Engine Mechanical (n32a) Suzuki Grand Vitara II рестайлинг

Engine Construction Description

The engine is a water-cooled, 60° V6 cylinders, 4-stroke-cycle gasoline unit with its DOHC (Double overhead camshaft) valve mechanism arranged for "V" type valve configuration. The double overhead camshafts are mounted over the cylinder head. They are driven from crankshaft through timing chains, and no push rod is provided in the valve train system.

Scheme 235

1. Warm up engine to normal operating temperature.
2. Stop engine after warming up.
3. After warming up, place shift select lever to "P" range, and set parking brake and block drive wheels.
4. Remove engine cover and air cleaner outlet hose. CAUTION: When removing engine cover, be sure to lift up its front side to prevent breakage of engine cover claws.
5. Remove spark plug. See «SPARK PLUG REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-n32a) .
6. Disconnect fuel injector connectors.
7. Install special tools (Compression gauge) into spark plug hole. Special Tool (A): 09915-64512 (B): 09915-64530 (C): 09915-67010
8. Depress accelerator pedal all the way to make throttle fully open.
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 using fully charged battery. If measured compression pressure is lower than limit value, check installation condition of special tool. If it is properly installed, it way be leakage from piston ring and valve seat. Compression pressure Standard: 1200 kPa (12.2 kgf/cm 2 , 174 psi) Limit: 1000 kPa (10.2 kgf/cm 2 , 145 psi) Max. difference between any two cylinders: 150 kPa (1.5 kgf/cm 2 , 21.8 psi)
10. Carry out Steps 6) through 8) on all cylinders to obtain 6 readings.
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-n32a) .
12. Connect ignition coil connectors.
13. Connect fuel injector wires to their connectors.
14. Install engine cover and air cleaner outlet hose.

Engine Vacuum Check

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

Scheme 236

1. Warm up engine to normal operating temperature.
2. After warming up, place select lever to "P" range, and set parking brake and block drive wheels.
3. Stop engine and turn off all electric switches.
4. Connect SUZUKI scan tool to DLC (1) with ignition switch turned off. Special Tool (A): SUZUKI scan tool (SUZUKI-SDT)
5. Run engine at specified idle speed, and then select "Manifold Absolute Pressure" under "Data List" mode on scan tool. Manifold absolute pressure should be lower than specification.

Manifold absolute pressure specification (at sea level)

42 kPa (0.42 kgf/cm 2 , 6.09 psi, 0.42 bar) or less at specified idle speed

Not using SUZUKI scan tool

1. Warm up engine to normal operating temperature.
2. After warming up, place select lever to "P" range, and set parking brake and block drive wheels.
3. Stop engine and turn off all electric switches.
4. Remove PCV hose (1) from breather pipe (2).
5. Connect special tool (Vacuum gauge) to PCV hose. Special Tool (A): 09915-67311
6. Close breather pipe using tape (3) or the like.
7. Run engine at specified idle speed and read vacuum gauge. Vacuum should be higher than specification. Vacuum specification (at sea level) -59 kPa (-0.60 kgf/cm 2 , -8.56 psi, -0.59 bar) or more at specified idle speed
8. Disconnect special tool (Vacuum gauge) from breather pipe.
9. Open breather pipe and connect PCV hose to breather pipe.

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Scheme 238

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.

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Scheme 240

1. Disconnect negative cable from battery.
2. Disconnect MAF sensor connector (1) and remove MAF sensor (2).
3. Disconnect air cleaner outlet hose (3) from air cleaner assembly (4).
4. Remove air cleaner assembly.

Reverse removal procedure for installation noting the following.

1. Tighten MAF sensor bolt to specified torque.

Tightening torque

MAF sensor bolt: 3 N.m (0.3 kg-m, 2.5 lbf-ft)

Scheme 241

Tightening Order figure callout references

7), 8), 9): INTAKE MANIFOLD REMOVAL AND INSTALLATION

Throttle Body Removal and Installation

Reference: INTAKE MANIFOLD AND THROTTLE BODY COMPONENTS

Scheme 242

1. Disconnect negative cable from battery.
2. Disconnect air cleaner outlet hose (1) and throttle body connector (2) from throttle body (3).
3. Remove throttle body from intake manifold.

Scheme 243

1. Clean mating surfaces of intake manifold and throttle body.
2. Install new gasket and throttle body (3) to intake manifold.
3. Connect air cleaner outlet hose (1) and throttle body connector (2) to throttle body (3) securely.
4. Connect negative cable to battery.

Throttle Body Cleaning

Reference: THROTTLE BODY REMOVAL AND INSTALLATION

Clean throttle body assembly. See ELECTRIC THROTTLE SYSTEM ON-VEHICLE INSPECTION .

Intake Manifold Removal and Installation

Reference: INTAKE MANIFOLD AND THROTTLE BODY COMPONENTS

Scheme 244

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF PROCEDURE»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-n32a__fuel-pressure-relief-procedure) .
2. Disconnect negative cable at battery.
3. Remove engine cover. CAUTION: When removing engine cover, be sure to lift up its front side to prevent breakage of engine cover claws.
4. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__cooling-system-draining) .
5. Remove throttle body assembly. See «THROTTLE BODY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__throttle-body-removal-and-installation) .
6. Remove the following parts. Purge pipe bolt (1) Purge valve bracket bolt (2) Electric wire bracket bolt (3) Water bypass hose (4) PCV hose (5) Brake booster hose (6) Purge hose (7)
7. Remove intake upper manifold and intake manifold upper gasket.
8. Remove fuel injectors. See «FUEL INJECTOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-n32a__fuel-injector-removal-and-installation) .
9. Remove intake lower manifold and intake manifold lower gasket.

Reverse removal procedure for installation noting the following.

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Scheme 248

1. Install new gaskets (1) as shown in figure.
2. Tighten intake manifold bolt as follows. Tighten intake manifold bolts (No. 1 and No. 2) to 10 N.m (1.0 kgf-m, 7.5 lbf-ft) in numerical order ("1" - "6") shown in figure evenly and gradually. Tighten intake manifold bolts (No. 1, No. 2 and No. 3) to 25 N.m (2.5 kgf-m, 18.5 lbf-ft) in numerical order ("1" - "8") shown in figure evenly and gradually. Tightening torque Intake manifold bolt No. 1* (a): 10 N.m --> 25 N.m (1.0 kgf-m --> 2.5 kgf-m, 7.5 lbf-ft --> 18.5 lbf-ft) Intake manifold bolt No. 2* (b): 10 N.m --> 25 N.m (1.0 kgf-m --> 2.5 kgf-m, 7.5 lbf-ft --> 18.5 lbf-ft) Intake manifold bolt No. 3* (c): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
3. Tighten purge pipe bolt (1) and purge valve bracket bolt (2) to specified torque. Tightening torque Purge pipe bolt (a): 10 N.m (1.0 kg-m, 7.5 lbf-ft) Purge valve bracket bolt (b): 10 N.m (1.0 kg-m, 7.5 lbf-ft)
4. Check to ensure that all removed parts are back in place.
5. Upon completion of installation, turn ignition switch ON position without starting engine and check for fuel leaks.
6. Finally, start engine and check for engine coolant leaks.

Cylinder Head Cover Components

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 249

Tightening Order figure callout references

7): CYLINDER HEAD COVER REMOVAL AND INSTALLATION

Removal

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

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Scheme 251

1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF PROCEDURE»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-n32a__fuel-pressure-relief-procedure) .
2. Disconnect negative cable from battery.
3. Remove engine cover. CAUTION: When removing engine cover, be sure to lift up its front side to prevent breakage of engine cover claws.
4. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__cooling-system-draining) .
5. Remove intake upper manifold. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__intake-manifold-removal-and-installation) .
6. Remove ignition coil. See «IGNITION COIL ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-n32a) .
7. Remove delivery pipe. See «FUEL INJECTOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-n32a__fuel-injector-removal-and-installation) .
8. Disconnect the following electric wires. CMP sensor (1) OCV (2) Ground terminals (3) Engine wire harness clamps
9. Remove the following parts. Fuel pipe bracket (4) Engine wire harness bracket (5) Harness protector (6) Oil filler cap (7)
10. Remove cylinder head cover.
11. Install special tool to spark plug tube. Special Tool (A): Spark plug tube seal guide (EN-46101)
12. Disassemble cylinder head cover, if necessary. See «CYLINDER HEAD COVER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__cylinder-head-cover-components)

Reverse removal procedure for installation noting the following.

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Scheme 258

1. Install new O-ring.
2. Install new spark plug hole gasket (1) using special tool as shown in figure [A] or [B]. Special Tool (A): 09913-75510 Special Tool (B): Oil seal installer (J-25254-A) (C): Bearing and seal driver (J-5590)
3. Clean mating surface of cylinder head cover (bank 2) and plate. Apply sealant to plate mating surface as shown in figure. "A": Sealant 99000-31290 (SUZUKI Bond No. 1217F)
4. Clean mating surface of cylinder head and cylinder head cover. Apply sealant to cylinder head and cylinder head cover mating surface as shown in figure. "A": Sealant 99000-31290 (SUZUKI Bond No. 1217F)
5. Install new cylinder head cover gasket (1) as shown in figure.
6. Tighten cylinder head cover bolt to 10 N.m (1.0 kgf-m, 7.5 lbf-ft) in numerical order ("1" - "13") shown in figure evenly and gradually. NOTE: When installing cylinder head cover, use care so that cylinder head cover gasket or spark plug hole gaskets will not get out of place or fall off. Tightening torque Cylinder head cover bolt* (a): 10 N.m (1.0 kg-m, 7.5 lbf-ft)
7. Remove special tool from spark plug tube. Special Tool (A): Spark plug tube seal guide (EN-46101)
8. Check to ensure that all removed parts are back in place.
9. Upon completion of installation, turn ignition switch to ON position without starting engine and check for fuel leaks.
10. Finally, start engine and check for engine coolant leaks.

Camshaft, CMP Actuator, Valve Lash Adjuster and Valve Rocker Arm Components

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 259

Tightening Order figure callout references

CAMSHAFT, CMP ACTUATOR, VALVE LASH ADJUSTER AND VALVE ROCKER ARM REMOVAL AND INSTALLATION

Camshaft, CMP Actuator, Valve Lash Adjuster and Valve Rocker Arm Removal and Installation

Reference: CAMSHAFT, CMP ACTUATOR, VALVE LASH ADJUSTER AND VALVE ROCKER ARM COMPONENTS

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 260

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Scheme 267

1. Remove cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
2. Remove CMP sensor. See «CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-n32a__camshaft-position-cmp-sensor-removal-and) .
3. Make sure that the flat sections (1) of camshafts are parallel to cylinder head (2).
4. Hold timing chain using special tool as follows. CAUTION: Do not remove special tool until camshaft and timing chain are installed. If special tool is removed before operations are completed, timing chain may not be installed correctly. Special Tool (A): 09918-57800 Insert special tool, align groove (1) of special tool and top surface (2) of cylinder head as shown in figure. Tighten special tool by hand until special tool hangs in timing chain (1) as shown in figure. NOTE: When tightening special tool, insert feet (3) of special tool into pocket (2) of timing chain to avoid misalignment of timing chain. Rotating hexagonal section of intake and exhaust camshafts inward with wrench or the like, tighten special tool by hand and fix timing chain.
5. Give match marks (1) on CMP actuator and timing chain as shown in figure.
6. With hexagonal section of camshaft held stationary with wrench or the like, remove CMP actuator bolt (1).
7. Loosen camshaft housing bolts in numerical order ("1" - "16") shown in figure, and remove intake and exhaust camshafts.
8. Remove intake and exhaust CMP actuators.
9. Remove valve lash adjusters (1) and valve rocker arms (2).

Scheme 268

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Scheme 276

1. Apply engine oil to sliding part of valve lash adjusters and valve rocker arms, and install them to cylinder head. NOTE: Do not expose valve lash adjuster to excessive shock so as to prevent oil leakage.
2. Install new seal rings (1) to camshafts (2) as shown in figure. NOTE: Position end gap of seal ring in a specified range.
3. Confirm identification mark (1) of camshafts, to install them to the correct positions in cylinder heads.
4. Apply engine oil to sliding part of camshafts, install camshafts to cylinder head as follows. Align match marks (1) on CMP actuators and timing chain, install intake and exhaust CMP actuators. Align lock pin (1) of CMP actuator with groove (2) of camshaft, install CMP actuator bolt by hand. That the flat sections (1) of camshafts are parallel to cylinder head (2). Install camshaft housings as indicated by embossed mark. Tighten new camshaft housing bolt to specified torque in numerical order ("1" - "16") shown in figure evenly and gradually. NOTE: Do not apply engine oil to camshaft housing bolt. Tightening torque Camshaft housing bolt* (a): 10 N.m (1.0 kg-m, 7.5 lbf-ft) With hexagonal section of camshaft held with wrench or the like, install CMP actuator bolt to specified torque. Tightening torque CMP actuator bolt (a): 58 N.m (5.9 kg-m, 43.0 lbf-ft)
5. Remove special tool. Special Tool (A): 09918-57800
6. Install CMP sensors. See «CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-n32a__camshaft-position-cmp-sensor-removal-and) .
7. Install cylinder head covers. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
8. Install delivery pipe. See «FUEL INJECTOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-n32a__fuel-injector-removal-and-installation) .
9. Install ignition coils. See «IGNITION COIL ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-n32a) .
10. Install intake upper manifold. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__intake-manifold-removal-and-installation) .
11. Refill cooling system with coolant. See «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
12. Install engine cover.
13. Connect negative cable to battery.
14. Upon completion of installation, turn ignition switch to ON position without starting engine and check for fuel leaks.
15. Finally, start engine and check for engine coolant leaks.

Camshaft, CMP Actuator, Valve Lash Adjuster and Valve Rocker Arm Inspection

Reference: CAMSHAFT, CMP ACTUATOR, VALVE LASH ADJUSTER AND VALVE ROCKER ARM REMOVAL AND INSTALLATION

Cam Wear

Using micrometer, measure cam height "a". If measured height is lower than its limit, replace camshaft.

Cam height "a" of camshaft

CAM HEIGHT SPECIFICATION

Scheme 277

Camshaft Runout

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

If measured runout exceeds limit, replace camshaft.

Camshaft runout limit

CAMSHAFT RUNOUT SPECIFICATION

Scheme 278

Scheme 279

1. Check camshaft journals and camshaft housings for pitting, scratches, wear or damage. If any defective condition is found, replace camshaft or cylinder head with housings. Never replace cylinder head without replacing housings.
2. Check clearance using gauging plastic as follows.

Scheme 280

Scheme 281

Scheme 282

1. Clean housings and camshaft journals.
2. Remove all valve lash adjusters and valve rocker arms.
3. Install camshafts to cylinder head.
4. Place a piece of gauging plastic to full width of journal of camshaft (parallel to camshaft).
5. Install camshaft housing referring to steps 2) to 4) of "Installation" under «CAMSHAFT, CMP ACTUATOR, VALVE LASH ADJUSTER AND VALVE ROCKER ARM REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__camshaft-cmp-actuator-valve-lash-adjuster) .
6. Remove housing, and using scale (2) on gauging plastic envelop, measure gauging plastic (1) width at its widest point. Camshaft journal clearance CAMSHAFT JOURNAL CLEARANCE SPECIFICATION Standard Limit 0.040 - 0.084 mm (0.0016 - 0.0033 in.) 0.10 mm (0.0039 in.)
7. If measured camshaft journal clearance exceeds limit, measure journal (housing) bore and outside diameter of camshaft journal. Replace camshaft or cylinder head assembly whichever the difference from specification is greater. Camshaft journal diameter [A] CAMSHAFT JOURNAL DIAMETER SPECIFICATION Item Standard Intake and Exhaust side No. 1 housing 34.936 - 34.960 mm (1.3754 - 1.3764 in.) Others 26.936 - 26.960 mm (1.0605 - 1.0614 in.) Camshaft journal housing bore [B] CAMSHAFT JOURNAL HOUSING BORE SPECIFICATION Item Standard Intake and Exhaust side No. 1 housing 35.000 - 35.020 mm (1.3780 - 1.3787 in.) Others 27.000 - 27.020 mm (1.0630 - 1.0638 in.)

Scheme 283

1. Install intake and exhaust camshaft without valve lash adjuster and valve rocker arm, measure intake and exhaust camshaft housing thrust clearance using dial gauge. If measured clearance exceed limit, replace camshaft or cylinder head. Camshaft housing thrust clearance CAMSHAFT HOUSING THRUST CLEARANCE SPECIFICATION Camshaft housing thrust clearance Standard 0.045 - 0.215 mm (0.0018 - 0.0085 in.) Limit 0.50 mm (0.0020 in.)

Valve Lash Adjuster and Valve Rocker Arm

Check valve rocker arm (1) and valve lash adjuster (2) for pitting, scratches, wear or damage.

If any defective condition is found, replace.

Scheme 284

CMP Actuator

Check CMP actuator for pitting, scratches, wear or damage.

If any defective condition is found, replace.

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1. Relieve fuel pressure. See «FUEL PRESSURE RELIEF PROCEDURE»(/suzuki/grand-vitara/ii-2008-2012/remont/fuel-system/#fuel-system-n32a__fuel-pressure-relief-procedure) .
2. Remove battery.
3. Disconnect ECM connectors. See «ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-n32a__engine-control-module-ecm-removal-and) .
4. Remove engine cover. CAUTION: When removing engine cover, be sure to lift up its front side to prevent breakage of engine cover claws.
5. Remove engine front under cover and engine rear under cover.
6. Drain engine oil. See «ENGINE OIL AND FILTER CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-n32a__engine-oil-and-filter-change) .
7. Drain A/T fluid (5A/T model). See «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) .
8. Drain front differential oil (4WD model). See «FRONT DIFFERENTIAL OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/differentials-drive-axles/#differential-front) .
9. Drain transfer oil (4WD model). See «TRANSFER OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/transfer-case/#transfer-motor-shift-type) .
10. Drain coolant. See «COOLING SYSTEM DRAINING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a__cooling-system-draining) .
11. Drain 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) .
12. Recover refrigerant from A/C system. See «OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system) .
13. Remove air cleaner assembly and air cleaner suction pipe. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
14. Disconnect suction hose and discharge hose from compressor. See «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system__compressor-assembly-removal-and-installation) .
15. Remove glove box (1) and instrument panel under cover (2).
16. Remove P/S reservoir tank (1) from bracket.
17. Remove fuse block (2) from bracket.
18. Remove engine wire harness clamps from vehicle body.
19. Disconnect the following electric wires and connectors. Connector from relay box (3) Ground terminal (4) Radiator cooling fan connector (5) Fuse block connector (6) TCM connector (7) 4WD Control Module connector (4WD model) (8) Height sensor connector (9)
20. Disconnect engine harness from cabin.
21. Disconnect the following hoses. Brake booster hose (1) Heater hoses (2) Fuel feed hose (3)
22. Remove front bumper. See «FRONT BUMPER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exterior-body-panels/#body-structure) .
23. Remove liquid pipe (1) from condenser.
24. Disconnect steering lower shaft assembly from pinion shaft of 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) .
25. Remove exhaust center pipe and exhaust No. 1 pipe. See «EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-pipe-and-muffler-removal-and) .
26. Remove front propeller shaft (4WD model) and rear propeller shaft. See «PROPELLER SHAFT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/driveshaft-universal-joints/#propeller-shaft) .
27. Remove front drive shaft. See «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/axle-shafts/#drive-shaftaxle-front__front-drive-shaft-assembly-removal-and) .
28. Disconnect select cable from transmission range sensor and bracket (5A/T model). See «SELECT CABLE COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) .
29. Before removing engine with transmission, transfer, front suspension frame and engine rear mounting member from engine compartment, make sure all hoses, electric wires and cables from them are disconnected.
30. Support front suspension frame and engine rear mounting member using engine jack.
31. Remove front suspension frame mounting bolts and engine rear mounting member bolts.
32. Lower engine with transmission, transfer, front suspension frame and engine rear mounting member from engine compartment.
33. Remove engine harness from engine, transmission and transfer.
34. Disconnect high pressure hose and suction hose from P/S pump. See «P/S HOSE/PIPE COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/accessory-drive-belts/#power-assisted-steering-system) .
35. Disconnect transmission from engine (5A/T model). See «AUTOMATIC TRANSMISSION UNIT COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) . NOTE: Only when over hauling engine proceed to Step 36) - 43).
36. Using lifting device, support engine.
37. Remove intake manifold. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__intake-manifold-removal-and-installation) .
38. Remove exhaust manifold. See «EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A)»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-manifold-removal-and-installation-n32a) .
39. Remove starting motor. See «STARTING MOTOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/starter/#starting-system) .
40. Remove generator. See «GENERATOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
41. 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) .
42. Remove A/C compressor. See «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system__compressor-assembly-removal-and-installation) .
43. Remove front suspension frame. See «FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/wheel-hubs/#front-suspension) .

Scheme 297

Scheme 298

Scheme 299

1. Using lifting device, support engine.
2. Install front suspension frame to engine. See «FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/wheel-hubs/#front-suspension) .
3. Install A/C compressor. See «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system__compressor-assembly-removal-and-installation) .
4. 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) .
5. Install generator. See «GENERATOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
6. Install starting motor. See «STARTING MOTOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/starter/#starting-system) .
7. Install exhaust manifold. See «EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A)»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-manifold-removal-and-installation-n32a) .
8. Install intake manifold. See «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__intake-manifold-removal-and-installation) .
9. Connect transmission to engine (5A/T model). See «AUTOMATIC TRANSMISSION UNIT COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) .
10. Connect high pressure hose and suction hose to P/S pump. See «P/S HOSE/PIPE COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/accessory-drive-belts/#power-assisted-steering-system) .
11. Install engine harness to engine, transmission and transfer.
12. Lift engine with transmission, transfer, front suspension frame and engine rear mounting member into engine compartment. See «ENGINE MOUNTINGS COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
13. Tighten front suspension frame bolt. See «FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/wheel-hubs/#front-suspension) .
14. Remove engine jack.
15. Connect select cable to transmission range sensor and bracket (5A/T model). See «SELECT CABLE COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) .
16. Install front drive shaft. See «FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/axle-shafts/#drive-shaftaxle-front__front-drive-shaft-assembly-removal-and) .
17. Install front propeller shaft (4WD model) and rear propeller shaft. See «PROPELLER SHAFT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/driveshaft-universal-joints/#propeller-shaft) .
18. Install exhaust center pipe and exhaust No. 1 pipe. See «EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-pipe-and-muffler-removal-and) .
19. Connect steering lower shaft assembly to pinion shaft of 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) .
20. Install liquid pipe (1) to condenser. 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) .
21. Install front bumper. See «FRONT BUMPER COMPONENTS»(/suzuki/grand-vitara/ii-2008-2012/remont/exterior-body-panels/#body-structure) .
22. Connect suction hose and discharge hose to compressor. See «COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system__compressor-assembly-removal-and-installation) .
23. Put back disconnected hoses, cables and electric wires for connection noting the following. Tighten ground terminal bolts to specified torque. Tightening torque Ground terminal bolt (a): 11 N.m (1.1 kg-m, 8.5 lbf-ft)
24. Install glove box (1) and instrument panel under cover (2).
25. Install air cleaner assembly and air cleaner suction pipe. See «AIR CLEANER ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
26. Check to ensure that all removed parts are back in place.
27. Evacuate and charge the A/C system. See «OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-hvac-system/#air-conditioning-system) .
28. Refill P/S system. See «P/S FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/accessory-drive-belts/#power-assisted-steering-system__ps-fluid-change) .
29. Refill cooling system with coolant. See «COOLING SYSTEM REFILLING»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
30. Refill transfer (4WD model). See «TRANSFER OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/transfer-case/#transfer-motor-shift-type) .
31. Refill front differential (4WD model). See «FRONT DIFFERENTIAL OIL CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/differentials-drive-axles/#differential-front) .
32. Refill A/T (5A/T model). See «A/T FLUID CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/automatic-trans/#automatic-transaxle-5at) .
33. Refill engine with engine oil. See «ENGINE OIL AND FILTER CHANGE»(/suzuki/grand-vitara/ii-2008-2012/remont/lubrication-system/#engine-lubrication-system-n32a__engine-oil-and-filter-change) .
34. Install engine front under cover and engine rear under cover.
35. Install engine cover.
36. Connect ECM connectors. See «ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-n32a__engine-control-module-ecm-removal-and) .
37. Install battery.

Scheme 300

Tightening Order/Removal and Installation figure callout references

1), 8), 11): TIMING CHAIN COVER REMOVAL AND INSTALLATION

Timing Chain Cover Removal and Installation

Reference: TIMING CHAIN COVER COMPONENTS

Scheme 301

Scheme 302

Scheme 303

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

1. Remove engine assembly from vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
2. Remove accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
3. Remove cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
4. Remove water pump pulley. See «WATER PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
5. Remove P/S pump bracket. 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 OCV. See «OCV REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
7. Remove belt idler arm from generator bracket.
8. Remove water outlet pipe No. 1 (1), water outlet pipe No. 2 (2), O-ring (3) and gasket (4).
9. Lock flywheel with special tool as shown in figure. Special Tool (A): 09916-97830
10. Remove crankshaft pulley bolt (1).
11. Using special tools, remove crankshaft pulley (1) as shown in figure. Special Tool (A): 09910-97810 (B): 09912-37830
12. Remove accessory drive belt tensioner (1) from timing chain cover.
13. Remove timing chain cover.
14. Remove water pump inner gasket (1) from timing chain cover (2).
15. Remove oil seal (1) from timing chain cover (2).
16. Using special tool, remove crankshaft oil seal (1) from timing chain cover (2) as shown in figure. Special Tool (A): 09913-57830
17. If necessary, remove water pump from timing chain cover. See «WATER PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
18. If necessary, remove CMP sensor from timing chain cover. See «CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-n32a__camshaft-position-cmp-sensor-removal-and) .

Scheme 309

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

Scheme 316

Scheme 317

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

1. Clean sealing surface on timing chain cover, cylinder block and cylinder head.
2. Install new water pump inner gasket (1) to timing chain cover (2).
3. Using special tool, install new crankshaft oil seal (1) to timing chain cover (2) as shown in figure [A] or [B]. NOTE: Do not apply engine oil and grease to crankshaft oil seal. Special Tool (A): 09926-68310 (B): 09913-75821 Special Tool (C): Oil seal installer (J-29184)
4. Using special tool, install new oil seal (1) to timing chain cover as shown in figure. Special Tool (A): 09913-57810
5. Install special tool to cylinder head. Special Tool (A): Engine front cover installation guide pins (EN-46109)
6. Apply sealant "A" to mating surface of cylinder head (1) and cylinder block (2) as shown in figure. "A": Sealant 99000-31290 (SUZUKI Bond No. 1217F)
7. Apply sealant "A" to mating surface of timing chain cover (1) as shown in figure. "A": Sealant 99000-31290 (SUZUKI Bond No. 1217F) Sealant amount for timing chain cover Width "a": 3 mm (0.12 in.) Width "b": 5 mm (0.20 in.) Height "c": 2.5 mm (0.10 in.)
8. Install timing chain cover and accessory drive belt tensioner as follows. NOTE: Before installing timing chain cover, check that dowel pin is securely fitted. Tighten timing chain cover bolt to 20 N.m (2.0 kgf-m, 15.0 lbf-ft) in numerical order ("1" - "22") shown in figure evenly and gradually. In the same manner as Step a), retighten them to 60°. Tighten accessory drive belt tensioner bolt ("23") to 25 N.m (2.5 kgf-m, 18.5 lbf-ft). Tightening torque Timing chain cover bolt * (a): 20 N.m --> +60° (2.0 kgf-m --> +60°, 15 lbf-ft --> +60°) Accessory drive belt tensioner bolt* (b): 25 N.m (2.5 kg-m, 18.5 lbf-ft)
9. Remove special tool. Special Tool (A): Engine front cover installation guide pins (EN-46109)
10. Install new O-ring (3) and new gasket (4).
11. Install water outlet pipe No. 1 (1) and water outlet pipe No. 2 (2)
12. Lock flywheel with special tool as shown in figure. Special Tool (A): 09916-97830
13. Apply engine oil between crankshaft pulley and crankshaft. NOTE: Do not apply engine oil between crankshaft oil seal and crankshaft pulley.
14. Using special tool, install crankshaft pulley (1) to crankshaft as shown in figure. Special Tool (A): 09912-37820
15. Remove special tool, tighten crankshaft pulley bolt as follows. Tighten crankshaft pulley bolt to 120 N.m (12.2 kgf-m, 88.5 lbf-ft). Loosen crankshaft pulley bolt until loosening torque is 0. Tighten crankshaft pulley bolt to 100 N.m (10.2 kgf-m, 74.0 lbf-ft). Retighten crankshaft pulley bolt to 150°. Tightening torque Timing chain cover bolt * (a): 120 N.m --> 0 N.m --> 100 N.m --> +150° (12.2 kgf-m --> 0 kgf-m --> 10.2 kgf-m --> +150°, 88.5 lbf-ft --> 0 lbf-ft --> 74.0 lbf-ft --> +150°)
16. Install belt idler arm to generator bracket. See «TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
17. Install OCV. See «OCV REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
18. Install P/S pump bracket. 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 pulley. See «WATER PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
20. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
21. Install accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
22. Install engine assembly to vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .

Timing Chain Cover Inspection

Reference: TIMING CHAIN COVER REMOVAL AND INSTALLATION

Oil Seal

Check oil seal lip for damage. Replace as necessary.

Scheme 323

1. Remove engine block heater (1) while lock lever (2) is unlocked.
2. Disconnect engine block heater harness (3) from engine block heater.

Reverse removal procedure for installation.

Engine Block Heater Inspection (Canadian Specification)

Reference: ENGINE BLOCK HEATER REMOVAL AND INSTALLATION (CANADIAN SPECIFICATION)

Check continuity between terminal "a" and "b". If there is no continuity, replace engine block heater.

Scheme 324

Scheme 325

1. Disconnect negative cable from battery.
2. With hose connected, detach P/S reservoir tank (1) from its bracket.
3. With hose connected, detach water reservoir tank (2) from radiator.
4. Disconnect OCV connector (3).
5. Remove OCV (4) from timing chain cover.

Reverse removal procedure for installation noting the following.

Scheme 326

1. Tighten OCV bolt to specified torque. Tightening torque OCV bolt (a): 12 N.m (1.2 kg-m, 9.0 lbf-ft)
2. Check to ensure that all removed parts are back in place.
3. Finally, start engine and check for engine oil leaks.

OCV Inspection

Reference: OCV REMOVAL AND INSTALLATION

Refer to OCV INSPECTION

Scheme 327

Scheme 328

1. Remove engine assembly from vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
2. Lock flywheel with special tool as shown in figure. Special Tool (A): 09916-97830
3. Remove drive plate (1).

Reverse removal procedure for installation noting the following.

Scheme 329

1. Use new drive plate bolt.
2. Tighten drive plate bolt as follows. Tighten drive plate bolt to 30 N.m (3.1 kgf-m, 22.5 lbf-ft) in numerical order ("1" - "8") evenly and gradually. In the same manner as Step a), retighten them to 45°. Tightening torque Drive plate bolt * (a): 30 N.m --> +45° (3.1 kgf-m --> +45°, 22.5 lbf-ft --> +45°)

Drive Plate Inspection

Reference: DRIVE PLATE REMOVAL AND INSTALLATION

Visual Inspection

1. If ring gear is damaged, cracked or worn, replace drive plate.

Drive Plate Face Runout

Check drive plate face runout with a dial gauge.

If runout exceeds its limit, replace drive plate.

Drive plate face runout

Limit: 0.2 mm (0.0079 in.)

Scheme 330

2nd Timing Chain (Bank 1) and Timing Chain Tensioner Adjuster No. 1 Components

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 331

2nd Timing Chain (Bank 1) and Timing Chain Tensioner Adjuster No. 1 Removal and Installation

Reference: 2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 COMPONENTS

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 332

Scheme 333

Scheme 334

Scheme 335

Scheme 336

Scheme 337

1. Remove timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__timing-chain-cover-removal-and-installation) .
2. By turning crankshaft, align camshaft (bank 1) and crankshaft at specific position as follows. Using special tool, align circle mark (1) on crankshaft timing sprocket with circle mark (2) on oil pump. Special Tool (A): Crankshaft rotation socket (EN-46111) Make sure that the flat sections (1) of camshafts are parallel to cylinder head (2). Hold camshafts (bank 1) with special tool as shown in figure. Special Tool (A): 09917-67810
3. Remove timing chain tensioner adjuster No. 1 (1) and gasket (2).
4. Remove timing chain tensioner No. 1 (1).
5. Remove timing chain guide No. 1 (1).
6. Remove 2nd timing chain (Bank 1).

Scheme 338

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Scheme 350

Scheme 351

1. Check that circle mark (1) on crankshaft timing sprocket is in alignment with circle mark (2) on oil pump.
2. Install timing chain by aligning discrimination plates (2) of timing chain and triangle mark (1) on intake and exhaust CMP actuator as shown in figure.
3. Fit idler sprocket No. 1 to timing chain by aligning discrimination plate (2) of timing chain and match mark (3) on idler sprocket No. 1.
4. Remove special tool from camshaft (bank 1). Special Tool (A): 09917-67810
5. Turn crankshaft by about 90° paying attention to keep the alignment of timing chain.
6. Apply engine oil to sliding surface of timing chain guide No. 1 (1) and install it. Tighten timing chain guide No. 1 bolt to specified torque. Tightening torque Timing chain guide No. 1 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
7. Apply engine oil to sliding surface of timing chain tensioner No. 1 (1) and install it. Tighten timing chain tensioner No. 1 bolt to specified torque. Tightening torque Timing chain tensioner No. 1 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
8. Fix plunger in timing chain tensioner adjuster No. 1 as follows. Remove plunger (1) from timing chain tensioner adjuster No. 1 (2). Using special tool, turn plunger in arrow direction to contract it and install it to timing chain tensioner adjuster No. 1. Special Tool (A): 09917-67810 Hold plunger using lock pin (1) as follows.
9. Install new gasket (1) and timing chain tensioner adjuster No. 1 (2) and tighten timing chain tensioner adjuster No. 1 bolt to specified torque. Tightening torque Timing chain tensioner adjuster No. 1 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
10. Check that triangle mark (1) on intake CMP actuator, triangle mark (2) on exhaust CMP actuator and match mark (3) on idler sprocket No. 1 are in alignment with discrimination plates (4) of timing chain.
11. Remove lock pin (1) from timing chain tensioner adjuster No. 1.
12. Turn crankshaft clockwise by 2 revolutions and check that circle mark (1) on crankshaft timing sprocket are in alignment with circle mark (2) on oil pump.
13. Confirm that special tool is installed to camshaft (bank 1) and camshaft (bank 2). Special Tool (A): 09917-67830 (B): 09917-67810
14. Remove special tool. Special Tool (A): Crankshaft rotation socket (EN-46111)
15. Install timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__timing-chain-cover-removal-and-installation) .
16. Install belt idler arm to generator bracket. See «TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
17. Install OCV. See «OCV REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
18. Install P/S pump bracket. 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 pulley. See «WATER PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
20. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
21. Install accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
22. Install engine assembly to vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .

2nd Timing Chain (Bank 1) and Timing Chain Tensioner Adjuster No. 1 Inspection

Reference: 2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 REMOVAL AND INSTALLATION

Timing Chain Guide No. 1

Check shoe (1) for wear or damage.

Scheme 352

Timing Chain Tensioner No. 1

Check shoe (1) and contact surface of plunger (2) for wear or damage.

Scheme 353

2nd Timing Chain (Bank 1)

Check timing chain for wear or damage.

Scheme 354

Scheme 355

1. Check timing chain tensioner adjuster No. 1 and contact surface (1) of timing chain tensioner No. 1 for wear or damage. If any malfunction is found, replace adjuster No. 1.
2. Check that plunger (2) operates smoothly. If any malfunction is found, replace plunger (2).

1st Timing Chain and Timing Chain Tensioner Adjuster No. 2 Components

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 356

1st Timing Chain and Timing Chain Tensioner Adjuster No. 2 Removal and Installation

Reference: 1ST TIMING CHAIN AND TIMING CHAIN TENSIONER ADJUSTER NO. 2 COMPONENTS

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 357

Scheme 358

Scheme 359

Scheme 360

Scheme 361

Scheme 362

Scheme 363

Scheme 364

Scheme 365

Scheme 366

1. Remove 2nd timing chain (bank 1). See «2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-1-and) .
2. By turning crankshaft, align camshaft (bank 2) and crankshaft at specific position as follows. By using special tool, align circle mark (1) on crankshaft timing sprocket with circle mark (2) on oil pump. Special Tool (A): Crankshaft rotation socket (EN-46111) Make sure that the flat sections (1) of camshafts (bank 2) is parallel to cylinder head (2). Hold camshafts (bank 2) with special tool as shown in figure. Special Tool (A): 09917-67810 Remove special tool. Special Tool (A): Crankshaft rotation socket (EN-46111)
3. Remove timing chain tensioner adjuster No. 2 (1) and gasket (2).
4. Remove timing chain guide No. 2 (1).
5. Remove timing chain lower guide (1).
6. Remove 1st timing chain.
7. Remove idler sprocket No. 1 (1).
8. Remove crankshaft timing sprocket (1) and key (2).

Scheme 367

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Scheme 376

Scheme 377

Scheme 378

Scheme 379

Scheme 380

1. Install idler sprocket No. 1 (1) and tighten idler sprocket No. 1 bolt to specified torque. Tightening torque Idler sprocket No. 1 bolt (a): 58 N.m (5.9 kg-m, 43.0 lbf-ft)
2. Install key (2) to crankshaft.
3. Install crankshaft timing sprocket (1) to crankshaft. NOTE: Be sure to face circle mark (3) on crankshaft timing sprocket to timing chain cover side.
4. Check that circle mark (1) on crankshaft timing sprocket is in alignment with circle mark (2) on oil pump.
5. Install timing chain by aligning discrimination plates (2) of timing chain and triangle mark (1) on idler sprocket No. 1 and No. 2 as shown in figure.
6. Fit crankshaft timing sprocket to timing chain by aligning discrimination plate (2) of timing chain and circle mark (3) on crankshaft timing sprocket.
7. Apply engine oil to sliding surface of timing chain lower guide (1) and install it. Tighten timing chain lower guide bolt to specified torque. Tightening torque Timing chain lower guide bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
8. Apply engine oil to sliding surface of timing chain guide No. 2 (1) and install it. Tighten timing chain guide No. 2 bolt to specified torque. Tightening torque Timing chain guide No. 2 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
9. Fix plunger in timing chain tensioner adjuster No. 2 as follows. Remove plunger (1) from timing chain tensioner adjuster No. 2 (2). Using special tool, turn plunger in arrow direction to contract it and install it to timing chain tensioner adjuster No. 2. Special Tool (A): 09918-57810 Hold plunger using lock pin (1) as follows.
10. Install new gasket (1) and timing chain tensioner adjuster No. 2 (2) and tighten timing chain tensioner adjuster No. 2 bolt to specified torque. Tightening torque Timing chain tensioner adjuster No. 2 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
11. Check that triangle mark (1) on idler sprocket No. 1, triangle mark (2) on idler sprocket No. 2 and circle mark (3) on crankshaft timing sprocket are in alignment with discrimination plates (4) of timing chain.
12. Remove lock pin (1) from timing chain tensioner adjuster No. 2.
13. Turn crankshaft clockwise by 2 revolutions and check that circle mark (1) on crankshaft timing sprocket are in alignment with circle mark (2) on oil pump.
14. Confirm that special tool is installed to camshaft (bank 2).
15. Remove special tool from camshaft (bank 2). Special Tool (A): 09917-67810
16. Install 2nd timing chain (bank 1). See «2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-1-and) .
17. Install timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__timing-chain-cover-removal-and-installation) .
18. Install belt idler arm to generator bracket. See «TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
19. Install OCV. See «OCV REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
20. Install P/S pump bracket. 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) .
21. Install water pump pulley. See «WATER PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
22. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
23. Install accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
24. Install engine assembly to vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .

Timing Chain Guide No. 2

Check shoe (1) for wear or damage.

Scheme 381

Timing Chain Lower Guide

Check shoe (1) for wear or damage.

Scheme 382

1st Timing Chain

Check timing chain for wear or damage.

Scheme 383

Scheme 384

1. Check shoe (1) of timing chain tensioner adjuster No. 2 for wear or damage. If any malfunction is found, replace it.
2. Check that plunger (2) operates smoothly. If any malfunction is found, replace it.

Idler Sprocket No. 1

Check teeth of idler sprocket No. 1 for wear or damage.

Scheme 385

Crankshaft Timing Sprocket

Check teeth of crankshaft timing sprocket for wear or damage.

Scheme 386

2nd Timing Chain (Bank 2) and Timing Chain Tensioner Adjuster No. 3 Components

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 387

2nd Timing Chain (Bank 2) and Timing Chain Tensioner Adjuster No. 3 Removal and Installation

Reference: 2ND TIMING CHAIN (BANK 2) AND TIMING CHAIN TENSIONER ADJUSTER NO. 3 COMPONENTS

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 388

Scheme 389

Scheme 390

Scheme 391

1. Remove 1st timing chain. See «1ST TIMING CHAIN AND TIMING CHAIN TENSIONER ADJUSTER NO. 2 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__1st-timing-chain-and-timing-chain) .
2. Remove timing chain tensioner adjuster No. 3 (1) and gasket (2).
3. Remove timing chain tensioner No. 2 (1).
4. Remove timing chain guide No. 3 (1).
5. Remove 2nd timing chain (bank 2).
6. Remove idler sprocket No. 2 (1).

Scheme 392

Scheme 393

Scheme 394

Scheme 395

Scheme 396

Scheme 397

Scheme 398

Scheme 399

Scheme 400

Scheme 401

1. Install idler sprocket No. 2 (1) and tighten idler sprocket No. 2 bolt to specified torque. Tightening torque Idler sprocket No. 2 bolt (a): 58 N.m (5.9 kg-m, 43.0 lbf-ft)
2. Install timing chain by aligning discrimination plates (2) of timing chain and circle mark (1) on intake and exhaust CMP actuator as shown in figure.
3. Fit idler sprocket No. 2 to timing chain by aligning discrimination plate (2) of timing chain and match mark (3) on idler sprocket No. 2.
4. Apply engine oil to sliding surface of timing chain guide No. 3 (1) and install it. Tighten timing chain guide No. 3 bolt to specified torque. Tightening torque Timing chain guide No. 3 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
5. Apply engine oil to sliding surface of timing chain tensioner No. 2 (1) and install it. Tighten timing chain tensioner No. 2 bolt to specified torque. Tightening torque Timing chain tensioner No. 2 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
6. Fix plunger in timing chain tensioner adjuster No. 3 as follows. Remove plunger (1) from timing chain tensioner adjuster No. 3 (2). Using special tool, turn plunger in arrow direction to contract it and install it to timing chain tensioner adjuster No. 3. Special Tool (A): 09918-57810 Hold plunger using lock pin (1) as follows.
7. Install new gasket (1) and timing chain tensioner adjuster No. 3 (2) and tighten timing chain tensioner adjuster No. 3 bolt to specified torque. Tightening torque Timing chain tensioner adjuster No. 3 bolt (a): 23 N.m (2.3 kg-m, 17.0 lbf-ft)
8. Check that circle mark (1) on intake CMP actuator, circle mark (2) on exhaust CMP actuator and alignment mark (3) on idler sprocket No. 2 are in match with discrimination plates (4) of timing chain.
9. Remove lock pin (1) from timing chain tensioner adjuster No. 3.
10. Install 1st timing chain. See «1ST TIMING CHAIN AND TIMING CHAIN TENSIONER ADJUSTER NO. 2 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__1st-timing-chain-and-timing-chain) .
11. Install 2nd timing chain (bank 1). See «2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-1-and) .
12. Install timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__timing-chain-cover-removal-and-installation) .
13. Install belt idler arm to generator bracket. See «TENSIONER AND IDLER PULLEY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
14. Install OCV. See «OCV REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
15. Install P/S pump bracket. 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) .
16. Install water pump pulley. See «WATER PUMP REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-n32a) .
17. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
18. Install accessory drive belt. See «ACCESSORY DRIVE BELT REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
19. Install engine assembly to vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .

Timing Chain Tensioner No. 2

Check shoe (1) and contact surface (2) of plunger for wear or damage.

Scheme 402

Timing Chain Guide No. 3

Check shoe (1) for wear or damage.

Scheme 403

2nd Timing Chain (Bank 2)

Check timing chain for wear or damage.

Scheme 404

Scheme 405

1. Check timing chain tensioner adjuster No. 3 and contact surface (1) of timing chain tensioner No. 2 for wear or damage. If any malfunction is found, replace it.
2. Check that plunger (2) operates smoothly. If any malfunction is found, replace it.

Idler Sprocket No. 2

Check teeth of idler sprocket No. 2 for wear or damage.

Scheme 406

Valve and Cylinder Head Components

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 407

Cylinder Head Bolt Tightening Order

See VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION .

Valve and Cylinder Head Removal and Installation

Reference: VALVE AND CYLINDER HEAD COMPONENTS

Note. For identification of each cylinder and bank, refer to PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK .

Scheme 408

1. Remove engine assembly from vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
2. Remove cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
3. Remove generator bracket. See «GENERATOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
4. Remove timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__timing-chain-cover-removal-and-installation) .
5. Remove 2nd timing chain (bank 1), timing chain tensioner adjuster No. 1, timing chain tensioner No. 1 and timing chain guide No. 1. See «2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-1-and) .
6. Remove 2nd timing chain (bank 2), timing chain tensioner adjuster No. 3, timing chain tensioner No. 2 and timing chain guide No. 3. See «2ND TIMING CHAIN (BANK 2) AND TIMING CHAIN TENSIONER ADJUSTER NO. 3 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-2-and) .
7. Loosen cylinder head bolts No. 1 and No. 2 in numerical order ("1" - "10") as shown in figure, and remove cylinder head bolts No. 1 and No. 2.
8. If necessary, remove exhaust manifold. See «EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A)»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-manifold-removal-and-installation-n32a) .
9. If necessary, remove valve lash adjusters, valve rocker arms, intake and exhaust camshafts. See «CAMSHAFT, CMP ACTUATOR, VALVE LASH ADJUSTER AND VALVE ROCKER ARM REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__camshaft-cmp-actuator-valve-lash-adjuster) .
10. Remove cylinder head.

Scheme 409

Scheme 410

1. Clean mating surface of cylinder head and cylinder block.
2. Install dowel pins (1) to cylinder block.
3. Install new cylinder head gaskets (2) to cylinder block.
4. Install cylinder head as follows. CAUTION: Do not apply engine oil to cylinder head bolts No. 1 and No. 2. Tighten cylinder head bolts No. 1 to 30 N.m (3.1 kgf-m, 22.5 lbf-ft) in numerical order ("1" - "8") shown in figure evenly and gradually. In the same manner as Step a), retighten them to +150°. Tighten cylinder head bolt No. 2 to 15 N.m (1.5 kgf-m, 11.0 lbf-ft) in numerical order ("9" - "10") shown in figure evenly and gradually. In the same manner as Step c), retighten them to +75°. Tightening torque Cylinder head bolt No. 1 bolt* (a): 30 N.m --> +150° (3.1 kgf-m --> +150°, 22.5 lbf-ft --> +150°) Cylinder head bolt No. 2 bolt* (a): 15 N.m --> +75° (1.5 kgf-m --> +75°, 11.0 lbf-ft --> +75°)
5. Install 2nd timing chain (bank 2), timing chain tensioner adjuster No. 3, timing chain tensioner No. 2 and timing chain guide No. 3. See «2ND TIMING CHAIN (BANK 2) AND TIMING CHAIN TENSIONER ADJUSTER NO. 3 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-2-and) .
6. Install 2nd timing chain (bank 1), timing chain tensioner adjuster No. 1, timing chain tensioner No. 1 and timing chain guide No. 1. See «2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-1-and) .
7. Install timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__timing-chain-cover-removal-and-installation) .
8. Install generator bracket. See «GENERATOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/charging-system/#charging-system) .
9. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
10. Install engine assembly to vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .

Valves and Cylinder Head Disassembly and Reassembly

Reference: VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION

Scheme 411

Scheme 412

Scheme 413

Scheme 414

Scheme 415

Scheme 416

Scheme 417

Scheme 418

1. Place disassembled parts except valve stem seal in order so that they can be installed in their original positions.
2. For ease in servicing cylinder head, remove ECT sensor, spark plug, exhaust manifold from cylinder head. «ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-n32a) «SPARK PLUG REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-n32a) «EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A)»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-manifold-removal-and-installation-n32a)
3. Using special tools (Valve lifter) as shown in figure [A] or [B], compress valve spring and then remove valve cotters using special tool (Forceps). Special Tool (A): 09916-14510 (B): 09916-14530 (C): 09916-84511 Special Tool (D): Off-vehicle valve spring compressor adapter (EN-46119) (E): Valve stem key remover/installer (EN-46117) (F): Valve spring compressor head off (J-8062)
4. Release special tools (Valve lifter), and remove valve spring retainer (1) and valve spring (2).
5. Remove valve (1) from cylinder block.
6. Remove valve stem seal (1). Special Tool (A): 09917-97810
7. If necessary, remove oil relief valve as follows. CAUTION: After removing oil relief valve, clean dust from cylinder block. Using special tool, cut down upper part of oil relief valve up to the extent that the ball in the valve can be removed. Special Tool (A): 09917-66520 Remove check ball and spring from oil relief valve. Using special tool, tap the threads of oil relief valve. Special Tool (A): 09917-66520 Using special tool, Remove oil relief valve from cylinder head. Special Tool (A): 09921-96010

Scheme 419

Scheme 420

Scheme 421

Scheme 422

Scheme 423

1. Using special tool, Install new oil relief valve to cylinder head. Special Tool (A): 09917-66520
2. After applying engine oil to new valve stem seal (1), install valve stem seal to valve guide by pushing special tool by hand. After installing, check to be sure 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 valve stem seal to valve guide only by pushing special tool by hand. Tapping or hitting special tool may cause damage to valve stem seal. Special Tool (A): 09917-97810
3. Apply engine oil to valve stem seal and valve guide hole.
4. Install valve spring and valve spring retainer. Each valve spring has top end (small-pitch (1)) and bottom end (large-pitch (2)). Be sure to position spring in place with its bottom end (large-pitch) facing the bottom (valve stem seal side).
5. Using special tools (Valve lifter) as shown in figure [A] or [B], compress valve spring and fit two valve cotters (1) into groove in valve stem. CAUTION: Do not compress valve spring by 24 mm (0.94 in.) or more. Special Tool (A): 09916-14510 (B): 09916-14530 (C): 09916-84511 Special Tool (D): Off-vehicle valve spring compressor adapter (EN-46119) (E): Valve stem key remover/installer (EN-46117) (F): Valve spring compressor head off (J-8062)
6. Install ECT sensor. See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/engine-control-systems/#engine-electrical-devices-n32a) .
7. Install spark plugs. See «SPARK PLUG REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/ignition-system/#ignition-system-n32a) .
8. Install exhaust manifold. See «EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A)»(/suzuki/grand-vitara/ii-2008-2012/remont/exhaust/#engine-exhaust-system__exhaust-manifold-removal-and-installation-n32a) .

Valve and Valve Guides Inspection

Reference: VALVES AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Valve stem-to-guide clearance

Using micrometer and bore gauge, take diameter readings on valve stems and guides to check stem-to-guide clearance.

Be sure to take reading at more than one place along the length of each stem and guide.

If clearance exceeds limit, replace valve and cylinder head.

Valve stem and valve guide specification

VALVE STEM AND VALVE GUIDE SPECIFICATION

Scheme 424

Valve stem end deflection

If bore gauge is not available, check end deflection of valve stem with a dial gauge instead.

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

If deflection exceeds its limit, replace valve stem and cylinder head.

Valve stem end deflection limit

In: 0.14 mm (0.0055 in.)

Ex: 0.18 mm (0.0071 in.)

Scheme 425

Scheme 426

1. Remove all carbon from valves (1).
2. Inspect each valve for wear, burn or distortion at its face and stem end, as necessary, replace it.
3. Measure each valve installation height. If measured height exceeds specification, replace valve. Valve installation height IN & EX: 35.23 - 36.69 mm (1.3870 - 1.4445 in.)

Valve head radial runout

Check each valve for radial runout with a dial gauge and "V" block. To check runout, rotate valve slowly. If runout exceeds its limit, replace valve.

Valve head radial runout

Standard: 0 - 0.038 mm (0 - 0.0015 in.)

Limit: 0.05 mm (0.0020 in.)

Scheme 427

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 rotatingly tapping seat with valve head. Valve lapper (tool used in valve lapping) must be used.

Pattern produced on seating face 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

Intake: 1.0 - 1.4 mm (0.0394 - 0.0551 in.)

Exhaust: 1.4 - 1.8 mm (0.0551 - 0.0709 in.)

Scheme 428

Valve seat repair

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 429

1. Use valve seat cutters (1) to make three cuts as illustrated in figure. Three cutters must be used: the 1st for making 30° 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 valve seat "a" Intake: 1.0 - 1.4 mm (0.0394 - 0.0551 in.) Exhaust: 1.4 - 1.8 mm (0.0551 - 0.0709 in.)
2. 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.

Oil relief valve

Check that oil relief valve in not clogged.

If oil relief valve is clogged, clean or replace oil relief valve.

Scheme 430

Cylinder Head Inspection

Reference: VALVES AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Scheme 431

Scheme 432

Scheme 433

Scheme 434

1. Remove all carbon deposits from 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. 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.
3. Using a straightedge (1) and thickness gauge (2), check flatness of cylinder block mating surface at a total of 6 locations. If distortion limit is exceeded, correct mating surface with surface plate and abrasive paper of about #400 (Waterproof silicon carbide abrasive paper): place abrasive paper on surface plate and rub mating surface against paper to grind off high spots. If distortion exceeds 0.25 mm (0.0098 in.), replace cylinder head. Leakage of combustion gases from this gasket joint is often due to warped mating surface: such leakage results in reduced power output. Distortion for cylinder head surface on piston side Standard: 0 - 0.05 mm (0 - 0.0020 in.)
4. Distortion of manifold seating faces: Check seating faces of cylinder head for manifolds, using straightedge and thickness gauge, in order to determine whether these faces should be corrected or cylinder head replaced. Distortion for cylinder head surface on intake and exhaust manifold Standard: 0 - 0.05 mm (0 - 0.0020 in.)

Valve Spring Inspection

Reference: VALVES AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY

Valve Spring Free Length and Preload

Referring to data, check that each spring is in good condition, free of any evidence of breakage or weakening. Remember, 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

Standard: 42.5 - 45.5 mm (1.6732 - 1.7913 in.)

Limit: 42 mm (1.6535 in.)

Valve spring preload

Standard: 247 - 273 N (25.2 - 27.8 kgf) for 35 mm (55.5 - 61.4 lbf/1.378 in.)

Limit: 240 N (24.5 kgf/54.0 lbf) for 35 mm (1.3780 in.)

Scheme 435

Removal and Installation figure callout references

1) - 4): 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-n32a) .
2. Remove cylinder head. See «VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__valve-and-cylinder-head-removal-and) .
3. Mark cylinder number on all pistons, connecting rods and connecting rod caps using silver pencil or quick drying paint.
4. Remove connecting rod bearing caps.
5. Remove carbon from top of cylinder bore before removing piston from cylinder.
6. Push out piston and connecting rod assembly through the top of cylinder bore.
7. Remove connecting rod bearings from connecting rod and connecting rod bearing cap, if necessary.

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

Scheme 436

Scheme 437

Scheme 438

Scheme 439

Scheme 440

1. Apply engine oil to pistons, rings, cylinder walls, new connecting rod bearings and crank pins. NOTE: Do not apply oil between connecting rod and bearing or between bearing cap and bearing.
2. Install new connecting rod bearing to connecting rod bearing cap and connecting rod as follows, if removed. Fit tab (1) of connecting rod bearing to groove (2) of connecting rod and bearing cap. Press bearing end (3) until bearing end be comes flush with surface of 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.
4. Install piston and connecting rod assembly into cylinder bore. Use special tool (Piston ring compressor) 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 cylinder bore. Special Tool (A): 09916-77310
5. Install bearing cap (1) as follows. CAUTION: Do not apply engine oil to new connecting rod bolt. NOTE: Tighten connecting rod bolt gradually till they are tightened to specified torque. Point projection part (2) on cap to cylinder head (bank 1) side. Tighten all connecting rod bolts to 30 N.m (3.1 kgf-m, 22.5 lbf-ft) evenly and gradually. Loosen all bolts until loosening torque becomes 0. In the same manner as Step a), tighten them to 25 N.m (2.5 kgf-m, 18.5 lbf-ft). In the same manner as Step a), retighten them by 110°. Tightening torque Connecting rod bolt*: 30 N.m --> 0 N.m --> 25 N.m --> +110° (3.1 kgf-m --> 0 kgf-m --> 2.5 kgf-m --> +110°, 22.5 lbf-ft --> 0 lbf-ft --> 18.5 lbf-ft --> +110°)
6. Install cylinder head. See «VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__valve-and-cylinder-head-removal-and) .

Piston, Piston Ring and Connecting Rod Disassembly and Reassembly

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

Scheme 441

Scheme 442

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

Reassembly

Reference: PISTON AND PISTON RING INSPECTION

Reference: PISTON PINS AND CONNECTING RODS INSPECTION

Reference: CRANK PIN AND CONNECTING ROD BEARINGS INSPECTION

Scheme 443

Scheme 444

Scheme 445

1. Remove carbon from piston head and ring grooves using suitable tool.
2. Install piston pin to piston (1) and connecting rod (2) as follows. Apply engine oil to piston pin and piston pin holes in piston and connecting rod. Fit connecting rod as shown in figure. NOTE: Be sure to position front mark (4) on piston and match mark (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 circlip so that its end gap comes within the range indicated by arrow (6).
3. 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 by referring to the figure. When installing oil ring (4), install spacer (5) first and then two rails.
4. After installing three rings (1st, 2nd and oil rings), distribute their end gaps as shown in figure.

Piston and Piston Ring Inspection

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

Inspect piston for cracks or other damages.

Damaged or faulty piston should be replaced.

Piston diameter

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

Piston diameter specification

Standard size: 88.949 - 88.961 mm (3.5019 - 3.5024 in.)

Scheme 446

Piston clearance

Measure cylinder bore diameter and piston diameter to find their difference called piston clearance. Piston clearance should be within specification. If it is out of specification, replace cylinder block, piston rings and/or pistons.

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

Piston clearance

Standard: 0.031 - 0.059 mm (0.0012 - 0.0023 in.)

Scheme 447

Ring groove clearance

Before checking, piston grooves must be clean, dry and free of carbon deposits.

Fit new piston ring (1) into piston groove, and measure clearance between ring and ring land by using thickness gauge (2). If clearance is out of limit, replace piston.

Ring groove clearance

RING GROOVE CLEARANCE SPECIFICATION

Scheme 448

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 ring.

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

Piston ring end gap

PISTON RING END GAP SPECIFICATION

Scheme 449

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 bore for wear or damage, paying particular attention to condition of small end bore bush. If pin, connecting rod small end bore or piston bore is badly worn or damaged, replace pin, connecting rod and/or piston.

Piston pin clearance

Check piston pin clearance in 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: 0.007 - 0.024 mm (0.0003 - 0.0009 in.)

Limit: 0.034 mm (0.00013 in.)

Piston pin clearance in piston

Standard: 0.004 - 0.012 mm (0.00016 - 0.00047 in.)

Limit: 0.017 mm (0.0007 in.)

Small-end bore

24.007 - 24.021 mm (0.9452 - 0.9457 in.)

Piston pin diameter

23.997 - 24.0000 mm (0.9448 - 0.9449 in.)

Piston bore

24.004 - 24.009 mm (0.94503 - 0.94523 in.)

Scheme 450

Big-end side clearance

Check big-end of connecting rod for side clearance with connecting rod fitted and connected to its crank pin in the normal manner. If measured clearance is found to exceed its limit, replace connecting rod.

Big-end side clearance

Standard: 0.095 - 0.355 mm (0.0037 - 0.0140 in.)

Limit: 0.42 mm (0.0165 in.)

Scheme 451

Connecting rod alignment

Mount connecting rod on aligner to check it for bow and twist. If measured value exceeds the limit, replace it.

Connecting rod alignment

Limit on bow: 0.05 mm (0.0020 in.)

Limit on twist: 0.10 mm (0.0039 in.)

Scheme 452

Crank Pin and Connecting Rod Bearings Inspection

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

Crank Pin Diameter

Inspect crank pin for uneven wear or damage. Measure crank pin for out-of-roundness or taper using micrometer. If crank pin is damaged or out-of round or taper is out of limit, replace crankshaft.

Crank pin diameter

Standard: 55.992 - 56.008 mm (2.2044 - 2.2050 in.)

Crank pin taper (a, b) and out-of-round (A - B)

Limit: 0.01 mm (0.0004 in.)

Scheme 453

Connecting Rod Bearing Visual Inspection

Inspect bearing shells for signs of fusion, pitting, burn or flaking and observe contact pattern. Defective bearing shells must be replaced.

Scheme 454

Scheme 455

1. Clean bearing and crank pin.
2. Place a piece of gauging plastic (1) to full width of crank pin as contacted by bearing (parallel to crankshaft), avoiding oil hole.
3. Install new connecting rod bearing and its cap. See «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__piston-piston-ring-and-connecting-rod) .
4. After three minutes, remove cap and using scale (2) on gauging plastic envelope, measure gauging plastic (1) width at the widest point (clearance). Connecting rod bearing clearance Standard: 0.027 - 0.081 mm (0.0011 - 0.0032 in.) Limit: 0.081 mm (0.0032 in.)
5. If clearance is out of specification, measure crank pin diameter referring to «CRANK PIN AND CONNECTING ROD BEARINGS INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__crank-pin-and-connecting-rod-bearings) . If crank pin diameter is out of specification, replace crankshaft. If crank pin diameter is within specification, replace connecting rod.

Scheme 456

Tightening Order/Removal and Installation figure callout references

1): CRANKSHAFT POSITION (CKP) SENSOR REMOVAL AND INSTALLATION

5), 9), 10), 12), 16): MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION

15): DRIVE PLATE REMOVAL AND INSTALLATION

17): KNOCK SENSOR REMOVAL AND INSTALLATION

Scheme 457

1. Use dial gauge to read displacement in axial (thrust) direction of crankshaft. If its limit is exceeded, replace thrust bearing with new one to obtain standard thrust play. Crankshaft thrust play Standard: 0.10 - 0.33 mm (0.0039 - 0.0130 in.) Limit: 0.42 mm (0.0165 in.)

Main Bearings, Crankshaft and Cylinder Block Removal and Installation

Reference: MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Scheme 458

Scheme 459

Scheme 460

1. Remove engine assembly from vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
2. Remove drive plate. See «DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
3. 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-n32a__piston-piston-ring-and-connecting-rod) .
4. 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-n32a__oil-pan-and-oil-pump-strainer) .
5. Remove engine rear crankshaft oil seal housing (1).
6. Remove main bearing cap bolt and crank bearing cap side bolt in numerical order ("1" - "24") as indicated in figure.
7. Using special tool, remove main bearing caps (1). Special Tool (A): 09912-36510 (B): 09912-36520
8. Remove crankshaft from cylinder block.
9. Remove oil jets from cylinder block, if necessary.

Reference: CRANKSHAFT INSPECTION

Reference: MAIN BEARINGS INSPECTION

Reference: SENSOR PLATE INSPECTION

Reference: DRIVE PLATE INSPECTION

Reference: CYLINDER BLOCK INSPECTION

Scheme 461

Scheme 462

Scheme 463

Scheme 464

Scheme 465

Scheme 466

Scheme 467

Scheme 468

Scheme 469

Scheme 470

1. Install oil jets (1) to cylinder block and tighten oil jet bolts (2) to specified torque. Tightening torque Oil jet bolt (a): 10 N.m (1.0 kg-m, 7.5 lbf-ft)
2. Install new main bearings (1) to cylinder block. Upper half of bearing has an oil groove (2). Install it to cylinder block (3), and the other half without oil groove to bearing cap. CAUTION: Do not apply engine oil between main bearing and main bearing cap, between main bearing and cylinder block. Fit tab (4) of crankshaft upper and lower bearing to groove (5) of cylinder block or bearing cap. Press bearing end (6) until bearing end surface becomes flush with surface of cylinder block or bearing cap.
3. Apply engine oil to new thrust bearings (1), install thrust bearings to cylinder block between No. 4 and No. 5 cylinders. NOTE: Be sure to face oil groove (2) side to crank web.
4. Apply engine oil to main bearings and sliding surface of crankshaft, install crankshaft to cylinder block.
5. Install bearing caps (1) to cylinder block, making sure to point arrow mark (on each cap) to crankshaft pulley side. Fit them sequentially in ascending order, 1, 2, 3 and 4, starting from pulley side.
6. Tighten main bearing cap bolts and main bearing cap side bolts as follows. CAUTION: Do not apply engine oil to main bearing cap bolts and main bearing cap side bolts. After tightening cap bolts, check that crankshaft rotates smoothly. Tighten new main bearing cap bolts No. 1 to 20 N.m (2.0 kgf-m, 14.5 lbf-ft) in numerical order ("1" - "8") shown in figure evenly and gradually. In the same manner as Step a), retighten them by +80°. Tighten new main bearing cap bolts No. 2 to 15 N.m (1.5 kgf-m, 11.0 lbf-ft) in numerical order ("9" - "16") shown in figure evenly and gradually. In the same manner as Step c), retighten them by +110°. Tighten new main bearing cap side bolts No. 1 and new main bearing cap side bolts No. 2 to 30 N.m (3.1 kgf-m, 22.5 lbf-ft) in numerical order ("17" - "24") shown in figure evenly and gradually. In the same manner as Step e), retighten them by +60°. Tightening torque Main bearing cap bolt No. 1* (a): 20 N.m --> +80° (2.0 kgf-m --> +80°, 15.0 lbf-ft --> +80°) Main bearing cap bolt No. 2* (a): 15 N.m --> +110° (1.5 kgf-m --> +110°, 11.0 lbf-ft --> +110°) Main bearing cap side bolt No. 1* (a): 30 N.m --> +60° (3.1 kgf-m --> +60°, 22.5 lbf-ft --> +60°) Main bearing cap side bolt No. 2* (a): 30 N.m --> +60° (3.1 kgf-m --> +60°, 22.5 lbf-ft --> +60°)
7. Clean sealing surface between oil seal housing and cylinder block.
8. Install special tool to cylinder block. Special Tool (A): Engine front cover installation guide pins (EN-46109)
9. Install special tool to cylinder block. Special Tool (A): 09919-87800 (B): 09913-57820
10. Apply sealant to mating surface of new rear oil seal housing as shown in figure. "A": Sealant 99000-31290 (SUZUKI Bond No. 1217F) Sealant bead size for rear oil seal housing Width: "a": 3 mm (0.12 in.) Height: "b": 2.5 mm (0.10 in.)
11. Install oil seal housing to cylinder block. NOTE: Do not apply engine oil to oil seal housing.
12. Tighten oil seal housing bolt in numerical order ("1" - "5") shown in figure evenly and gradually. CAUTION: Confirm that engine rear crankshaft oil seal lip is not turned over after engine rear crankshaft oil seal housing is installed. Tightening torque Oil seal housing bolt* (a): 10 N.m (1.0 kg-m, 7.5 lbf-ft)
13. Install piston and connecting rod. See «PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__piston-piston-ring-and-connecting-rod) .
14. Install drive plate. See «DRIVE PLATE REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
15. Install cylinder head. See «VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__valve-and-cylinder-head-removal-and) .
16. Install 2nd timing chain (bank 2). See «2ND TIMING CHAIN (BANK 2) AND TIMING CHAIN TENSIONER ADJUSTER NO. 3 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-2-and) .
17. Install 1st timing chain. See «1ST TIMING CHAIN AND TIMING CHAIN TENSIONER ADJUSTER NO. 2 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__1st-timing-chain-and-timing-chain) .
18. Install 2nd timing chain (bank 1). See «2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__2nd-timing-chain-bank-1-and) .
19. Install timing chain cover. See «TIMING CHAIN COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__timing-chain-cover-removal-and-installation) .
20. Install cylinder head cover. See «CYLINDER HEAD COVER REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .
21. Install engine assembly to vehicle. See «ENGINE ASSEMBLY REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a) .

Crankshaft Inspection

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

Crankshaft Runout

Using dial gauge, measure runout at center of journal. Rotate crankshaft slowly. If runout exceeds its limit, replace crankshaft.

Crankshaft runout

Limit: 0.03 mm (0.0012 in.)

Scheme 471

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 if amount of uneven wear in the sense exceeds its limit, regrind or replace crankshaft.

Crankshaft journal diameter

Standard: 67.992 - 68.008 mm (2.6769 - 2.6775 in.)

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

Limit: 0.01 mm (0.0004 in.)

Scheme 472

Main Bearings Inspection

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

Scheme 473

1. Upper half of bearing (1) has oil groove (2) as shown in figure. Install this half with oil groove to cylinder block (3).
2. Lower half of bearing does not have an oil groove.

Main Bearing Clearance

Note. Do not rotate crankshaft while gauging plastic is installed.

Check clearance by using gauging plastic according to the following procedure.

Scheme 474

Scheme 475

1. Remove bearing caps.
2. Clean bearings and main journals.
3. Place a piece of gauging plastic (1) the full width of bearing (parallel to crankshaft) on journal, avoiding oil hole.
4. Install new main bearings and main bearing caps referring to steps 2) through 6) of "Installation" under «MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__main-bearings-crankshaft-and-cylinder-block) . Remove bearing caps and using scale (2) on gauging plastic envelop (1), measure gauging plastic width at its widest point.
5. If clearance is out of specification, measure crankshaft journal diameter referring to «CRANKSHAFT INSPECTION»(/suzuki/grand-vitara/ii-2008-2012/remont/mechanical/#engine-mechanical-n32a__crankshaft-inspection) . If crankshaft journal diameter is out of specification, replace crankshaft. If crankshaft journal diameter is within specification, replace cylinder block and main bearing caps. Main bearing clearance Standard: 0.032 - 0.083 mm (0.0013 - 0.0033 in.) Limit: 0.083 mm (0.0033 in.)

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 crankshaft (2).

Scheme 476

Oil Jet Inspection

Check that there is no blocking in the oil jet.

If oil jet is blocked, clean or replace it.

Scheme 477

Cylinder Block Inspection

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

Inspect cylinder walls for scratches, roughness or ridges which indicate excessive wear. If cylinder bore is very rough, deeply scratched, ridged, replace cylinder block, piston rings and/or pistons.

Distortion of Cylinder Head Mating Surface

Using straightedge and thickness gauge, check cylinder head mating surface for distortion and, if flatness exceeds its limit, correct It.

Cylinder block flatness

Limit: 0.05 mm (0.0020 in.)

Scheme 478

Scheme 479

Cylinder bore diameter, taper and out-of-round

Using a cylinder gauge (1), measure cylinder bore in thrust and axial directions at two positions ("a" and "b") and cylinder taper ("A" and "B") as shown in figure.

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

Scheme 480

Scheme 481

1. Cylinder bore dia. exceeds limit.
2. Difference of measurements at two positions exceeds taper limit.
3. Difference between thrust and axial measurements exceeds out-of-round limit. Cylinder bore diameter Standard: 88.992 - 89.008 mm (3.5036 - 3.5043 in.) Limit: 89.050 mm (3.5059 in.) Cylinder out-of-roundness Limit: 0.020 mm (0.0008 in.) Cylinder taper Limit: 0.013 mm (0.0005 in.)

Tightening Torque Specifications

TORQUE SPECIFICATION

Note. The specified tightening torque is described in the following. AIR CLEANER COMPONENTS INTAKE MANIFOLD AND THROTTLE BODY COMPONENTS CYLINDER HEAD COVER COMPONENTS CAMSHAFT, CMP ACTUATOR, VALVE LASH ADJUSTER AND VALVE ROCKER ARM COMPONENTS ENGINE MOUNTINGS COMPONENTS TIMING CHAIN COVER COMPONENTS 2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 COMPONENTS 1ST TIMING CHAIN AND TIMING CHAIN TENSIONER ADJUSTER NO. 2 COMPONENTS 2ND TIMING CHAIN (BANK 2) AND TIMING CHAIN TENSIONER ADJUSTER NO. 3 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

MATERIAL SPECIFICATION

Note. Required service material is also described in the following. CYLINDER HEAD COVER COMPONENTS CAMSHAFT, CMP ACTUATOR, VALVE LASH ADJUSTER AND VALVE ROCKER ARM COMPONENTS TIMING CHAIN COVER COMPONENTS 2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 COMPONENTS 1ST TIMING CHAIN AND TIMING CHAIN TENSIONER ADJUSTER NO. 2 COMPONENTS 2ND TIMING CHAIN (BANK 2) AND TIMING CHAIN TENSIONER ADJUSTER NO. 3 COMPONENTS VALVE AND CYLINDER HEAD COMPONENTS PISTON, PISTON RING AND CONNECTING ROD COMPONENTS MAIN BEARING, CRANKSHAFT AND CYLINDER BLOCK COMPONENTS

Special Tool

SPECIAL TOOL SPECIFICATION 09910-97810 Crankshaft Balancer Remover J-41816 09912-36510 Slide Hammer Adapter J-6125-1B 09912-36520 Crankshaft Bearing Cap Remover J-41818 09912-37820 Crankshaft Balancer Installer J-41998 09912-37830 Crankshaft Button J-38416 09913-57810 OCV Seal Remover/Installer EN-46103 09913-57820 Oil Seal Installer EN-47893 09913-57830 Seal Remover J-45000 09913-75510 Bearing installer 09913-75821 Bearing installer attachment 09915-64512 Compression gauge 09915-64530 Compression gauge hose 09915-67010 Compression gauge attachment (C) 09915-67311 Vacuum gauge 09916-14510 Valve lifter 09916-14530 Valve spring compressor attachment 09916-77310 Piston ring compressor (50-125 mm) 09916-84511 Forceps 09916-97830 Flywheel Holding Tool EN-46106 09917-66520 Check Valve Remover/Installer EN-46122 09917-67810 Camshaft Locking Tool EN-48383-3 09917-67830 Camshaft Locking Tool EN-48383-2 09917-97810 Stem Seal Remove/Installer EN-46116 09918-57800 Timing Chain Retention Tool EN-48313 09918-57810 Tensioner Tool J-45027 09919-87800 Handle J-42183 09921-96010 Oil seal remover & slider 09926-68310 Differential bevel pinion bearing installer SUZUKI scan tool (SUZUKI-SDT) - This kit includes following items. SUZUKI-SDT DLC3 cable USB cable AC/DC power supply Voltage meter probe Storage case Spark plug tube seal guide - EN-46101: This tool is not applied with SUZUKI part number. Crankshaft rotation socket - EN-46111: This tool is not applied with SUZUKI part number. Engine front cover installation guide pins - EN-46109: This tool is not applied with SUZUKI part number. Valve stem key remover/installer - EN-46117: Substitute special tool for 09916-14510, 09916-14530 and 09916-84510. Off-vehicle valve spring compressor adapter - EN-46119: Substitute special tool for 09916-14510, 09916-14530 and 09916-84510. Valve spring compressor head off - J-8062: Substitute special tool for 09916-14510, 09916-14530 and 09916-84510. Bearing and seal driver - J-5590: Substitute special tool for 09913-75510. Oil seal installer - J-25254-A: Substitute special tool for 09913-75510. Oil seal installer - J-29184: Substitute special tool for 09913-75820 and 09926-68310

Scheme 482

Scheme 483

Scheme 484

Scheme 485

Scheme 486

Scheme 487

Scheme 488

Scheme 489

Scheme 490

Scheme 491

Scheme 492

Scheme 493

Scheme 494

Scheme 495

Scheme 496

Scheme 497

Scheme 498

Scheme 499

Scheme 500

Scheme 501

Scheme 502

Scheme 503

Scheme 504

Scheme 505

Scheme 506

Scheme 507

Scheme 508

Scheme 509

Scheme 510

Scheme 511

Scheme 512

Scheme 513

Scheme 514

Scheme 515

Scheme 516

See also:
• SPARK PLUG REMOVAL AND INSTALLATION
• ELECTRIC THROTTLE SYSTEM ON-VEHICLE INSPECTION
• FUEL PRESSURE RELIEF PROCEDURE
• COOLING SYSTEM DRAINING
• FUEL INJECTOR REMOVAL AND INSTALLATION
• PRECAUTION FOR IDENTIFICATION OF CYLINDER AND BANK
• CAMSHAFT POSITION (CMP) SENSOR REMOVAL AND INSTALLATION
• COOLING SYSTEM REFILLING
• ENGINE CONTROL MODULE (ECM) REMOVAL AND INSTALLATION
• ENGINE OIL AND FILTER CHANGE
• A/T FLUID CHANGE
• FRONT DIFFERENTIAL OIL CHANGE
• TRANSFER OIL CHANGE
• P/S FLUID CHANGE
• OPERATION PROCEDURE FOR CHARGING A/C WITH REFRIGERANT
• COMPRESSOR ASSEMBLY REMOVAL AND INSTALLATION
• FRONT BUMPER COMPONENTS
• STEERING LOWER SHAFT ASSEMBLY REMOVAL AND INSTALLATION
• EXHAUST PIPE AND MUFFLER REMOVAL AND INSTALLATION
• PROPELLER SHAFT REMOVAL AND INSTALLATION
• FRONT DRIVE SHAFT ASSEMBLY REMOVAL AND INSTALLATION
• P/S HOSE/PIPE COMPONENTS
• EXHAUST MANIFOLD REMOVAL AND INSTALLATION (N32A)
• STARTING MOTOR REMOVAL AND INSTALLATION
• GENERATOR REMOVAL AND INSTALLATION
• P/S PUMP REMOVAL AND INSTALLATION
• FRONT SUSPENSION FRAME, STABILIZER BAR AND/OR BUSHINGS REMOVAL AND INSTALLATION
• A/C CONDENSER ASSEMBLY REMOVAL AND INSTALLATION
• ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL AND INSTALLATION
• CRANKSHAFT POSITION (CKP) SENSOR REMOVAL AND INSTALLATION
• KNOCK SENSOR REMOVAL AND INSTALLATION
• OIL PAN AND OIL PUMP STRAINER REMOVAL AND INSTALLATION
• FASTENER INFORMATION
• AIR CLEANER FILTER INSPECTION AND CLEANING
• AIR CLEANER FILTER REMOVAL AND INSTALLATION
• INTAKE MANIFOLD REMOVAL AND INSTALLATION
• THROTTLE BODY REMOVAL AND INSTALLATION
• CYLINDER HEAD COVER COMPONENTS
• CAMSHAFT, CMP ACTUATOR, VALVE LASH ADJUSTER AND VALVE ROCKER ARM REMOVAL AND INSTALLATION
• TIMING CHAIN COVER REMOVAL AND INSTALLATION
• OCV INSPECTION
• 2ND TIMING CHAIN (BANK 1) AND TIMING CHAIN TENSIONER ADJUSTER NO. 1 COMPONENTS
• 1ST TIMING CHAIN AND TIMING CHAIN TENSIONER ADJUSTER NO. 2 COMPONENTS
• 2ND TIMING CHAIN (BANK 2) AND TIMING CHAIN TENSIONER ADJUSTER NO. 3 COMPONENTS
• VALVE AND CYLINDER HEAD REMOVAL AND INSTALLATION
• VALVE AND CYLINDER HEAD COMPONENTS
• VALVES AND CYLINDER HEAD DISASSEMBLY AND REASSEMBLY
• PISTON, PISTON RING AND CONNECTING ROD REMOVAL AND INSTALLATION
• PISTON AND PISTON RING INSPECTION
• PISTON PINS AND CONNECTING RODS INSPECTION
• CRANK PIN AND CONNECTING ROD BEARINGS INSPECTION
• MAIN BEARINGS, CRANKSHAFT AND CYLINDER BLOCK REMOVAL AND INSTALLATION
• CRANKSHAFT INSPECTION
• MAIN BEARINGS INSPECTION
• SENSOR PLATE INSPECTION
• DRIVE PLATE INSPECTION
• CYLINDER BLOCK INSPECTION