BEARINGS INSPECTION

Scheme 150

Scheme 151

Scheme 152

Scheme 153

1. Apply engine oil to pistons, piston rings, cylinder walls, connecting rod bearings and crankshaft pins. NOTE: Do not apply engine oil between connecting rod and bearing, between connecting rod bearing cap and bearing.
2. Install connecting rod bearing to connecting rod bearing cap and connecting rod as follows. Fit tab (1) of connecting rod bearing to groove (2) of connecting rod or bearing cap. Press bearing end (3) until it fully seats in connecting rod and bearing cap.
3. When installing piston and connecting rod assembly into cylinder bore, point front mark (1) on piston head to crankshaft pulley side (2).
4. Install piston and connecting rod assembly into cylinder bore. Use special tool to compress rings. Guide connecting rod into place on crankshaft. Using a hammer handle, tap piston head to install piston into bore. Hold ring compressor firmly against cylinder block until all piston rings have entered in cylinder bore. Special Tool (A): 09916-77310
5. Install connecting rod bearing cap (1) as follows. NOTE: Before installing connecting rod bearing cap, check connecting rod bearing cap bolts for deformation. Refer to " «CONNECTING ROD BOLT DEFORMATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__connecting-rod-bolt-deformation) " under «PISTON PINS AND CONNECTING RODS INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__piston-pins-and-connecting-rods-inspection) . Tighten connecting rod bearing cap bolt (3) gradually. Point arrow mark (2) on connecting rod bearing cap (1) to crankshaft pulley side. Apply engine oil to bolt thread and seat of connecting rod bearing cap bolt. Tighten all connecting rod bearing cap bolt to 15 N.m (1.5 kgf-m, 11.0 lbf-ft) evenly and gradually. In the same manner as Step c), retighten them to 45°. In the same manner as Step c), retighten them to 45°. Tightening torque Connecting rod bolt* (a): 15 N.m --> +45° --> +45° (1.5 kgf-m --> +45° --> +45°, 11.0 lbf-ft --> +45° --> +45°
6. Install oil pump. See «OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-j24b__oil-pump-assembly-removal-and-installation) .
7. Install cylinder head. See «VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__valve-and-cylinder-head-removal-and) .
8. Install engine assembly. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Piston, Piston Ring and Connecting Rod Disassembly and Reassembly

Reference: PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

Scheme 154

Scheme 155

1. Using piston ring expander, remove 1st and 2nd rings and oil ring from piston.
2. Remove piston pin from connecting rod as follows. Remove piston pin circlips (1), as shown. Take out piston pin.

Reference: CYLINDER, PISTON AND PISTON RING INSPECTION

Reference: PISTON PINS AND CONNECTING RODS INSPECTION

Reference: CRANKSHAFT PIN AND CONNECTING ROD BEARINGS INSPECTION

Note. Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance. When installing a standard size piston, make sure to match piston with cylinder.

Scheme 156

Scheme 157

Scheme 158

Scheme 159

1. To replace piston, select proper piston according the following procedure Check stamped number (2) on piston (1) as shown in figure. Check stamped number or painted color (4) on cylinder block (3) as shown in figure. Stamped number on piston and stamped number or painted color on cylinder block correspond with each other. Select proper piston referring the following table. Piston selection table PISTON STAMPED NUMBER REFERENCE Stamped number or painted color on cylinder block 1 or Red 2 or Blue Stamped number on piston 1 2
2. Remove carbon deposit from piston head and ring grooves using a suitable tool.
3. Assemble piston pin, piston (1) and connecting rod (2) as follows. Apply engine oil to piston pin, piston pin hole in piston and connecting rod. Fit connecting rod to piston. NOTE: Be sure to position front mark (4) on piston and oil hole (5) of connecting rod (2) at specified position as shown in figure. Insert piston pin to piston and connecting rod. Install new piston pin circlips (3). NOTE: Install so that circlip end gap comes within the range indicated by arrow (6).
4. Install piston rings to piston noting the following. As indicated in figure, 1st and 2nd rings have direct discrimination mark (1) respectively. When installing these piston rings to piston, direct discrimination mark side of each ring toward top of piston. 1st ring (2) differs from 2nd ring (3) in thickness, shape and color of surface contacting cylinder wall. Distinguish 1st ring from 2nd ring referring to the figure. When installing oil ring (4), install spacer first and then install two rails.
5. After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.

Cylinder, Piston and Piston Ring Inspection

Reference: PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY

Visual inspection

Check cylinder walls for scratches, roughness or ridges which indicate excessive wear.

If cylinder wall is too rough, deeply scratched, ridged, replace cylinder block, piston rings and/or pistons.

Cylinder bore diameter, taper and out-of-round

Using cylinder gauge, measure cylinder bore in thrust and axial directions.

If any of the following conditions is noted, replace cylinder block.

1. Cylinder bore exceeds limit.
2. Difference of measurements at two positions ([1] and [2]) exceeds taper limit.
3. Difference between thrust [4] and axial [3] measurements exceeds roundness limit. CAUTION: If abnormality is found on cylinder inside wall, replace cylinder block. NOTE: There are two sizes for cylinder bore, to keep clearance between piston and cylinder properly. To distinguish standard value, refer to «PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__piston-piston-ring-and-connecting-rod) .

Cylinder bore diameter

Standard

CYLINDER BLOCK DIAMETER REFERENCE

Cylinder bore diameter

Limit: 92.050 mm (3.6240 in.)

Cylinder bore roundness ([3] - [4])

Limit: 0.020 mm (0.00078 in.)

Cylinder bore taper ([1] - [2])

Limit: 0.013 mm (0.00051 in.)

Scheme 160

Scheme 161

Piston

Note. Two sizes of piston are available as standard size spare part so as to ensure proper piston-to-cylinder clearance.

Inspect piston for cracks or other damages.

If abnormality is found, replace piston.

Piston diameter

As indicated in figure, piston diameter should be measured at specified position "a" 11.4 mm (0.449 in) from piston skirt end in the direction perpendicular to piston pin.

If measured diameter is less than its limit, replace piston.

New piston diameter standard size

PISTON STAMPED NUMBER REFERENCE

Piston diameter limit size

PISTON STAMPED NUMBER REFERENCE

Scheme 162

Piston clearance

Measure cylinder bore diameter and piston diameter to find their difference called is piston clearance.

Piston clearance should be within its standard value.

If it is out of its limit, replace piston.

Note. Cylinder bore diameters used here are measured in thrust direction at two positions.

Piston clearance

Limit: 0.12 mm (0.0047 in.)

Scheme 163

1. Before checking, piston grooves must be clean, dry and free from carbon deposits.
2. Fit new piston ring (1) into piston groove.
3. Measure clearance between ring and ring land using thickness gauge (2). If clearance is out of limit, replace piston. Ring groove clearance OIL RING SPECIFICATION Standard Limit 1st ring 0.24 - 0.28 mm (0.0095 - 0.0110 in.) 0.13 mm (0.0052 in.) 2nd ring 0.03 - 0.07 mm (0.0012 - 0.0027 in.) 0.11 mm (0.0433 in.) Oil ring 0.04 - 0.18 mm (0.0016 - 0.0070 in.)

Piston ring end gap

To measure end gap, insert piston ring (1) into cylinder bore and then measure the gap using thickness gauge (2).

If measured gap exceeds limit, replace piston ring.

Note. Remove carbon deposit from and clean top of cylinder bore before inserting piston ring.

Piston ring end gap

ITEM STANDARD CHART

Scheme 164

Piston Pins and Connecting Rods Inspection

Reference: PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY

Check piston pin, connecting rod small-end bore and piston pin hole in piston for wear or damage, paying particular attention to condition of small-end bore bush.

If piston pin, connecting rod small-end bore or piston pin hole in piston is badly worn or damaged, replace piston pin, connecting rod and/or piston.

Piston pin clearance

Check piston pin clearance in connecting rod small-end and piston. Replace connecting rod and/or piston if its small-end is badly worn or damaged or if measured clearance exceeds limit.

Piston pin clearance in connecting rod small-end

Standard: 0.003 - 0.017 mm (0.0002 - 0.0006 in.)

Limit: 0.040 mm (0.0015 in.)

Piston pin clearance in piston

Standard: 0.010 - 0.016 mm (0.00040 - 0.00062 in.)

Limit: 0.05 mm (0.0019 in.)

Small-end bore

21.003 - 21.011 mm (0.82689 - 0.83720 in.)

Piston pin outside diameter

20.994 - 21.000 mm (0.82654 - 0.82677 in.)

Diameter of piston pin hole in piston

21.007 - 21.013 mm (0.82705 - 0.82728 in.)

Scheme 165

Big-end side clearance

Check big-end side clearance of connecting rod, with rod fitted and connected to its crankshaft pin in the normal manner.

If measured clearance is out of its standard value, replace connecting rod.

Big-end side clearance

Standard: 0.25 - 0.40 mm (0.0099 - 0.0157 in.)

Scheme 166

Connecting rod alignment

Mount connecting rod on aligner to check for bow and twist.

If measured value exceeds the limit, replace it.

Connecting rod alignment

Limit on bow: 0.05 mm (0.0019 in.)

Limit on twist: 0.10 mm (0.0039 in.)

Scheme 167

Connecting rod bolt deformation

Measure each thread, diameter of connecting rod bolt (1) "A" at "a" and "B" at "b" using a micrometer (3).

Calculate difference in diameters ("A" - "B").

If it is exceeds limit, replace connected rod (1).

Connecting rod bolt measurement points

"a": 28.5 mm (1.12 in.)

"b": 42.0 mm (1.65 in.)

Connecting rod bolt diameter difference

Limit ("A" - "B"): 0.05 mm (0.0019 in.)

Scheme 168

Crankshaft Pin and Connecting Rod Bearings Inspection

Reference: PISTON, PISTON RING AND CONNECTING ROD DISASSEMBLY AND REASSEMBLY

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

Crankshaft Pin Diameter

1. Using micrometer, measure crankshaft pin diameter at several points and calculate taper and out-of-round conditions. If calculated taper and/or out-of-round is out of their service limit, replace crankshaft or regrind crankshaft pin to undersize and use undersize bearing.

Crankshaft pin diameter

Standard: 49.982 - 50.000 mm (1.96780 - 1.96850 in)

Crankshaft pin taper ([a] -[b]) and out-of-round ([1] -[2])

Limit: 0.01 mm (0.0003 in.)

Scheme 169

Scheme 170

1. Service connecting rod bearings are available in five standard sizes and 0.25 mm (0.0098 in) undersize bearing. The difference of those sizes is thickness.
2. Specified colors for identification of sizes are painted at specified location (1) as shown in figure. BEARING THICKNESS CHART Painted color Bearing thickness Standard size Blue 1.494 - 1.497 mm (0.05882 - 0.05893 in.) Yellow 1.491 - 1.494 mm (0.05871 - 0.05881 in.) Colorless 1.488 - 1.491 mm (0.05859 - 0.05870 in.) Black 1.485 - 1.488 mm (0.05847 - 0.05858 in.) Green 1.482 - 1.485 mm (0.05835 - 0.05846 in.) 0.25 mm (0.0098 in) undersize Red 1.605 - 1.615 mm (0.06319 - 0.06358 in.)

Connecting Rod Bearing Visual Inspection

Check bearing shells for signs of fusion, pitting, burn or flaking and observe contact pattern. If abnormality is found, replace connecting rod bearings.

Connecting Rod Bearing Clearance

Note. After checking connecting rod bearing clearance, check connecting rod bolt for deformation referring to " CONNECTING ROD BOLT DEFORMATION " under PISTON PINS AND CONNECTING RODS INSPECTION .

Scheme 171

Scheme 172

1. Clean connecting rod bearings and crankshaft pin.
2. Place a piece of gauging plastic (1) to full width of crankshaft pin as contacted by bearing (parallel to crankshaft), avoiding oil hole.
3. Install connecting rod bearings and its cap. See «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__piston-piston-ring-and-connecting-rod) .
4. After three minutes elapsed, remove cap and using a scale (2) on gauging plastic envelope, measure gauging plastic (1) width at the widest point. Connecting rod bearing clearance Standard: 0.045 - 0.063 mm (0.0018 - 0.0024 in.) Limit: 0.065 mm (0.0025 in.)

If measured oil clearance is less than standard value or more than service limit, replace connecting rod bearings with new ones referring to SELECTION OF CONNECTING ROD BEARINGS , and recheck oil clearance. Depending on measured oil clearance with new bearing, select other bearings according to the following procedures, and recheck oil clearance.

1. More than standard: Replace bearings with one size thicker or regrind crank shaft pin to under size and use 0.25 mm (0.0098 in) undersize bearings.
2. Less than standard: Replace bearings with one size thinner or regrind crank shaft pin to under size and use 0.25 mm (0.0098 in) undersize bearings.

Scheme 173

Scheme 174

1. Check connecting rod big-end inside diameter according to the following procedures. There is stamped number (any of "1", "2" or "3") on each connecting rod and it cap as shown in figure. That number represent connecting rod big-end inside diameter as follows. Connecting rod big-end inside diameter CONNECTING ROD BIG-END INSIDE DIAMETER CHART Stamped number Connecting rod big-end inside diameter 1 53.0000 - 53.0060 mm (2.08662 - 2.08685 in.) 2 53.0061 - 53.0120 mm (2.08686 - 2.08708 in.) 3 53.0121 - 53.0180 mm (2.08710 - 2.08732 in.)
2. Check crankshaft pin diameter according to the following procedures. There are four stamped alphabets (any of "A", "B" or "C") on crank web No. 5 as shown in figure. Those alphabets represent crankshaft pin diameter as follows. Crankshaft pin diameter CRANKSHAFT PIN DIAMETER CHART Stamped alphabet Crankshaft pin diameter A 49.9940 - 50.0000 mm (1.96827 - 1.96850 in.) B 49.9880 - 49.9939 mm (1.96804 - 1.96826 in.) C 49.9820 - 49.9879 mm (1.96780 - 1.96802 in.)
3. From numbers stamped on connecting rods and its caps and alphabets stamped on crank web No. 5, determine new standard bearings to be installed to connecting rod big-end from the following table. Connecting rod bearing cross-reference selection table CONNECTING ROD STAMPED NUMBER REFERENCE Stamped number for connecting rod big-end inside diameter 1 or A 2 or B 3 or C Stamped alphabet for Crankshaft pin outside diameter A Green Black Colorless B Black Colorless Yellow C Colorless Yellow Blue

Scheme 175

1. Determine target diameter of crankshaft pin for regrinding according to the following procedure. Assemble connecting rod, connecting rod cap and undersize bearings (0.25 mm), referring to step 2) to 5) of "Installation" under «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__piston-piston-ring-and-connecting-rod) . Using bore gauge, measure connecting rod bearing inside diameter "a". Calculate target diameter according to formula below. Formula for target diameter of crankshaft pin A = B - 0.054 mm (0.0021 in.) A: Target diameter of crankshaft pin B: Measured connecting rod bearing inside diameter "a" .
2. Grind crankshaft pin to target diameter.
3. Check connecting rod bearing oil clearance. See «CONNECTING ROD BEARING CLEARANCE»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__connecting-rod-bearing-clearance) .

Scheme 176

Tightening Order/Removal and Installation figure callout references

1) CKP (CRANKSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION

2) KNOCK SENSOR REMOVAL AND INSTALLATION

5), 6), 7), 10) MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

Main Bearings, Crankshaft and Cylinder Block Removal and Installation

Reference: MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Note. For identification of each cylinder, refer to PRECAUTIONS FOR IDENTIFICATION OF CYLINDER .

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

1. Remove engine assembly. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
2. Remove flywheel for 5 M/T model or drive plate for 4 A/T model. See «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
3. Remove generator. See «GENERATOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
4. Remove water pump. See «WATER PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) .
5. Remove P/S pump. See «P/S PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/accessory-drive-belts/#power-assisted-steering-system__ps-pump-removal-and-installation) .
6. Remove engine front mounting brackets (1).
7. Remove piston and connecting rod. See «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__piston-piston-ring-and-connecting-rod) .
8. Remove oil pump chain adjuster (1) from lower crank case.
9. Remove CKP sensor. See «CKP (CRANKSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__ckp-crankshaft-position-sensor-removal-and) .
10. Loosen crank case bolt No. 2s in numerical order ("1" - "12") evenly and gradually.
11. Loosen crank case bolt No. 1s in numerical order ("1" - "10") evenly and gradually, and then remove lower crank case and rear oil seal. NOTE: Use 12-point socket wrench to crank case bolt No. 1s.
12. Remove crankshaft and oil pump chain from cylinder block.
13. Remove sensor plate (2) from crankshaft (1), if necessary. NOTE: Use T-30 security TORX® to loosen sensor plate screws (3).

Reference: CRANKSHAFT INSPECTION

Reference: MAIN BEARINGS INSPECTION

Reference: SENSOR PLATE INSPECTION

Reference: FLYWHEEL/DRIVE PLATE INSPECTION

Reference: CYLINDER BLOCK INSPECTION

Reference: OIL PUMP DRIVE SPROCKET INSPECTION

Reference: OIL PUMP CHAIN AND OIL PUMP CHAIN ADJUSTER INSPECTION

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

1. Install sensor plate (1) according to the following procedure. Attach spring pin (2) to crankshaft (3). NOTE: Use spring pin which is genuine SUZUKI part (09205-05006). Install sensor plate to crankshaft. CAUTION: Align spring pin hole (4) on sensor plate with spring pin on crankshaft. Inside edge (5) of sensor plate is bent. Install sensor plate properly. Tightening torque Sensor plate screw (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft) Detach spring pin from crankshaft.
2. Install main bearings to cylinder block and lower crankcase according to the following procedure. NOTE: Install main bearing halves with oil groove to cylinder block. Install other main bearing halves to lower crankcase. Fit the tab (1) on each bearing into recess (2) in cylinder block or lower crank case. Press bearing end (3) until it fully seat in cylinder block or lower crankcase. Apply engine oil to sliding surface (4) of main bearing halves. CAUTION: Do not apply engine oil between bearing halves (5) and cylinder block or lower crank case (5).
3. Install new O-rings (1) to cylinder block (3).
4. Install dowel pins (2) to cylinder block (3).
5. Apply engine oil to thrust bearings (1) and install them to cylinder block journal No. 3, with oil grooves (2) facing outward.
6. Apply engine oil to sliding surface of main bearings and crankshaft.
7. Install crankshaft to cylinder block, with oil pump chain installed to oil pump drive sprocket on crankshaft.
8. Apply sealant to mating surface of lower crankcase (1) as shown in figure. "A": Sealant 99000-31260 (SUZUKI Bond No. 1217G) Sealant bead size for lower crankcase Width "a": 3 mm (0.12 in.) Height "b": 2 mm (0.08 in.)
9. Install lower crank case to cylinder block and tighten crank case bolt No. 1s according to the following procedure. NOTE: If crank case bolt No. 1s are reused, check them for deformation referring to " «CRANK CASE BOLT NO. 1 INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__crank-case-bolt-no-1-inspection) " under «MAIN BEARINGS INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__main-bearings-inspection) . Use 12-point socket wrench to crank case bolt No. 1s. Apply engine oil to bolt threads and seats of crank case bolt No. 1 and tighten bolt to 50 N.m (5.1 kgf-m, 37.0 lbf-ft) in numerical order ("1" - "10") evenly and gradually. Loosen all bolts in reverse numerical order until loosening torque becomes 0. In the same manner as Step a), retighten them to 20 N.m (2.0 kgf-m, 15.0 lbf-ft). In the same manner as Step a), retighten them to 35 N.m (3.6 kgf-m, 26.0 lbf-ft). In the same manner as Step a), retighten them to 40°. In the same manner as Step a), retighten them to 40°. Tightening torque Crank case bolt No. 1* (a): 50 N.m --> 0 N.m --> 20 N.m --> 35 N.m --> 40° --> 40° (5.1 kgf-m --> 0 kgf-m --> 2.0 kgf-m --> 3.6 kgf-m --> 40° --> 40°, 37.0 lbf-ft --> 0 lbf-ft --> 15.0 lbf-ft --> 26.0 lbf-ft --> 40° --> 40°)
10. Tighten crank case bolt No. 2s in numerical order ("1" - "12") evenly and gradually. Tightening torque Crank case bolt No. 2* (a): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
11. Check that crankshaft rotates smoothly when turning it by hand.
12. Apply engine oil to new rear oil seal (1) and install it to cylinder block (2) using special tools. Special Tool (A): 09911-97710 (B): 09911-97811
13. Install pistons and connecting rods. See «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__piston-piston-ring-and-connecting-rod) .
14. Install oil pump chain adjuster (1). Tightening torque Oil pump chain adjuster bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
15. Install CKP sensor. See «CKP (CRANKSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-j24b__ckp-crankshaft-position-sensor-removal-and) .
16. Install flywheel for 5 M/T model, or drive plate for 4 A/T model. See «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .
17. Install engine front mounting brackets (1). Tightening torque Engine front mounting bracket bolt (a): 55 N.m (5.6 kg-m, 40.5 lbf-ft)
18. Install P/S pump. See «P/S PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/accessory-drive-belts/#power-assisted-steering-system__ps-pump-removal-and-installation) .
19. Install water pump. See «WATER PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-j24b) .
20. Install generator. See «GENERATOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
21. Install engine assembly. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Crankshaft Inspection

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

Crankshaft Runout

Using dial gauge, measure runout at center journal. Rotate crankshaft slowly.

If runout exceeds its limit, replace crankshaft.

Crankshaft runout

Limit: 0.02 mm (0.0007 in.)

Scheme 192

Scheme 193

1. Assemble crankshaft, main bearings, thrust bearings and lower crank case. See «MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__main-bearings-crankshaft-and-cylinder-block) .
2. Using dial gauge (1), measure crankshaft thrust play (2) as shown in figure. If measured thrust play is out of standard value, replace thrust bearing with new one (standard size or over size) to obtain standard thrust play. Recheck crankshaft thrust play. Crankshaft thrust play Standard: 0.10 - 0.35 mm (0.0040 - 0.0137 in.) Thrust bearing thickness Standard size: 2.470 - 2.520 mm (0.973 - 0.9921 in.) Oversize (0.125 mm, 0.00492 in.): 2.533 - 2.583 mm (0.0998 - 0.1016 in.)

Out-of-Round and Taper (Uneven Wear) of Journals

An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This difference, if any, is determined by taking micrometer readings.

If any one of journals is badly damaged or uneven wear exceeds its limit, regrind or replace crankshaft.

Crankshaft journal outside diameter

Standard: 51.982- 52.000 mm (2.0466 - 2.0472 in)

Limit: 51.972 mm (2.0461 in.)

Crankshaft out-of-round (A - B) and taper (a - b)

Limit: 0.01 mm (0.0003 in.)

Scheme 194

Main Bearings Inspection

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

Check bearings for pitting, scratches, wear or damage.

If any defective condition is found, replace both upper and lower halves. Never replace either half without replacing the other half.

Main Bearing Clearance

Note. After checking main bearing clearance, check crank case bolt No. 1 for deformation. See CRANK CASE BOLT NO. 1 INSPECTION .

Scheme 195

1. Remove lower crank case.
2. Clean bearings and crankshaft journals.
3. Place a piece of gauging plastic (1) over the full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.
4. Install lower crank case. See «MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__main-bearings-crankshaft-and-cylinder-block) .
5. After three minutes, remove lower crank case and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point. NOTE: If pair of crankshaft journal and cylinder block journal is in the following condition, different values are applied as standard. Stamped number for crankshaft journal diameter is "4", and stamped alphabet for cylinder block journal inside diameter is "A". Standard: 0.019 - 0.031 mm (0.00075 - 0.00122 in.) Stamped number for crankshaft journal diameter is "9", and stamped alphabet for cylinder block journal inside diameter is "F". Standard: 0.025 - 0.037 mm (0.00098 - 0.00145 in.) For more information about stamped number and stamped alphabet, refer to «SELECTION OF MAIN BEARINGS»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) . Main bearing clearance Standard: 0.022 - 0.034 mm (0.00087 - 0.00133 in.) Limit: 0.050 mm (0.00196 in.)

Scheme 196

If measured clearance is less than standard or more than service limit, replace main bearings with new ones referring to SELECTION OF MAIN BEARINGS and recheck main bearing clearance.

If measured clearance with new bearings is out of standard, select other bearings according to the following procedures and recheck main bearing clearance.

1. More than standard: Replace bearing with one size thicker or regrind crank shaft journal to undersize and use 0.25 mm undersize bearing (0.0098 in).
2. Less than standard: Replace bearing with one size thinner or regrind crank shaft journal to undersize and use 0.25 mm undersize bearing (0.0098 in).

Standard size bearing

If engine is under one of the following conditions, select a new standard bearings as follows, and install it.

1. Bearing is in defective condition.
2. Bearing clearance is out of specification.
3. Crankshaft or cylinder block is replaced.

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1. Check crankshaft journal diameter according to the following procedures. There are five stamped numbers (any of "4" through "9") on crank web No. 4 as shown in figure. Those numbers represent crankshaft journal diameter as follows. Determine crankshaft journal diameter for journals No. 1 through No. 5 using stamped numbers and following table. Crankshaft journal diameter CRANKSHAFT JOURNAL DIAMETER CHART Stamped numbers Journal diameter 4 51.997 - 52.000 mm (2.04713 - 2.04724 in.) 5 51.994 - 51.997 mm (2.04701 - 2.04712 in.) 6 51.991 - 51.994 mm (2.04689 - 2.04700 in.) 7 51.988 - 51.991 mm (2.04678 - 2.04688 in.) 8 51.985 - 51.988 mm (2.04666 - 2.04677 in.) 9 51.982 - 51.985 mm (2.04654 - 2.04665 in.)
2. Check cylinder block journal inside diameter according to the following procedures. There are five stamped alphabets (any of "A" through "F") on Lower crank case as shown in figure. Those alphabets represent cylinder block journal inside diameter as follows. Determine cylinder block journal inside diameter for journals No. 1 through No. 5 using stamped alphabets and following table. CRANKSHAFT JOURNAL DIAMETER CHART Stamped number Cylinder block journal in side diameter A 56.000 - 56.003 mm (2.20473 - 2.20484 in.) B 56.003 - 56.006 mm (2.20485 - 2.20496 in.) C 56.006 - 56.009 mm (2.20496 - 2.20507 in.) D 56.009 - 56.012 mm (2.20508 - 2.20519 in.) E 56.012 - 56.015 mm (2.20520 - 2.20531 in.) F 56.015 - 56.018 mm (2.20532 - 2.20543 in.)
3. There are 5 kinds of standard bearings differing in thickness. To distinguish them, they are painted in the following colors at the position as shown in figure. Each color indicated the following thickness at the center of bearing. Standard size crankshaft main bearing thickness BEARING THICKNESS CHART Painted color Bearing thickness Blue 2.011 - 2.014 mm (0.07918 - 0.07929 in) Yellow 2.008 - 2.011 mm (0.07906 - 0.07917 in) Colorless 2.005 - 2.008 mm (0.07894 - 0.07905 in) Black 2.002 - 2.005 mm (0.07882 - 0.07893 in) Green 1.999 - 2.002 mm (0.07870 - 0.07881 in)
4. Select new standard crankshaft bearings using stamped numbers for crankshaft journal diameter, stamped alphabets for cylinder block journal inside diameter and following table. Main bearing cross - reference selection table (standard size) MAIN BEARING CROSS REFERENCE Stamped number on crank web No. 4 4 5 6 7 8 9 Stamped alphabets on lower crank case A Upper Green Green Green Black Black Colorless Lower Green Green Black Black Colorless Colorless B Upper Green Green Black Black Colorless Colorless Lower Green Black Black Colorless Colorless Yellow C Upper Green Black Black Colorless Colorless Yellow Lower Black Black Colorless Colorless Yellow Yellow D Upper Black Black Colorless Colorless Yellow Yellow Lower Black Colorless Colorless Yellow Yellow Blue E Upper Black Colorless Colorless Yellow Yellow Blue Lower Colorless Colorless Yellow Yellow Blue Blue F Upper Colorless Colorless Yellow Yellow Blue Blue Lower Colorless Yellow Yellow Blue Blue Blue

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Scheme 201

1. 0.25 mm undersize bearing is available, in five kinds varying in thickness. To distinguish them, each bearing is painted in the following colors at such position as indicated in figure. Each color represents the following thickness at the center of bearing. Undersize of crankshaft main bearing thickness BEARING THICKNESS CHART Painted color Bearing thickness Red & Blue 2.136 - 2.139 mm (0.08410 - 0.08421 in.) Red & Yellow 2.133 - 2.136 mm (0.08398 - 0.08409 in.) Red 2.130 - 2.133 mm (0.08386 - 0.08397 in.) Red & Black 2.127 - 2.130 mm (0.08374 - 0.08385 in.) Red & Green 2.124 - 2.127 mm (0.08362 - 0.08374 in.)
2. If necessary, regrind crankshaft journal and select undersize bearing to use with it as follows. Regrind crankshaft journal to the following finished diameter. Finished crankshaft journal diameter 52.232 - 52.250 mm (2.05638 - 2.05708 in.) Using micrometer, measure reground journal diameter. See «CRANKSHAFT INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__crankshaft-inspection) Using measured journal diameter above and alphabets stamped on cylinder block, select an undersize bearing by referring to the following table. Main bearing cross - reference table (under size) MAIN BEARING CROSS REFERENCE Measured journal diameter 52.2470 - 52.2499 (2.05697 - 2.05708 in.) 52.2440 - 52.2469 (2.05686 - 2.05696 in.) 52.2410 - 52.2439 (2.05674 - 2.05684 in.) 52.2380 - 52.2409 (2.05662 - 2.05672 in.) 52.2350 - 52.2379 (2.05650 - 2.05661 in.) 52.2320 - 52.2349 (2.05638 - 2.05649 in.) Stamped alphabet on lower crank case A Upper Red & Green Red & Green Red & Green Red & Black Red & Black Red Lower Red & Green Red & Green Red & Black Red & Black Red Red B Upper Red & Green Red & Green Red & Black Red & Black Red Red Lower Red & Green Red & Black Red & Black Red Red Red & Yellow C Upper Red & Green Red & Black Red & Black Red Red Red & Yellow Lower Red & Black Red & Black Red Red Red & Yellow Red & Yellow D Upper Red & Black Red & Black Red Red Red & Yellow Red & Yellow Lower Red & Black Red Red Red & Yellow Red & Yellow Red & Blue E Upper Red & Black Red Red Red & Yellow Red & Yellow Red & Blue Lower Red Red Red & Yellow Red & Yellow Red & Blue Red & Blue F Upper Red Red Red & Yellow Red & Yellow Red & Blue Red & Blue Lower Red Red & Yellow Red & Yellow Red & Blue Red & Blue Red & Blue Install selected main bearings and measure bearing clearance. See «MAIN BEARING CLEARANCE»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b__main-bearing-clearance) . If measured clearance is more than standard, replace bearings with one size thicker and recheck bearing clearance. If measured clearance is less than standard, replace bearings with one size thinner and recheck bearing clearance.

Crank Case Bolt No. 1 Inspection

Measure each thread diameter at specified points on crank case bolt No. 1 (1) using micrometer (2).

Calculate difference in diameters ("A" - "B").

If it exceeds limit, replace with new one.

Crank case bolt diameter measurement points

"a": 61.0 mm (2.40 in.)

"b": 98.0 mm (3.86 in.)

Crank case cap bolt diameter difference

Limit ("A" - "B"): 0.013 mm (0.0051 in.)

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Sensor Plate Inspection

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

Check sensor plate (1) for crack or damage.

If defective condition is found, replace it.

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Oil Pump Drive Sprocket Inspection

Check oil pump drive sprocket (2) for crack or any damage.

If defective condition is found, replace crankshaft (1).

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Oil Pump Chain

Check oil pump chain for wear or any damage.

If malcondition is found, replace oil pump chain.

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Oil Pump Chain Adjuster

Check oil pump chain adjuster according to the following procedures.

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1. Check latch (1), teeth (2), plunger (3) or tensioner (4) for crack, wear or any damage.
2. Check that plunger (3) moves in direction [b] and does not move in direction [a] when latch (1) engages with plunger teeth (2).
3. Check that plunger (2) moves in direction [b] freely and smoothly when latch (1) is raised up in direction [a].
4. Check that tensioner (3) moves in direction [c] freely and smoothly.

If defective condition is found, replace oil pump chain adjuster.

Flywheel/Drive Plate Inspection

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

1. Check ring gear of flywheel for 5 M/T model or drive plate for 4 A/T model, for crack, wear or any damage. If defective condition is found, replace flywheel for 5 M/T model or drive plate for 4 A/T model. See «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Flywheel/Drive Plate Face Runout

1. Check flywheel for 5 M/T model or drive plate for 4 A/T model for runout using dial gauge and "V" blocks. If measured runout exceeds its limit, replace flywheel for 5 M/T model or drive plate for 4 A/T model. See «FLYWHEEL/DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-j24b) .

Flywheel/drive plate face runout

Limit: 0.2 mm (0.0078 in.)

Scheme 208

Cylinder Block Inspection

Reference: MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

Distortion of Gasket Surface

Using straightedge and thickness gauge, check gasket surface for distortion and, if flatness exceeds its limit, repair It.

If repair is not possible, replace cylinder block.

Cylinder block flatness

Limit: 0.03 mm (0.001 in.)

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Tightening Torque Specifications

TIGHTENING TORQUE SPECIFICATIONS

Note. The specified tightening torque is described in the following. AIR CLEANER COMPONENTS CYLINDER HEAD COVER COMPONENTS CAMSHAFT AND TAPPET COMPONENTS ENGINE MOUNTINGS COMPONENTS TIMING CHAIN COVER COMPONENTS TIMING CHAIN AND CHAIN TENSIONER COMPONENTS VALVE AND CYLINDER HEAD COMPONENTS PISTON, PISTON RING AND CONNECTING ROD COMPONENTS MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Reference

For the tightening torque of fastener not specified in this information, refer to FASTENER INFORMATION .

Recommended Service Material

SPECIAL TOOLS REFERENCE

Note. Required service material is also described in the following. CYLINDER HEAD COVER COMPONENTS CAMSHAFT AND TAPPET COMPONENTS TIMING CHAIN COVER COMPONENTS TIMING CHAIN AND CHAIN TENSIONER COMPONENTS VALVE AND CYLINDER HEAD COMPONENTS PISTON, PISTON RING AND CONNECTING ROD COMPONENTS MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Special Tool

SPECIAL TOOL REFERENCE 09911-05120 Box end wrench (14 mm) 09911-97710 Oil seal guide 09911-97811 Oil seal installer 09913-75510 Bearing installer 09915-64512 Compression gauge 09915-64530 Compression gauge hose 09915-67010 Compression gauge attachment (C) 09915-67311 Vacuum gauge 09916-14510 Valve lifter 09916-14522 Valve spring compressor attachment 09916-34542 Reamer handle 09916-34550 Valve guide reamer (5.5 mm) 09916-37320 Valve guide outer reamer (10.5 mm) 09916-44910 Valve guide installer & remover 09916-56510 Valve guide installer attachment 09916-58210 Valve guide installer handle 09916-77310 Piston ring compressor (50-125 mm) 09916-84511 Forceps 09917-16510 Timing chain tensioner holder 09917-47011 Vacuum pump gauge 09917-68221 Camshaft pulley holder 09917-98221 Valve guide stem attachment 09924-17811 Flywheel holder 09926-58010 Bearing remover attachment 09944-36011 Steering wheel remover

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See also:
• SPARK PLUG REMOVAL AND INSTALLATION
• IDLE SPEED AND IAC THROTTLE VALVE OPENING INSPECTION
• COOLING SYSTEM DRAINING
• COOLING SYSTEM REFILLING
• ENGINE COOLING SYSTEM INSPECTION
• THROTTLE BODY ASSEMBLY ON-VEHICLE INSPECTION
• OIL COOLER HOSE AND PIPE COMPONENTS
• BRAKE BOOSTER COMPONENTS
• ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION
• FUEL PRESSURE RELIEF PROCEDURE
• BATTERY REMOVAL AND INSTALLATION
• ENGINE OIL AND FILTER CHANGE
• MANUAL TRANSMISSION OIL CHANGE
• P/S FLUID CHANGE
• TRANSFER OIL CHANGE
• TRANSFER OIL CHANGE
• FRONT DIFFERENTIAL OIL CHANGE
• FRONT BUMPER COMPONENTS
• COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION
• CLUTCH FLUID PIPE REMOVAL AND INSTALLATION
• EXHAUST SYSTEM COMPONENTS
• PROPELLER SHAFT REMOVAL AND INSTALLATION
• A/C CONDENSER ASSEMBLY REMOVAL AND INSTALLATION
• FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS COMPONENTS
• STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION
• FUEL LEAKAGE CHECK PROCEDURE
• OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
• COOLING SYSTEM COMPONENTS
• EXHAUST MANIFOLD REMOVAL AND INSTALLATION (J24B)
• FUEL INJECTOR REMOVAL AND INSTALLATION
• OIL PUMP ASSEMBLY REMOVAL AND INSTALLATION
• CKP (CRANKSHAFT POSITION) SENSOR REMOVAL AND INSTALLATION
• KNOCK SENSOR REMOVAL AND INSTALLATION
• P/S PUMP REMOVAL AND INSTALLATION
• FASTENER INFORMATION
• CYLINDER HEAD COVER REMOVAL AND INSTALLATION
• CAMSHAFT AND TAPPET REMOVAL AND INSTALLATION
• AIR CLEANER COMPONENTS
• AIR CLEANER FILTER INSPECTION AND CLEANING
• AIR CLEANER FILTER REMOVAL AND INSTALLATION
• THROTTLE BODY CLEANING
• AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION
• THROTTLE BODY ASSEMBLY REMOVAL AND INSTALLATION
• INTAKE MANIFOLD REMOVAL AND INSTALLATION
• CYLINDER BLOCK HEATER INSPECTION (IF EQUIPPED)
• CAMSHAFT AND TAPPET INSPECTION
• VALVE CLEARANCE INSPECTION AND ADJUSTMENT
• TIMING CHAIN COVER REMOVAL AND INSTALLATION
• TIMING CHAIN COVER INSPECTION
• TIMING CHAIN AND CHAIN TENSIONER INSPECTION
• TIMING CHAIN AND CHAIN TENSIONER REMOVAL AND INSTALLATION
• VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION
• CYLINDER HEAD INSPECTION
• CYLINDER HEAD BOLT INSPECTION
• VALVE AND VALVE GUIDE INSPECTION
• VALVE SPRING INSPECTION
• PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION
• CRANKSHAFT PIN AND CONNECTING ROD BEARINGS INSPECTION
• CONNECTING ROD BOLT DEFORMATION
• PISTON PINS AND CONNECTING RODS INSPECTION
• CYLINDER, PISTON AND PISTON RING INSPECTION
• CONNECTING ROD BEARING CLEARANCE
• MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION
• CRANKSHAFT INSPECTION
• MAIN BEARINGS INSPECTION
• SENSOR PLATE INSPECTION
• FLYWHEEL/DRIVE PLATE INSPECTION
• CYLINDER BLOCK INSPECTION
• OIL PUMP DRIVE SPROCKET INSPECTION
• CRANK CASE BOLT NO. 1 INSPECTION
• MAIN BEARING CLEARANCE