Suzuki Grand Vitara JB419. Service manual — part 48

Engine Mechanical: 1D-38

Camshaft and Tappet Inspection

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Camshaft
• Check journals and cam faces for wear or damage.

If any malcondition is found, replace camshaft.

Camshaft thrust play

1) Remove all tappets from cylinder head.
2) Install camshaft to cylinder head.
3) Install camshaft housing referring to “Installation”

under “Camshaft and Tappet Removal and
Installation”.

4) Measure camshaft thrust play using special tool and

dial gauge (1) as shown in figure.If measured thrust
play is out of specification, replace camshaft and/or
cylinder head.

Camshaft thrust play
0.045 – 0.135 mm (0.00178 – 0.00531 in.)

Cam Wear
Using a micrometer, measure cam height “a”. If
measured height underruns its limit, replace camshaft.

Camshaft Journal Wear
Check camshaft journals and camshaft housings for
pitting, scratches, wear or damage.
If any malcondition is found, replace camshaft or cylinder
head with housing. Never replace cylinder head without
replacing housings.

Wear of Tappet
Check tappet for pitting, scratches, or damage.
If any malcondition is found, replace.

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1D-39 Engine Mechanical:

Measure cylinder head bore and tappet outside diameter
to determine cylinder head-to-tappet clearance. If
measured clearance is out of specification, replace
tappet and/or cylinder head.

Cylinder head to tappet clearance
0.015 – 0.074 mm (0.00059 – 0.00291 in.)

Tappet outside diameter [A]
34.965 – 34.985 mm (1.37658 – 1.37736 in.)

Cylinder head tappet bore [B]
35.000 – 35.039 mm (1.37796 – 1.37948 in.)

Valve and Cylinder Head Assembly Components

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12

12

10

1

2

3

4

8

11

5

9

(a)

7

6

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1. Valve cotter

6. Intake valve

11. Cylinder head gasket

2. Valve spring retainer

7. Exhaust valve

12. Dowel pin

Engine Mechanical: 1D-40

Valve and Cylinder Head Assembly Removal
and Installation

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Removal

1) Remove engine assembly referring to “Engine

Assembly Removal and Installation”.

2) Remove timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation”.

3) Remove turbocharger referring to “Turbocharger

Assembly Removal and Installation”.

4) Remove EGR cooler referring to “EGR Pipe and

EGR Cooler Removal and Installation”.

5) Remove oil separator referring to “Oil Separator

Removal and Installation”.

6) Remove EGR valve referring to “EGR Valve

Removal and Installation”.

7) Remove ventilation pipe No.2 referring to “Oil

Separator Components”.

8) Remove injection pump rear bracket referring to

“Injection Pump Removal and Installation in Section
1G”, if necessary.

9) Loosen cylinder head bolts in numerical order (“1”

through “10”) as shown in figure, and remove them.

CAUTION

!

Never reuse cylinder head bolts once
removed it due to plastic deformation
tightening. Be sure to use new cylinder head
bolts when installing.

10) Check all around cylinder head for any other parts

required to be removed or disconnected, and
remove or disconnect whatever necessary.

11) Remove cylinder head and cylinder head gasket

from cylinder block.

12) Remove dowel pins, if necessary.
13) Remove vacuum pump referring to “Vacuum Pump

Removal and Installation”, if necessary.

14) Remove thermostat assembly referring to

“Thermostat Assembly Removal and Installation in
Section 1F”, if necessary.

15) Remove intake and exhaust manifolds referring to

“Intake Manifold and Exhaust Manifold Removal and
Installation”, if necessary.

16) Remove camshaft and tappets referring to

“Camshaft and Tappet Removal and Installation”, if
necessary.

17) Remove fuel injector referring to “Fuel Injector

Removal and Installation in Section 1G”, if
necessary.

18) Remove injection pump referring to “Injection Pump

Removal and Installation in Section 1G”, if
necessary.

19) Remove common rail (high pressure fuel injection

rail) referring to “Common Rail (High Pressure Fuel
Injection Rail) Removal and Installation in Section
1G”, if necessary.

3. Valve spring

8. Valve guide

: Tighten 30 N

⋅m (3.0 kgf-m, 22.0 lb-ft), 100°, 0 N⋅m

(0.0 kgf-m, 0.0 lb-ft), 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft)

and 213

° by the specified procedure.

4. Valve stem seat

9. Cylinder head bolt

: Do not reuse.

5. Valve stem seal

: Do not lubricate valve stem seal before fitting.

10. Cylinder head

: Apply engine oil to sliding surface of each part.

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1D-41 Engine Mechanical:

Installation

1) Remove oil, old sealant and dust from bolt holes and

mating surface of cylinder head and cylinder block.

2) Install camshaft and tappets referring to “Camshaft

and Tappet Removal and Installation”, if removed.

3) Install cylinder head cover referring to “Cylinder

Head Cover Removal and Installation”, if removed.

4) Install injection pump referring to “Injection Pump

Removal and Installation in Section 1G”, if removed.

5) Install common rail (high pressure fuel injection rail)

referring to “Common Rail (High Pressure Fuel
Injection Rail) Removal and Installation in Section
1G”, if removed.

6) Install fuel injector referring to “Fuel Injector Removal

and Installation in Section 1G”, if removed.

7) Install high pressure pipes referring to “High

Pressure Pipe Removal and Installation in Section
1G”, if removed.

8) Install intake and exhaust manifolds referring to

“Intake Manifold and Exhaust Manifold Removal and
Installation”, if removed.

9) Install vacuum pump referring to “Vacuum Pump

Removal and Installation”, if removed.

10) Install thermostat assembly referring to “Thermostat

Assembly Removal and Installation in Section 1F”, if
removed.

11) Install dowel pins (1) to cylinder block, if removed.

12) Install new cylinder head gasket (2) to cylinder block.

13) Install cylinder head to cylinder block, and tighten

new cylinder head bolts as follows.
a) Tighten cylinder head bolts to 30 N

⋅m (3.0 kgf-m,

22.0 lb-ft) according to numerical order (“1”
through “10”) as shown in figure.

b) Retighten them by turning through 100

° in same

manner as Step a).

c) Wait 3 minutes for setting time.
d) Loosen cylinder head bolts (“1” and “2”) until they

are completely free, and tighten them to 25 N

⋅m

(2.5 kgf-m, 18.0 lb-ft), then retighten then by
turning through 213

°.

e) Loosen and tighten bolts (“3” and “4”), bolts (“5”

and “6”), bolts (“7” and “8”) then bolt (“9” and
“10”) in the same manner as Step d).

Tightening torque
Cylinder head bolt (a): Tighten 30 N

⋅m (3.0

kgf-m, 22.0 lb-ft), 100

°, 0 N⋅m (0.0 kgf-m, 0.0

lb-ft), 25 N

⋅m (2.5 kgf-m, 18.0 lb-ft) and 213°

by the specified procedure

14) Install injection pump rear bracket referring to

“Injection Pump Removal and Installation in Section
1G”, if necessary.

15) Install EGR valve referring to “EGR Valve Removal

and Installation”.

16) Install oil separator referring to “Oil Separator

Removal and Installation”.

17) Install EGR cooler referring to “EGR Pipe and EGR

Cooler Removal and Installation”.

18) Install turbocharger referring to “Turbocharger

Assembly Removal and Installation”.

19) Install ventilation pipe No.2 referring to “Oil

Separator Components”.

20) Install timing belt referring to “Timing Belt and Belt

Tensioner Removal and Installation”.

21) Install engine assembly referring to “Engine

Assembly Removal and Installation”.

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